Maintenance Instructions - L Engine

MAN Energy Solutions
Technical Documentation
L48/60CR
Engine
Working Instructions
Engine .............................................. L48/60CR

Works No. of engine ......................... 1130952
1130953
1130954
Plant No............................................ 4305390
Date ................................................. 2021-03-07
2021-03-07
010.005
Translation of the original instructions

L48/60CR
2021-03-07
MAN Energy Solutions SE

86224 Augsburg
GERMANY
Phone +49 (0) 821 322-0
Fax +49 (0) 821 322-3382
010.005
primeserv-aug@man-es.com
https://primeserv.man-es.com/
Copyright © 2021 MAN Energy Solutions
All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.
Table of contents
Table of contents
1 Introduction
Preface ..................................................................................................................... 010.000.000-01
Structure and content of Work Instructions ............................................................... 010.000.000-02
Tools/aids required ................................................................................................... 010.000.000-03
2 Work Instructions, arranged by topics

001 Operating media systems/Pipes
Operating Fluid Systems Flushing and cleaning .......................................... 010.000.001-01
Piping and corresponding components installation and replacement .......... 010.000.001-02
Pipelines cleaning, pickling and preservation. Carry out the pressure test ... 010.000.001-03
Solderless pipe unions mounting ................................................................ 010.000.001-04
Solderless pipe unions Additional parts ...................................................... 010.000.001-05
002 Operating media/Auxiliary agents
Lubricating oil assessing and treating ......................................................... 010.000.002-01
Lubricating oil Carrying out the spot test..................................................... 010.000.002-02
Coolant inspecting...................................................................................... 010.000.002-03
Coolant system cleaning............................................................................. 010.000.002-04
Engine/Components preservation............................................................... 010.000.002-05
Taking an operating material sample .......................................................... 010.000.002-07
003 Machine Elements
Galvanised Bearings assessing................................................................... 010.000.003-01
Deep Groove Bearing assessing................................................................. 010.000.003-02
Bimetal Bearings (without a third layer) assessing ....................................... 010.000.003-03
Tightening of bolted connections Partial image ........................................... 010.000.003-04
Tightening of bolted connections Table ...................................................... 010.000.003-05
Tightening of bolt connections General notes ............................................. 010.000.003-07
Surface examination using penetration method .......................................... 010.000.003-08
Surface examination using magnetic leakage flux method .......................... 010.000.003-09
2021-03-07
Elastomer Seals storage, cleaning and fitting .............................................. 010.000.003-10

004 Work and Safety Regulations
Working and Safety Regulations Prepare Common-Rail engine for maintenance work
.................................................................................................................. 010.000.004-02
Working and Safety Regulations when working on the fuel admission system
L48/60CR
.................................................................................................................. 010.000.004-03
Working and Safety Regulations Securing the crankshaft and components linked to it
against movement ...................................................................................... 010.000.004-04
Work and safety regulations when turning the running gear ........................ 010.000.004-05
3 (10)
Work and safety specifications Depressurise the compressed air system ... 010.000.004-06
Table of contents
005 Operating values/Operating results

Charge air cooler/Crankcase differential pressure measure......................... 010.000.005-01
006 Hydraulic tensioners/High-pressure pump
Working and Safety Regulations using hydraulic tools ................................ 015.000.001-01
High pressure hoses use ............................................................................ 015.000.002-01
High-pressure pump use ............................................................................ 015.000.003-01
Dial gauge (measuring device) checking the screw elongation .................... 015.000.004-01
Hydraulic tensioner use .............................................................................. 015.000.030-01
Hydraulic tensioner disassembly and assembly .......................................... 015.000.030-02
Hydraulic tensioner Disassembly and assembly .......................................... 015.000.040-02
3 Work Instructions, arranged by PDS

010.005 Engine complete
010.005.000 Subassembly overview by PDS
Sub-assembly overview by PDS ........................................... 010.005.000-01
010.010 Engine structure
010.010.030 Cylinder crankcase
Flexible engine support inspection ........................................ 010.010.030-01
Crankshaft bearing bolts and cross tie rod (main bearing) Inspection
............................................................................................. 010.010.030-07
Crankshaft bearing bolts and the cross tie rod (external bearing) inspecting
............................................................................................. 010.010.030-08
Crankshaft bearing bolts and cross tie rod (main bearing) releasing and ten-
sioning .................................................................................. 010.010.030-09
Crankshaft bearing bolts and the cross tie rod (external bearing) releasing and
tensioning ............................................................................. 010.010.030-10
Cylinder head bolts removing and installing........................... 010.010.030-11
2021-03-07
010.020 Casing
010.020.010 Casing on CS
Casing on the coupling side Removing and fitting ................. 010.020.010-01
010.020.030 Crankcase casing
L48/60CR
Crankcase cover dismounting and attaching......................... 010.020.030-01

010.020.050 Camshaft covering
Camshaft casing removing and installing............................... 010.020.050-01
010.020.100 Safety valve for crankcase
4 (10)
Safety valve for crankcase dismounting and attaching .......... 010.020.100-01
Table of contents
010.030 Drive train
010.030.010 Crankshaft
Counterweight bolts inspecting ............................................. 010.030.010-01
Counterweight removing and installing .................................. 010.030.010-02
Coupling bolts inspection...................................................... 010.030.010-03
Coupling bolts releasing and tensioning ................................ 010.030.010-04
Crankshaft oil bore closing.................................................... 010.030.010-05
Crankshaft gearwheel bolts inspection .................................. 010.030.010-06
Crankshaft gearwheel bolts releasing and tensioning ............ 010.030.010-07
Crankshaft flange position in relation to the driven flange determining/check-
ing ........................................................................................ 010.030.010-11
Crankshaft web clearance measuring (mechanical) ............... 010.030.010-12
Counterweight bolts releasing and tensioning ....................... 010.030.010-13
010.030.020 Crankshaft bearing
Check the lower crankshaft bearing shell (main bearing) ....... 010.030.020-01
Upper crankshaft bearing shell (main bearing) removing and installing
............................................................................................. 010.030.020-02
Lower crankshaft bearing shell (external bearing) inspecting.. 010.030.020-03
Upper crankshaft bearing shell (external bearing) removing and installing
............................................................................................. 010.030.020-04
Axial clearance inspecting ..................................................... 010.030.020-06
Locating bearing rings inspecting.......................................... 010.030.020-07
010.030.030 Crankshaft vibration damper
Bolts of the crankshaft vibration damper inspection .............. 010.030.030-01
Bolts of the crankshaft vibration damper releasing and tensioning
............................................................................................. 010.030.030-02
Crankshaft vibration damper removing and installing............. 010.030.030-03
Crankshaft vibration damper inspecting ................................ 010.030.030-04
010.040 Connecting rod and piston
010.040.010 Connecting rod
Connecting rod shank bolts inspecting ................................. 010.040.010-01
2021-03-07
Connecting rod bearing bolts inspecting ............................... 010.040.010-02

Connecting rod shank bolts releasing and tensioning............ 010.040.010-03
Connecting rod bearing bolts releasing and tensioning ......... 010.040.010-04
Lower big-end bearing shell inspecting ................................. 010.040.010-05
L48/60CR
Upper connecting rod bearing shell inspecting...................... 010.040.010-06

Contact surface for connecting rod bearing shells checking.. 010.040.010-07
Contact surface for connecting rod bearing shells reworking 010.040.010-08
Connecting rod shank removing and installing ...................... 010.040.010-10
5 (10)
Contact surface conrod small end/conrod shank inspecting . 010.040.010-14

Table of contents
Contact surface conrod small end/conrod shank reworking.. 010.040.010-15

Contact surface conrod shank/big-end bearing cover inspecting
............................................................................................. 010.040.010-16
Contact surface conrod shank/big-end bearing cover reworking
............................................................................................. 010.040.010-17
010.040.050 Pistons/piston rings/piston pins
Piston removing and installing ............................................... 010.040.050-01
Piston inspection .................................................................. 010.040.050-03
Piston disassembling and assembling................................... 010.040.050-04
Piston pin and piston pin bush removing and installing/checking
............................................................................................. 010.040.050-05
Piston rings assessing .......................................................... 010.040.050-06
Piston rings with chrome ceramic coating Assessing ............ 010.040.050-07
010.050 Cylinder
010.050.010 Cylinder liner
Top land ring removing and installing .................................... 010.050.010-01
Cylinder liner measure........................................................... 010.050.010-03
Cylinder liner (with backing ring) removing and installing........ 010.050.010-04
Cylinder liner (without backing ring) removing and installing... 010.050.010-05
Cylinder liner honing.............................................................. 010.050.010-07
Sealing groove in the top land ring grinding........................... 010.050.010-08
Cylinder liner - fretting assessing and reworking.................... 010.050.010-12
Cylinder liner - running surface inspecting ............................. 010.050.010-13
010.060 Cylinder head, complete
010.060.020 Cylinder head
Cylinder head bolts inspection .............................................. 010.060.020-01
Cylinder head bolts releasing and tensioning......................... 010.060.020-02
Cylinder head dismounting and attaching ............................. 010.060.020-03
Cylinder head seat surfaces grinding..................................... 010.060.020-05
Sealing face on the cylinder head grinding ............................ 010.060.020-08
Valve seat rings removal and installation ............................... 010.060.020-09
2021-03-07
Cylinder head with turnover device working/machining ......... 010.060.020-10

Cylinder head check for tightness ......................................... 010.060.020-12
010.060.030 Inlet/exhaust valve
Valve rotator Inspecting ........................................................ 010.060.030-01
L48/60CR
Inlet/exhaust valve Removing and installing ........................... 010.060.030-02

Valve rotator Disassembly and reassembly ........................... 010.060.030-03
Valve seat ring inspecting...................................................... 010.060.030-04
Valve seat ring working/machining ........................................ 010.060.030-05
6 (10)
Valve cone inspecting ........................................................... 010.060.030-06
Table of contents
Valve cone machining ........................................................... 010.060.030-07
Valve guide inspecting .......................................................... 010.060.030-08
Valve guide Removing and installing...................................... 010.060.030-09
010.060.060 Fuel injection valve with nozzle
Fuel injection valve removing and installing............................ 010.060.060-01
Fuel injection valve check...................................................... 010.060.060-02
Fuel injection valve dismantling and assembling .................... 010.060.060-03
010.060.070 Starting valve
Starting valve removing and installing.................................... 010.060.070-01
Starting valve dismantling and assembling ............................ 010.060.070-02
010.060.080 Indicator valve
Ignition pressures determine ................................................. 010.060.080-01
Indicator valve opening and closing....................................... 010.060.080-02
010.090 Camshaft and control drive
010.090.020 Camshaft, assembled
Camshaft inspection ............................................................. 010.090.020-01
Camshaft Checking the cam setting ..................................... 010.090.020-02
010.090.030 Camshaft bearing bushing
Camshaft bearing screws Check .......................................... 010.090.030-01
Camshaft bearing screws releasing and tensioning ............... 010.090.030-02
Camshaft (thrust bearing) inspecting ..................................... 010.090.030-03
Camshaft bearing shells inspecting ....................................... 010.090.030-04
010.090.060 Control drive
Control drive inspecting ........................................................ 010.090.060-01
010.100 Valve drive
010.100.020 Control lever, rocker arm, valve bridge
Rocker arm casing with control levers dismounting and attaching
............................................................................................. 010.100.020-01
Valve clearance checking and adjusting ................................ 010.100.020-02
010.100.030 Push rod and plunger
Push rods removing and installing......................................... 010.100.030-03
2021-03-07
Cam follower assembly with adaptor device at turning device adaptor plate
............................................................................................. 010.100.030-06
010.100.050 Variable valve timing (VVT)
VVT drive removing and installing .......................................... 010.100.050-01
Pulse pick-ups for VVT scanning removing and installing ...... 010.100.050-02
L48/60CR
VVT block ............................................................................. 010.100.050-03

010.110 Fuel injection system
010.110.020 Drive for injection pump
7 (10)
Cam follower Removal and installation/inspection ................. 010.110.020-01

Table of contents
High-pressure pump drive removing and installing or dismantling and assem-

bling...................................................................................... 010.110.020-03
010.110.050 Common-Rail high-pressure pump
High-pressure pump removing and installing......................... 010.110.050-01
High-pressure pump dismantling and assembling ................. 010.110.050-02
Attachment of high-pressure pump to turnover stand using adaptor plate
............................................................................................. 010.110.050-03
High-pressure pump checking for leaks ................................ 010.110.050-04
010.110.052 High-pressure pipes - Common-Rail
Fuel injection pipe removing and installing............................. 010.110.052-01
High-pressure fuel pipe removal and installation.................... 010.110.052-02
High-pressure fuel pipe (spill pipe) removing and installing .... 010.110.052-03
High-pressure fuel pipe checking for leaks ............................ 010.110.052-04
Fuel injection pipe dismantling and assembling ..................... 010.110.052-05
010.110.054 Common-Rail accumulator unit with fitted components
Common rail accumulator unit removing and installing .......... 010.110.054-01
Holding fixture on turning device fitting and removal.............. 010.110.054-02
Valve group removal and installation ..................................... 010.110.054-03
Common rail accumulator unit dismantling and assembling .. 010.110.054-04
Flow limiter removal and installation ...................................... 010.110.054-05
Common-Rail accumulator unit check for tightness .............. 010.110.054-06
Valve block removing and installing ....................................... 010.110.054-07
Flush valve disassembly, clean and assembly ....................... 010.110.054-08
Pressure limiting valve removal and installation...................... 010.110.054-09
Non-return valve (purging) removing and installing ................ 010.110.054-10
Non-return valve (purging) disassembly and assembly .......... 010.110.054-11
Adapter with non-return valve (splitting) removing and installing
............................................................................................. 010.110.054-12
Adapter with non-return valve (splitting) dismantling and assembling
............................................................................................. 010.110.054-13
Cabling on the high-pressure pump and the common rail accumulator unit
connecting and disconnecting .............................................. 010.110.054-14
2021-03-07
Leakage points at the common rail injection system localising and repairing
............................................................................................. 010.110.054-15
010.110.060 Common-Rail system
Common rail system carrying out a pressure test, checking for leaks
............................................................................................. 010.110.060-01
L48/60CR
Common-Rail components Rework sealing face (tapered)/Handling of high-

pressure fuel pipes................................................................ 010.110.060-02
010.150 Starting air
010.150.010 Starting air pilot valve
8 (10)
Starting air pilot valve inspection ........................................... 010.150.010-01
Table of contents
Starting air pilot valve disassembly and assembly ................. 010.150.010-02
010.150.020 Main starting valve
Main starting valve Dismantling and assembling.................... 010.150.020-02
010.170 Intake air
010.170.010 Charge air line
Charge air pipe for emergency operation converting ............. 010.170.010-02
Charge air bypass device disassembly and assembly ........... 010.170.010-04
010.170.040 Intercooler with attachment
Charge air cooler removing and installing .............................. 010.170.040-01
Charge air cooler in ultrasonic cleaning bath cleaning ........... 010.170.040-04
010.180 Exhaust gas
010.180.010 Exhaust pipe and support
Exhaust pipe inspecting ........................................................ 010.180.010-01
Exhaust gas blow-off device disassembly and assembly....... 010.180.010-02
010.220 Lube oil system
010.220.010 Lube oil pump with drive
Lubricating oil pump removing and installing ......................... 010.220.010-01
Lube oil pump Dismantling and assembling .......................... 010.220.010-02
010.230 Coolant system
010.230.010 HT coolant pump
Coolant pump Removing and fitting ...................................... 010.230.010-01
Cooling water pump dismantling and assembling ................. 010.230.010-02
010.280 Engine control
010.280.020 Operator console on engine
Three-way valve M306 inspect.............................................. 010.280.020-02
Three-way valve M317 inspect.............................................. 010.280.020-04
3/2-way solenoid valve M329 inspect ................................... 010.280.020-05
Pressure reducing valve M409 inspect.................................. 010.280.020-11
2021-03-07
Compressed air filter M462 inspecting .................................. 010.280.020-12

M470 pressure governor Inspecting...................................... 010.280.020-13
Limit switch M745 inspect .................................................... 010.280.020-14
2/2-way solenoid valve M314/M315/M316 inspect ............... 010.280.020-16
L48/60CR
Pressure regulator station M615 inspect ............................... 010.280.020-17

Emergency stop unit function on the engine check ............... 010.280.020-19
Control valves of the slow-turn function Adjustment .............. 010.280.020-20
010.290 Engine control and monitoring
9 (10)
010.290.010 Installation/Drive speed measuring / indicating devices

Table of contents
Impulse transmitter removing and installing ........................... 010.290.010-01

010.290.157 Cabling Common-Rail on engine
Rail pressure measuring transducer removing and installing.. 010.290.157-01
Detection sensor removing and installing .............................. 010.290.157-02
Resistance thermometer at the high-pressure pump removing and installing
51323028363
............................................................................................. 010.290.157-03
2021-03-07
L48/60CR
10 (10)
1 Introduction
51354111115
1 Introduction
1 (1)
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1 Introduction
MAN Energy Solutions 010.000.000-01
Preface
General information
System-related Work Instructions

The Work Instructions are tailored to the specific system. This means
that there can be considerable differences in comparison with other
systems.
Work Instructions and The Work Instructions are closely connected to the engine Maintenance
maintenance schedule Schedule, contained in operating manual in Volume 010.005 of the technical
documentation. While this only specifies the necessary maintenance work in
keywords, the working sequences required in order to maintain the opera-
tional safety and efficiency of the engine are described in the Work Instruc-
tions step by step and clarified with the help of illustrations. The Work Instruc-
tions describe, by way of introduction, the purpose of the work and, amongst
other things, they contain information regarding the required tools and auxili-
ary equipment. Several Work Instructions are to be taken into account for
most of the work which is involved.
Work Instructions are for a specific purpose, i.e. they cover the primary in-
formation needs in simple language.
Filing system The Work Instructions are classified by subject in the first part, and according
to the sub-assembly system of the engine in the second part.
Work on the engine For any work on the engine, it is necessary to ensure:
▪ Maintenance, adjustment and installation work may only be performed by
trained specialists or engineers.
▪ Before any maintenance work, the engine must be brought into a technic-
ally safe condition. In relation to this, the following points are vital:
– The engine must be stopped and secured against re-starting.
– The waiting time of 20 minutes must be adhered to.
– All components must be cooled to a temperature below 60°C.
– Make sure that the engine and the all system components are
brought to a safe condition for maintenance personnel.
– It must be verified that the shut-off devices of all fluid-carrying systems
are set correctly.
2016-08-18 - de
– Personal protective equipment must be worn.

▪ After concluding the work, the following points must be observed:
– Check the emergency stop devices prior to the engine start.
– It must be verified that the shut-off devices of all fluid-carrying systems
are set correctly.
– Prior to the restarting engine operation it is important to pay careful at-
tention to the engine area where the works were carried out. The
Preface
work is considered as completed only when it is ensured that the en-

gine runs properly and in accordance with its intended purpose and
27021599487505035
all the safety devices are fully functional again.
General, M010.000.000-01-0001 1 (1)

010.000.000-01 MAN Energy Solutions
27021599487505035
2016-08-18 - de
Preface
General, M010.000.000-01-0001
Structure and content of Work Instructions
Structure
In general, the Work Instructions contain the following information:
▪ Tips on the significance and purpose of the work,
▪ the required tools and auxiliary equipment,
▪ relevant Work Instructions i.e. the Work Instructions containing required or
useful information,
▪ possible supplementary details /technical data and
▪ the individual working sequences beginning with the starting position fol-
lowed by the individual work steps.
Tools are identified with their respective tool number in the illustration and
text, while other parts are identified with their item number.
The index number of the Work Instructions, top right in the header, consists of
the nine-digit PDS (Product Data Structure) or a neutral digit group and a se-
quential number. Example: 010.010.030-027
How are the required Work Instructions found?

The work instructions are listed in the directories of sections 2 and 3. The dir-
ectory in section 2 contains the work instructions summarised by subject, the
directory in section 3 contains instructions sorted by PDS.
The component group overview by PDS ensures access to the filing system of
the directories in section 3. Illustrative / graphical representations of the en-
gine and a tabular overview, lead to the PDS numbers, according to which the
Work Instructions are sorted.

Safety instructions
Dangers, error sources, technical requirements and supplementary informa-
tion are highlighted by notes. Depending on the hazard level, the following
symbols are used:
Identification of Danger
Indicates a danger leading to fatality or severe injuries if not avoided.
2017-09-25 - de
Identification of Warning
Indicates a danger which may lead to fatality or severe injuries if not
avoided.
Identification of Caution
Indicates a danger which may lead to injuries if not avoided.
General, M010.000.000-02-0001 1 (2)

Identification of Note
Indicates measures designed to avoid material damage.
Identification of Information
Contains useful information.
Clearances and tolerances, temperatures and pressures

Clearances and tolerances, as well as temperatures and pressures are con-
tained in volume 010.005 Engine - Operating manual, Section 3.5.
The Work Instructions 010.000.003-04 and 010.000.003-05 as well as
010.000.003-07 contain the values for the tightening of bolted connections
and associated lubricants.
Ordering Tools
Instructions on ordering tools or parts of tools can be taken from Section 4.3
in Volume 010.005 Engine - operating manual or Volume 010.005 Engine -
Spare Parts Catalogue.
45035997996990603
2017-09-25 - de
2 (2) General, M010.000.000-02-0001

Tools/aids required
Comment
As an introduction, the Work Instructions contain a list of the tools and equip-
ment required for the described maintenance work in the Required tools/auxil-
iary equipment section. See example in the following table.
Quantity Designation Number Status
1 Removal and installation device 322.056 Option
2 Bracket 322.056-1 Option
1 Rail 322.056-4 Option
1 Open-jaw and ring spanner (set) 009.231 Option
4 Shackle A0.6 002.452 Standard
1 Hex screwdriver (set) -- Inventory
1 Lifting tackle with rope -- Inventory

Table 1: Example: list of required tools/auxiliary equipment
27021599487554443
Quantity
Quantity of required tools/ auxiliary equipment necessary for the work steps.
Designation
Designation of required tools/ auxiliary equipment necessary for the work
steps.
Number
Tool number of required tools/ auxiliary equipment necessary for the work
steps.
Status
▪ Inventory: refers to tool/auxiliary equipment which is not included in the
standard scope of supply. We assume that such tools/auxiliary equipment
are generally available.
▪ Standard: refers to a standard tool/auxiliary equipment which is contained
in the scope of supply for the engine unit as standard.
▪ Option: refers to tool/auxiliary equipment which is not included in the
2018-09-04 - de
standard scope of supply. Such tools are supplied upon request by MAN
Tools/aids required
Energy Solutions.
27021599487554443
General, M010.000.000-03-0001 1 (1)

27021599487554443
2018-09-04 - de
Tools/aids required
General, M010.000.000-03-0001
1 Introduction
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1 (1)


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1 (1)

Operating Fluid Systems

Flushing and cleaning
Summary
Keep the operating media systems free from impurities and residue, prevent
operational problems / damage.
Flush all engine-connected operating media systems before commissioning,
clean individual parts before installation. Depending on the system, this in-
cludes:
Flush system(s) (Step 1),
flush system(s) (Step 2),
drain system(s) and
clean components.
Safety requirements
l Engine stopped
l Fuel systems isolated / depressurised
l Engine secured against starting up
1. Lube oil system
1.1 Pipe section between the indicator filter and the engine inlet flange
(engine without attached lube oil filter)
In case of engines without attached lube oil filter, the pipe section between
the plant-related lube oil filter and the engine inlet flange is to be cleaned with
special care. Contaminants arising from this pipe section enter the lube-oil
supply system directly and can cause severe damages to this. In order to al-
low internal visual examination of this pipe section completely, each pipe bend
is to be installed using a pair of flanges. All the internal welding seams are to
be thoroughly smoothed over by grinding.
The pipe section is to be acidified, neutralised and treated with slushing oil ac-
cording to Work Card 010.000.001-03, which is later dissolved with lubricat-
ing oil (e.g. Esso Rustban No. 335, Shell Ensis Oil, Valvoline Tectyl, Tecto 6
SAE 30). If installation is to take place later, the openings are to be sealed with
covers. Our commissioning staff is instructed to check this equipment for
cleanliness before filling the system.

2020-12-08 - de
Prevent bearing damages

The pipelines are to be cleaned with utmost care. Severe bearing dam-
age can arise due to dirt particles entering the engine.
1.2 General information on the flushing the engine lube oil system
Dirt particles will always remain in the pipes in spite of careful installation and
cleaning. This requires thorough flushing of the entire lube oil system before
commissioning using electric lube oil pump. For engines with an ached lube
General, M010.000.001-01-0007 1 (9)

oil pump and electric priming pump with low flow rate, a separate lube oil
pump with sufficient flow rate. A sufficient flow rate is achieved when the lube
oil pressure before engine (after filter) > 3 bar (on pressure gauge) and the
volumetric flow is > 70% of the engine's nominal volumetric flow. Before / dur-
ing and after the flushing process, oil must be cleaned continuously by means
of a separator.
1.3 Flushing oil to be used

For the flushing operation, we recommend a special flushing oil with a (low)
viscosity of 45-70 cSt / 40°C (e.g. SAE 20). This oil is light and therefore re-
quires no preheating.
If no flushing oil is available, the operating oil SAE 40 to be subsequently used
for operation can be used for flushing. In these cases, the oil must be pre-
heated to 40-50°C (preheating units, separator preheater). The engine cooling
water must be preheated to at least 60°C to prevent condensed water form-
ing (or corrosion in the crankcase). During and after the flushing operation, oil
must be cleaned continuously by means of a filter and separator.
1.4 Preparation for the first flushing process (flushing the pipe system
outside the engine)
Hereby, only the pipe system outside the engine is flushed.
Laying a temporary pipeline Detach the plant-side pipeline from the last filter unit to the lube oil inlet flange
for return flow of the engine. Install a temporary pipeline for return flow from the plant-side
last filter unit to the crankcase. (Lay it through one of the crankcase covers in
the engine frame).
Installing a provisional lube A provisional lube oil filter (filter mesh < 50 μm) must be installed if:
oil filter ▪ No adequate plant-side lube oil filter is provided, and the automatic lube
oil filter is installed on the engine side. The provisional lube oil filter should
preferably be integrated in the provisional installed pipeline (for return
flow). The provisional lube oil filter must be designed depending on the
volumetric flow rate of the flushing pump used. The lube oil filter must
have a magnet installed within the filter chamber.
▪ On the plant side, an automatic filter is installed to return filtered dirt
particles into the tank. In this case, a temporary lube oil filter is to be in-
stalled in the backflushing line of the automatic filter during the flushing
process. The temporary lube oil filter must be designed depending on
volumetric return flow rate of the automatic lube oil filter used.
Automatic filter The filter cartridges of the plant-side installed automatic filter are to be dis-
mantled if an indicator filter is fitted downstream. The filter casing as well as fil-
ter bypass pipes are to be involved in the flushing process.
Lube oil separator The lubricating oil separator is to be put into operation.
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1.5 Performance of the first purging process

The first purging process must be performed with special caution. Further-
more, the first purging process must be performed with utmost vigilance due
to modifications made or due to temporarily-installed pipelines and lubrication
oil filters. Hence the purging process must only be carried out by expert per-
sonnel with thorough knowledge of the system.
The purging processes must be carried out in the presence of personnel from
MAN Energy Solutions.
When switching on the lubrication oil pump, the purging process starts.
2 (9) General, M010.000.001-01-0007

During the purging process, the lubrication oil system must be continuously
monitored for leaks. Pressures and differential pressures must be monitored.
Regular check of the filters At the start of the purging process, the temporarily-installed lubrication oil fil-
ters must be checked for contamination at short intervals. This is particularly
important if they are not equipped with differential pressure indicators. An ex-
cessive contamination level can lead to inadmissibly high pressure values,
thus causing damage to the filter fabric. If an indicator filter is used as lubrica-
tion oil filter, this must also be checked at short intervals. When the maximum
differential pressure is reached, switch over to the other filter chamber. Con-
taminated filter inserts must be professionally cleaned.
Hammer testing the entire All lubrication oil pipes, especially in the area of weld seams, should be ham-
pipe system mer tested throughout the purging process.
Lubrication oil cooler The lubrication oil cooler must be included in the purging process. Manual op-
eration of the temperature control valve alternately purges the cooler and its
bypass pipe.
Lubrication oil separator Proper operation of the lubrication oil separator must be continuously mon-
itored.
Minimum purging duration The minimum purging duration is 24 hours. However, the purging process
is 24 hours may only be terminated when filter contamination has reduced to a minimum.
The lubrication oil pump must be switched off.
1.6 Measure after the first flushing operation completed — Preparation for
the second flushing operation (flushing the pipe system outside the engine)
Removing the temporary ▪ Remove the temporary pipeline (for return flow) laid from plant-side last fil-
measures ter unit (upstream of lube oil inlet on the engine) to the crankcase.
▪ The lube oil inlet on the engine is to be re-connected to plant-side lube oil
system.
▪ The temporary installed filters are to be removed.
▪ The automatic filters are to be re-fitted.
▪ Re-connect opened bypass lines if necessary.
Cleaning the filters After the first flushing sequence is complete, clean the sieve inserts of the in-
dicator filter and check them for any damage.
Post-lubrication tank (upper If the engine or plant is equipped with post-lubrication tanks to ensure the
tank) for emergency power post-lubrication after shut-down or blackout these tanks shall be included in
unit and turbocharger the flushing circuit during the second flushing procedure. To remove the con-
taminations eventually present in the post-lubrication tank (upper tank) the oil
inlet and the oil outlet pipes shall be cross-connected, i.e. the pipes (with
round flanges) shall be cross-connected using available pipes and short flex-
ible hoses. Oil is then pumped through the overflow pipe into the post-lubrica-
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tion tank and is drained via the filling pipe again.

In addition, the lube oil feed pipe of turbocharger shall be closed, as the tur-
bocharger was already flushed during the test run. Remove the throttle plate
(orifice) installed in the filling pipe. If provided, a pressure control valve for set-
ting the lube oil pressure at turbocharger inlet is installed upstream of the tur-
bocharger. The pressure control valve is to be released.
1.7 Carrying out the second purging process

By installing the pipeline (cleaned) to the lubrication oil inlet on the engine, the
engine with its bearing points and spray nozzles is now included in the pur-
ging process.
General, M010.000.001-01-0007 3 (9)

The purging processes must be carried out in the presence of personnel from
When switching on the lubrication oil pump, the purging process starts.
During the purging process, the lubrication oil system must be continuously
monitored for leaks. Pressures and differential pressures must be monitored.
Minimum purging duration The minimum purging duration is 12 hours. However, the purging process
is 12 hours may only be terminated when filter contamination has reduced to a minimum.
The lubrication oil pump must be switched off.
Check differential pressure

If a running-in filter is attached to the engine, it must be monitored
continuously for differential pressure and, if necessary, cleaned.
1.8 Measures after carrying out the second flushing process

Removing the temporary ▪ The temporary measures installed for flushing the upper tank are to be re-
measures moved.
▪ Other temporary devices are to be removed.
▪ Contaminated filters are to be cleaned, if required.
Removal of flushing oil from If special flushing oil has been used, the lube oil system must be drained com-
the system pletely. Any oil remaining in the cooler, filter and separator preheater must be
removed via the drain pipes. The filter inserts must be cleaned correctly and
checked for damage.
If the flushing process has been carried out using the operating oil and the
findings of the oil analysis are satisfactory, the system does not need to be
drained.
1.9 Running in filter on the engine

If necessary, a running in filter is attached directly to the engine. The running in
filter is to be used from the beginning of the test run at the engine manufac-
turer's premises up to the completion of commissioning on-site.
Since the running in filter is not switchable, there will be a limited standstill in
operation (depending on the lubricating oil condition). An extended period of
operation with an activated contamination display can lead to problems in the
lube oil supply. Therefore, when the differential pressure alarm is triggered, in-
creased attention is to be paid to the lube oil pressure in front of the engine,
and the filter insert must be cleaned as soon as possible, in accordance with
the manufacturer's instructions.

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Remove the filter insert after the system run-in period (normally after comple-
tion of commissioning) - but definitely before taking up continuous operation
of the equipment. The filter body remains in the engine. After that, there will be
no further filtering effect from this running in filter. A corresponding note on the
filter body points this out.
In case of structural changes to the lube oil system, or for other reasons that
require flushing the lube oil system, the filter insert must be refitted until the
flushing process is complete.
4 (9) General, M010.000.001-01-0007

2. Fuel oil system

The pipeline between the double filter installed directly upstream of the engine
and the engine inlet must be cleaned thoroughly.
For a thorough visual inspection of the internal part of the pipe, the latter must
be separated by a flange connection at every bend. Internal welding seams
must always be ground smooth. In accordance with Work Instructions
010.000.001-03, the individual pipe sections must be pickled, neutralised and
treated with slushing oil. It must be possible to dissolve the used slushing oil
with diesel oil (e.g. Esso Rustban No. 335, Shell Ensis, Valvoline Tectyl, Tecto
6 SAE 30). All openings that are not immediately closed during assembly must
be sealed.
The personnel responsible for the commissioning are instructed to check
these pipes for cleanliness before filling the system.
2.1 Flushing the fuel system

This system must also be flushed in two processes in order to entirely remove
the installation dirt from the pipes. Distillate oil or diesel oil should be used for
this purpose.
2.2 First flushing process (without engine)

During this process, the entire shipyard-side or installation-side pipe system is
flushed via the existing single or duplex filter. If the single or duplex filter is
built-in on engine and thus not usable for the first flushing process, a separate
flushing filter with maximum filter mesh of 25 µm must be used.
The bypass pipes existing in the system (e.g. for viscosity control units, heat
exchangers, etc.) must be opened. It is recommended to install an additional
magnet separator before the feed pump on plant side - only for the period of
the complete flushing process. The filter cartridges of the automatic filter must
be removed to flush the filter housing.
The fuel flow and return pipe must be connected to each other in front of the
engine by means of a temporary bypass pipe. The fuel oil system is to be
switched so that the entire pipe system will be flushed, and fuel oil will return
into the service tank. In the meantime, put the heat exchangers in the fuel oil
return line (if any) into operation! Flush the system with the opened return line
to the service tank.
When starting the plant-side feed pump, the flushing process starts. The
booster pump remains in this case deactivated. The flushing process must be
performed until the filters are free of contaminants and impurities. To determ-
ine the cleanliness of the total shipyard-side or plant-side pipe system the
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single or duplex filter must be cleaned several times during the flushing pro-
cess depending on the loading. After completion of the flushing process the
cocks of the plant-side bypass pipes, e.g. of the automatic filter, viscosity
control units or mixing pipe must be closed.
Experience shows that the minimum flushing duration is 24 hours.
After closing the above listed bypass pipes in the supply and return lines the
new connected components must be flushed within an additional period of
about 6 h.
General, M010.000.001-01-0007 5 (9)

After completing this flushing process, all temporary modifications on the fuel
oil system are to be cancelled. All filter elements including the pre-filter of the
feed pump ("strainer") must be cleaned according to the manufacturer's in-
structions and checked for eventual damage, and replaced if necessary.
2.3 Second purging process

The purging process must be carried out in the presence of personnel from
The fuel supply and return pipe must be connected to the engine. The entire
fuel system including the engine is now purged. In the case of common rail
engines, the purging valve must be opened by manual actuation of the com-
pressed air after about 2 hours of purging.
The purging process starts when the plant-side booster pump is actuated.
The purging process must be performed until the single or duplex filters are
free of contaminants and impurities. To determine the cleanliness of the sys-
tem as a whole, the single or duplex filter must be cleaned several times dur-
ing the purging process, depending on the loading.
Experience has shown that the minimum purging duration is 6 hours.
2.4 Draining and Cleaning the System Components

The end preheater, the filter chambers and if applicable the existing mixing
tank must be de-sludged through their drain pipes. After 24 hours settling
time, the service tank must also have the sludge drained off.
3. Cooling water system

Before commissioning the engine and injection valve cooling system, ensure
that there is no rust or other deposits on the surfaces where the cooling water
is admitted.
If rust is detected, the system needs to be cleaned in accordance with Work
Instructions 010.000.001-03 and 010.000.002-04.
The cooling water system must be flushed with fresh water prior to commis-
sioning the engine. Add a detergent to the water in order to remove any
residues of the preservative used. Suitable agents are listed alphabetically in
Table 1. Detergents by other manufacturers may also be used provided they
have the same properties. After cleaning, rinse with untreated fresh water.
In order to filter out coarser impurities, temporary installation of strainers is a
must. The mesh must be 1 mm for the low and high temperature system.
The smallest gap in the injection valve is 0.5 mm. Provisional installation of a
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strainer with a width of mesh of ≤ 0.25 mm is necessary for flushing the cool-
ing water system of the injection valves in order to prevent dirt deposits here
and thus avoid reduced heat dissipation.
The integration of two gate valves in each case means that there will be no
water leakage when cleaning or removing the strainers.
After flushing, the fresh water is to be treated in accordance with the quality
requirements for cooling water. See 010.005 Engine - Operating Instructions,
010.000.023-14.
Manufacturer Product Concentration Cleaning Time / Temperature
Drew HDE - 777 4 - 5% 4 h at 50 - 60 °C
6 (9) General, M010.000.001-01-0007

Manufacturer Product Concentration Cleaning Time / Temperature

Nalfleet MaxiClean 2 2 - 5% 4 h at 60 °C
Unitor Aquabreak 0.05 - 0.5% 4 h at ambient temperature
Seaclean Plus 0.5% 4 h at 50 - 60 °C
Vecom Ultrasonic 4% 12 h at 50 - 60 °C
Multi Cleaner
Table 1: Detergents for removing oily residues
4. Compressed air system
4.1 Installation-side system

The whole system must be carefully cleaned before operating the engine. All
pressure and control pipes must be free of flammable media and slag, scale
and rust.
High noise levels

When blowing out the piping with compressed air, high noise levels are
produced.
• Wear hearing protection
Danger of fire/explosion
Flammable fluids (slushing oil, ...) may be ignited by open flames and
hot surfaces. Insufficient ventilation may result in low-speed detona-
tion/explosion.
• smoking, fire and naked light prohibited
• allow hot surfaces to cool down, or cover them
• provide adequate ventilation
• wear protective clothing
The air pipes are cleaned by blowing through 3 or 4 times with compressed
air at a pressure of 30 bar from the starter air tank.
In order to do this, separate the installation-side pipeline from the connection

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flange on the engine and securely fasten the pipeline to prevent deformation
when blowing. Close the open engine entry point. Also remove the control air
pipe in front of the engine. The blowing out of the system is carried out by
opening the slide-valve on the connecting tank.
After the cleaning process, reconnect all the pipes that have been removed.
4.2 Engine-side system

Primary pressurisation of the engine-side compressed air system may only be
performed by the personnel responsible for commissioning.
General, M010.000.001-01-0007 7 (9)

Fundamentally, proceed as follows with first pressurisation of the engine-side

compressed air system:
1. Any fuel oil supply/gas supply to the engine is blocked.
2. Emergency stop devices have been tested and are functional.
3. Open any indicator valves on the cylinder head if necessary.
4. Actuate the engine with brief compressed air pulses via the local start
button on the engine (pulses of 1-2 seconds) so that the engine only
briefly turns and only few crankshaft revolutions occur.
5. The actuating time of the start button can be increased to up to 5
seconds if the engine turns and runs down again each time.
6. This process is considered to be completed when the engine turns
without problem and then runs down again after an actuation duration in
accordance with the later starting operation (approx. 5 seconds).
5. Gas system
5.1 Installation-side system

Prior to starting up, make sure that both internal and external piping is made
of high quality stainless steel in accordance with the specifications of MAN
Energy Solutions.
The whole system must be carefully cleaned before operating the engine. All
pipes must be free of flammable fluids and slag, scale, rust, oil and passivat-
ing agent.
High noise levels

produced.
Danger of fire/explosion
Flammable fluids (slushing oil, ...) may be ignited by open flames and
hot surfaces. Insufficient ventilation may result in low-speed detona-
tion/explosion.
• smoking, fire and naked light prohibited
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• allow hot surfaces to cool down, or cover them

• provide adequate ventilation
• wear protective clothing
The gas pipe is cleaned by blowing through 3 to 4 times with air compressed
to 8 bar. For this purpose, detach the pipe on the gas control unit and on the
engine connection on the plant side, and securely fasten it. The open pipes at
the engine connection and at the gas control unit outlet must be closed. Con-
8 (9) General, M010.000.001-01-0007

nect compressed air to the gas pipe on the plant side, and blow the pipe
through. After the cleaning process, reconnect all the pipes that have been re-
moved.
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General, M010.000.001-01-0007 9 (9)

72057605048855435
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General, M010.000.001-01-0007
Piping and corresponding components

installation and replacement
Summary
Insert/replace components, process and install professionally. Pipes must be
replaced/supplemented if necessary. The materials must, therefore, be selec-
ted according to the requirements, and must be properly processed.
This covers: choosing suitable materials, correct processing and correct as-
sembly of the piping and corresponding components such as tanks and other
equipment which is in contact with the corresponding media.
General regulations
Surfaces and surface treatment of media circuits

Fuel circuit It is prohibited to use components made of zinc, copper and lead or their
base alloys in the fuel circuit.
If this cannot be avoided, surfaces containing zinc, copper, and/or lead (also
applies to any surface treatment for corrosion protection of the components)
must be treated in such a way that the metal is fully protected against any
contact with fuel. These metals are responsible for chemical reactions in the
fuel. The products resulting from these reactions can cause failure or at least a
reduction in service life of the injection system and the exhaust gas aftertreat-
ment system (if installed).
Seals must be selected specifically so that zinc, copper and lead materials
and their base alloys are avoided as much as possible.
Oil circuit It is prohibited to use components made of zinc, copper and lead or their
base alloys in the oil circuit.
If this is not possible, surfaces containing zinc, copper, and/or lead (also ap-
plies to any surface treatment for corrosion protection of the components)

contact with engine oil. These metals are responsible for chemical reactions in
the engine oil. Among other things, this can trigger premature ageing of the
engine oil. This, in turn, has a negative effect on the service life of the com-
ponents in the oil circuit (e.g. bearings).
Seals must be selected specifically so that zinc, copper and lead materials
and their base alloys are avoided as much as possible.
Coolant circuit It is prohibited to use components made of zinc, copper and lead or their
2019-07-08 - de
base alloys in the coolant circuit.

If this is not possible, surfaces containing zinc, copper, and/or lead (also ap-
plies to any surface treatment for corrosion protection of the components)
contact with coolant.
The use of brass must be kept to a minimum. Brass may only be used if the
component cannot be made of an alternative material which is free of non-fer-
rous metals. There is only low compatibility between the non-ferrous metal
surfaces and the constituents of the coolant additive. There is no compatibility
between zinc and the constituents of the coolant additive.
General, M010.000.001-02-0005 1 (4)

Damage resulting from using the metals listed above

Damage resulting from using the metals mentioned above (incl. their
base alloys) and surface treatments and the metals mentioned above
contained in the media circuits are not the responsibility of MAN En-
ergy Solutions.
Removing ferrous metals If the metals mentioned above are removed from surfaces mechanically, it
from the media-carrying must be ensured that the grinding or blasting material used as well as other
circuits residues from the cleaning process are removed from the media circuits
without leaving behind any residue before the circuit is filled with media. For
this process, the cleaning instructions for the corresponding media circuits
must be consulted and followed.
Before filling with media, the circuit must also be free from corrosion or other
corrosion products. This can be achieved by applying a media-compatible
corrosion protection agent after removing the corresponding prohibited corro-
sion protection layer. A list of suitable corrosion protection agents can be
found at http://dieselturbo-staging.md-man.biz/preservation.
In the case of fuels and engine oils, agent b, agent d, agent e (fuel only!) and
agent m can be used. In order to achieve satisfactory corrosion protection,
the ambient conditions must be taken into account.
For the coolant circuit, agent m can be used.
Preliminary remark
If any pipes in the fuel, lubricating oil, cooling water or starting air system, or
on the pneumatic operating device need to be repaired, modified or replaced,
the instructions in the following paragraph must be observed in order to avoid
malfunction in subsequent operation.
Before working on pipelines, clarify whether plant-related, specific require-
ments prescribed by authorities or special guidelines for materials, manufac-
turing, installation and inspection of pipelines are applicable.

In each case, the highest requirements are applicable.
Instructions
Pipe dimensions In general, the pipes with identical dimensions are to be refitted on the engine
when replacing the pipelines.
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Material specification for General

piping and corresponding The properties of pipelines must be in accordance with international norms,
components e.g. DIN EN 10208, DIN EN 10217, DIN EN 10305 or DIN EN 13480.
For pipelines, carbon steel must be used. Stainless steel may be used, where
it is required.
The pipes must be clean and free of outer and inner surface defects. The
pipe's inner wall must be cleaned thoroughly, and all chips, grits, dirt and
sand must be removed.
The pipes are to be externally primed and painted. Surface coatings on pipes
containing any of the metals mentioned above (zinc, copper, lead) or are
based on them (e.g. plating) are not permissible or must be coated further to
2 (4) General, M010.000.001-02-0005

ensure that any contact between the metal and the fluid is avoided. Alternat-
ively, the coating must be completely removed before use. The same require-
ments must also be observed for tanks and equipment.
LT, HT, and nozzle cooling water system

The specifications in the section General regulations must be observed.
Erosion appears at points where the zinc layer is not properly bonded to the
pipe surface.
Recommended materials (EN)
▪ P235GH
▪ E235
▪ X6CrNiMoTi17 - 12-2
Fuel / lubricating oil system

The specifications in the section General regulations must be observed. It
must be ensured that no traces of zinc, copper and/or lead remain in the sys-
tem. This must be ensured by employing suitable measures.
▪ P235GH
▪ E235
Gas pipes
No galvanised steel components must be used in gas system.
▪ P235GH
▪ E235

Connecting line between gas duct and engine
Generally, stainless pipes are to be used for the connecting line
between gas duct and engine.
Starting air pipes / Control air pipes

No galvanised steel pipes and corresponding components may be used in the
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starting air and control air system.

▪ P235GH
▪ E235
General, M010.000.001-02-0005 3 (4)

Urea pipes (for SCR catalytic converter system only)

No unalloyed steel pipes, galvanised steel pipes, brass pipes or copper pipes
may be used in the SCR catalytic converter system. The selected material for
all components must be resistant to the highly corrosive medium urea. This
also applies to sealing materials (e.g. seals made of copper or copper-based
alloys are not permissible).
Recommended material (EN)
Production Pipes of a small diameter may be cold-bent using commercial pipe bending
devices. No pipe bending is allowable by means of sand.
When using solderless pipe unions in accordance with DIN 2353, heat treat-
ment may, in most cases, be avoided (see Work Card 010.000.001-04).
Any welding on stainless pipelines must be performed so that the stainless
properties of pipe materials inside and outside are not affected.
Before performing the weld connection of pipes with pre-fabricated pipe
bends, make sure that the surfaces are rust-free and clean. After welding,
make sure that the surfaces are smoothed, non-contaminated, without weld
slags, weld beads and scale.
For air pipes of the pneumatic operating device and for these in the starter
system as well as for gas lines of the high-pressure gas system, stainless
screwed fittings may only be used. Particular attention shall be paid to the
thread, since, depending upon the location, both metric and Whitworth
threads, and both cylindrical and cone shaped, can be provided.
If hot bending becomes necessary when using other pipe qualities or larger
dimensions, or if soldering and/or welding is used on the pipes, then the pipes
must be acidified, leached and washed afterwards (see Work Instructions
010.000.001-03).
Production of lube oil pipes Lube oil pipes with larger diameter, especially the pipe after the lube oil fil-
ter(s), are to be manufactured by bending. Connection flanges and sockets
must be joined to the pipes by gas welding.
When gas welding is used, the slag on the filler rod jacket is not required. This
is of special importance, since the roots of the welding seam penetrate to the
inside of the pipe, i.e. the joint gap must be completely filled. On the inside of
the pipe no unfilled butt joints may remain since foreign bodies could become
stuck there. They would not (hardly ever) be eliminated by cleaning the pipes,
and could be drawn into the engine bearings during operation. Operational
malfunction caused by damage to the bearings could result. If prefabricated
pipe bends have to be welded in, then intermediate flange connections are to
be used, whereby their number and location are to be selected in such a way
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that the welding seams inside the pipe line can be seen clearly, filled up and
checked.
The above welded joints can also be made using the TIG welding method.
Both with gas welding and with TIG welded joints, the tack and finished weld-
ing seams must be carried out using the same welding method.
Laying/Support When laying the pipes, ensure that the pipe routing and fastening is as vibra-
tion-free as possible. Pipes must not be supported on oscillating or vibrating
parts. Oscillations harden and embrittle even soft copper pipes which can res-
ult in the formation of cracks.
27021608776947723
4 (4) General, M010.000.001-02-0005

Pipelines
cleaning, pickling and preservation. Carry out the pressure test
Summary
Keep operating media systems free from contamination and residues, ensure/
restore operating safety. Pipes that are replaced or added must, after manu-
facture/machining, be mechanically or chemically cleaned, and preserved if
required.
Depending on the actual situation, this includes: Mechanical cleaning of the
components, chemical cleaning of the components, a pressure test and pre-
servation.
Preliminary remark
All pipes used in the fluid systems of the engine as a replacement shall be
cleaned mechanically or chemically after manufacture. If pipes are not at-
tached immediately, they shall be preserved and closed on ends. Sealing
plugs or plastic caps are ideal for closing. For this purpose, sealing plugs or
caps in conspicuous colours are optimal to ensure that they are not over-
looked during installation.
Normally, mechanical cleaning is performed on the cooling water, heating, ex-
haust gas and intake air systems. Mechanical and chemical cleaning is per-
formed on the lubricating oil, fuel, compressed air, gas, steam and water con-
densate system piping. Isolating and regulating units, as well as other devices
in the individual systems, may only be fitted after the cleaning process.
All pipe systems must undergo a compression test, either in sections, or as a
whole system. The entire lubricating oil, fuel, gas and compressed air system
must be thoroughly rinsed before commissioning the engine installation.
If pipes of stainless steel are used, chemical cleaning may be omitted,
provided the welded seams are of high quality.
Notes on acids and alkaline solutions

Properties and dangers Liquid acids and alkaline solutions as well as their vapours may cause irrita-
tion, inflammation and damage to skin, mucous membrane and eye tissue de-
pending on the concentration, exposure time and temperature. Prolonged
contact may lead to necrosis (local tissue death), in the case of contact with
eyes to irreversible damage to the cornea (scarring, clouding) or perforation.
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The vapours can also cause extreme and painful visual impairment and thus
impede escape.
If the respiratory organs are left exposed without any protection, this may lead
to irritation of the throat, inflammation of the upper airways and even oedema
(risk of suffocation). Swallowing concentrated acids poses life-threatening
danger.
Acids often have other properties which are dangerous to health, such as tox-
Pipelines
icity (hydrofluoric acid), flammability (acetic acid), or oxidising properties (nitric

acid). Acids react violently and exothermically with alkalis and many organic
materials. Concentrated sulphuric acids can destroy many organic sub-
General, M010.000.001-03-0005 1 (6)

stances by dehydration. Knowledge of these health risks, including the afore-

mentioned special properties of these materials, is an important prerequisite
for safe handling.
Technical protection device Technical protective measures can prevent dangers most effectively.
and safety devices Examples of such measures are:
▪ Replacing dangerous materials with less dangerous ones
▪ Effective ventilation measures
▪ Explosion-proof electrical devices and installations
▪ Closed or automatically operated systems
▪ Organisational measures (transparency, cleanliness, care)
Personal protective meas- Do not smoke, eat or drink in areas where chemicals are stored and handled.
ures Wear personal protective equipment:
▪ Dense and acid-resistant protective gloves (with long cuffs where re-
quired)
▪ Protective eyewear or visor, if required also breathing apparatus (mask)
with the correct filter
▪ Protective suit, overalls or apron
▪ Antistatic protective shoes or protective boots
Mechanical Cleaning
High noise levels

produced.
Acid burn risk

Liquid acids and alkaline solutions as well as their vapours may cause
severe injury if not handled properly.
• Wear personal protective equipment
• Ensure sufficient ventilation or extraction
• Do not inhale developing gases and fumes
• Observe the Safety Data Sheets or operating manual of the relevant
2019-07-08 - de
manufacturer
Scale and weld splatter shall be removed carefully from the welded joints, us-
ing a chisel, file or grinding disc. The complete pipe section shall be knocked
with a hammer and blown through with compressed air, simultaneously if
possible, so that even the smallest particles are removed.
Pipelines
All pipe connections are to be blocked off until assembly.

For pipes cleaned mechanically and chemically, an acid bath is required. The
acid bath device essentially consists of:
▪ a hydrochloric acid bath for steel pipes
2 (6) General, M010.000.001-03-0005

▪ a water bath for washing the acid off

▪ an alkaline bath for neutralising and phosphating
▪ a sulphuric acid bath for copper pipes
With the hydrochloric acid and sulphuric acid bath, the rising vapour must be
extracted using fans and dispersed via wet scrubbers. The vapour from the
alkaline bath must also be directed outside using a fan. The regional protec-
tion regulations must also be observed.
The water bath needs a water connection and a compressed-air connection.
The alkaline bath must be capable of being heated up to 80 C.
Treatment of Steel Pipes by Pickling
Acid burn risk

manufacturer
First pickle in the hydrochloric acid bath and then in the tri-sodium phosphate
bath for neutralising the acid and for simultaneous short-term preservation.
Hydrochloric acid (HCI) is available commercially at a concentration of 31-33
%, and with less than 1 % arsenic.
Mixing ratio for the HCl bath: H20 = 3 : 2 (by weight).
The treatment must not to be performed at a temperature below 20 C. The
duration is determined by visual inspection.
With pipes with threads, acid corrosion on the crest of the thread must be
monitored. It determines the duration of treatment in this case.
After completion of the pickling procedure, the acid solution adhering to the
pipes must be washed off in the water bath.
The acid solution which remains in the grooves and pores in the surface tex-
ture is neutralised in a tri-sodium phosphate bath. Here, the pipes are simul-
taneously coated with a phosphate layer which provides short-term protection
2019-07-08 - de
against corrosion.
Mixing ratio for the bath Na3PO4 : H2O = 1 : 8 (by weight). Treatment temper-
ature 80 C.
Pipelines
General, M010.000.001-03-0005 3 (6)

Unwanted chemical reaction

Copper pipes should not be treated in a hydrochloric acid bath if steel
pipes are to be pickled afterwards.
The reaction of the copper (Cu) with the diluted hydrochloric acid (HCl)
creates the salt copper chloride dissociated in the aqueous solution
(CuCl2). If a steel pipe is placed in the pickling bath again, the base iron
in the steel oxidises by the discharge of its positive charge units, so
that iron ions go into solution, while the copper separates out. The
steel pipe gets coated with a not intensely adhesive layer of copper.
Copper deposits are undesirable on the internal walls of fuel-carrying
pipes. Washed-off copper particles cause subsequent operational mal-
functions in the injection elements, such as pumps and nozzles.
Treatment of Copper Pipes
Acid burn risk

manufacturer
First pickle in the sulphuric acid bath and then possibly in the tri-sodium phos-
phate bath for neutralising the acid, and for phosphating.
Sulphuric acid (H2SO4) is commercially available at a concentration of 98 %
(concentrated acid). It must be transported in closed tanks.
Mixing ratio for the bath H2SO4 : H2O = 1 : 8 (by weight).
Before using, rest the prepared bath for 24 hours.
Treatment duration: initially 1/4 hour for copper pipes, later on increasing the
duration at appropriate levels in accordance with the age of the bath.
After taking the pipes out of the sulphuric acid bath, the pipes must be rinsed
2019-07-08 - de
with water and dried afterwards using a gentle flame.

A neutralisation in the tri-sodium phosphate bath is not required; with longer
storage it is advisable for the prevention of verdigris formation.
Carry out the pressure test

A pressure test must be carried out after work on pipeline systems. The
Pipelines
pipeline system must show no leaks and deformations under the respective
test pressure (see 010.005 - Engine operating manual, chapter
010.000.035-02). Performance of a pressure test must be documented in the
operation logbook.
4 (6) General, M010.000.001-03-0005

Rupture of pipelines
High pressure may result in rupture of pipelines. Due to pressure wave
effect as well as due to fragments and parts ejecting around persons
may be injured very seriously.
• The pressure test of the pipe system concerned may only be per-
formed with specified test fluid and at specified pressure.
• Presence during the pressure test – as far as possible outside the dan-
gerous area.
Lubrication oil system

The pressure test of the lubrication oil system must be carried out with lubric-
ation oil as test fluid.
Fuel system
The pressure test of the fuel system must be carried out with a distillate fuel
as test fluid. This distillate fuel must meet the specification of MAN Energy
Solutions. (see 010.005 Engine operating manual, chapter 2.3)
Cooling water system

The pressure test of the cooling water system must be carried out with water
as test fluid.
Gas system
The pressure test of the gas system must be carried out with air or water as
test fluid.
Starting air system

The pressure test of the starting air system must be carried out with air or wa-
ter as test fluid.
Control air system

The pressure test of the control air system must be carried out in form of a
leak test.
During the respective pressure tests, observe the following items:

▪ Components such as filters, coolers, etc. must be excluded from the
2019-07-08 - de
pressure test. Insert blanking washers if necessary.

▪ Operational pressure gauges as well as measuring and regulating devices
must be excluded from the pressure test. For these components, pres-
sure/leak-tightness tests must be carried out in accordance with relevant
manufacturer’s instructions.
▪ If the pressure test is carried out with water as test fluid, the piping must
be preserved immediately after the test.
Pipelines
General, M010.000.001-03-0005 5 (6)

Preservation of Pipes
For short term storage under a roof or in dry warehouses, phosphating and
applying an oil film provides sufficient corrosion protection. Phosphating also
offers a sound basic protection before applying the actual corrosion protec-
tion in form of slushing oil, varnish or fat in case of long-term storage for ser-
vice. Pipe end and connection points must be sealed with coloured plastic
caps. Plastic caps in signal colour have the advantage that they are more eas-
ily noticeable when attaching the piping to the engine. They must always be
removed again for assembly.
The base coat for the preservation must not contain any zinc, copper and/or
lead since this can cause damage to the engine.
45036007286434699
2019-07-08 - de
Pipelines
6 (6) General, M010.000.001-03-0005

Solderless pipe unions

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

Solderless pipe unions Accessories 010.000.001-05
Advantages of solderless pipe unions

Solderless pipe unions are preferably used where small diameter pipes can be
cold-bent, i.e. where no heat treatment is necessary. The usual process of
pickling and neutralising is then not required.
Copper pipes must be provided with reinforcing sleeves on the inside. See
Work Instructions 010.000.001-05.
Work steps
1. Cut pipe at a right angle and deburr. Pipe cutters (see figure 1) are per-
fect for doing this. The pipe is cut through using a cutting wheel. The in-
ternal edge of the pipe can then be deburred using the 3 blades in the
handle or using a counterbore tool. Remove swarf by blowing out!
2. Oil (do not grease) the threads and the cutting ring and the tapered ring
2014-04-09 - de
(4) well. Then slide the nut and ring over the pipe end as shown. If the
cutting and tapered ring cannot be pushed over the pipe end, or if this is
difficult to do, do not expand the ring but reduce the pipe end by grind-
ing/filing.
3. Screw the cap nut on by hand up to perceptible contact with the cutting
ring and tapered ring. Then push the pipe against the stop in the inner
cone and tighten cap nut by about 1/2 to 3/4 revolution. By doing this,
the cutting and tapered ring grips the pipe. It is no longer necessary to
continue pushing the pipe. Final tightening is performed by a further tight-
ening of the cap nut by approx. one revolution. Here the ring cuts into the
pipe and a visible collar (6) rises before its cutting edge. A line (7) marked
on the cap nut allows you to monitor the stipulated number of turns.
General, M010.000.001-04-0001 1 (4)

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

without sub-assembly, if they are firmly screwed in to the engine.
Pipes of larger outside diameter and all connections in free pipes are best
pre-assembled in the vice. The open-jaw spanner should have an ap-
prox. fifteen fold length of the width across flats (possibly extended by
using a pipe). Otherwise proceed as above. The final tightening is easier if
the cap nut is loosened several times so that oil is once again admitted
between the friction surfaces.
5. Once the final tightening has been successfully performed, loosen the
cap nut and check whether a raised, visible collar (6) fills out the area in
front of the cutting edge, if not, briefly tighten again. It does not matter if
the cutting and tapered ring on the pipe end can be rotated.
After establishing the connection, and after each release process, the
cap nut is to be tightened without using an extension for the spanner and
without using increased force.
Ensure that each pipe end again reaches the same inner cone where
pre-assembly took place.
2014-04-09 - de
Figure 1: Required tools - counterbore cutter, pipe cutter and pipe bending
device
2 (4) General, M010.000.001-04-0001

1 Cap nut 4 Cutting ring and tapered

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

2014-04-09 - de
7 Mark
Figure 3: Assembly of pipe unions. Assembly on site - on the left, pre-as-
sembly in the vice - on the right
General, M010.000.001-04-0001 3 (4)

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

2H Min. distance to a pipe D Outside diameter
bend
Figure 4: Minimum distances/Bend radii
9007201000609035
2014-04-09 - de
4 (4) General, M010.000.001-04-0001


Additional parts
Summary
Insert/replace components, process and install professionally. Accessories for
solderless pipe unions extend their application range. The following can be
used: Reinforcement sleeves, nozzle inserts and screwed hose connections.
The work/work steps include: Proper processing and installation.
Preliminary remarks
Solderless pipe unions will be used in conjunction with reinforcing sleeves,
nozzle inserts and screwed hose connections. In this way the application
range can be extended, amongst other things, to copper pipes and hose con-
nections.
Instructions
Reinforcing sleeves When using solderless screwed connections on soft copper pipes reinforcing
sleeves must be used to prevent the pipe the pipe from collapsing when tight-
ening the cap nut.
1 Reinforcing sleeve
Figure 1: Use of Reinforcing Sleeves. Left top –sleeve inserted, left bottom -
sleeve knocked in. Right factory assembled pipe union
Nozzle inserts By using nozzle inserts, the ventilation and bleeding time of the devices can
be adapted to the individual requirements. They can later be inserted into the
pipe fittings, if the cap nut has been released and the pipe pulled out before-
2012-08-20 - de
hand. Ensure that the pipe end is shortened by the length of the nozzle collar.
General, M010.000.001-05-0001 1 (2)

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

Figure 3: Using screwed hose connections
1745903755
2012-08-20 - de
2 (2) General, M010.000.001-05-0001


51354074251
1 (1)

Lubricating oil
assessing and treating
Summary
Collating and assessing operating media parameters, maintaining the consist-
ency within the permitted range, avoiding/reducing damaging effects. Lubric-
ating oil must be assessed and continuously maintained at regular intervals
with regard to consistency, in accordance with the maintenance schedule.
This includes: Analysing oil samples, maintaining and replacing operating me-
dia.
Oil Evaluation
Spot test/oil analysis The condition of the used oil in the engine must be continuously monitored.
The intervals of spot tests to be carried out on filter paper, or of oil sampling
for examination in a laboratory set up for this purpose, are specified in the
maintenance schedule. The oil sample must be taken downstream of the filter
while the engine is running. This ensures that the result will be representative
for the oil in the engine. We can analyse lubrication oil samples for customers
at our laboratory (PrimeServ Lab).
A definitive statement concerning continued use can only be made on the
basis of a full analysis, the values of which are determined by standard test
procedures.
A test kit can be obtained for routine operating media examination on site.
This enables the bunkered residual fuel and the parameters required for treat-
ment, as well as the condition of the waste lubrication oil, to be determined
with sufficient accuracy. Supporting documents can be obtained from the
company Mar-Tec., Warnckesweg 6, 22453 Hamburg.
Characteristic value Limit value Measurement method
2
Viscosity at 40°C mm /s > 110 ISO 3104
< 220
Flash point (PM) °C > 185 ISO 2719
Water content % vol. < 0.2 ISO 3733

(0.5% only permissible for a short period)
TBN % TBN ≥ 50 ISO 3771

(based on fresh oil)
2020-12-08 - de
Contamination % by weight in general < 1.5 depends on the available DIN 51 592
dispersing capacity and viscosity increase
IP 316
Metal content mg/kg dependent on engine type and operating ASTM 5185-91
Lubricating oil
conditions
Table 1: Examination of lubrication oil – parameters/limit values
Colour No conclusions concerning the level of contamination can be drawn from

used doped lubricating oil, since very fine soot particles (< 1.0 mm) are
present as a result of the dispersant-detergent-capacity, which lead to intens-
ive black colouring of the oil, even at lower concentrations. The total contam-
General, M010.000.002-01-0002 1 (3)

ination of the lube oils can be ascertained, amongst others, by using DIN
51592 or IP 316. The appearance of the spot test also allows conclusions to
be drawn.
Fuel in the lubricating oil Fuel in the lubricating oil can be verified by determining the flash point and the
viscosity of the cleaned used oil, in comparison with the values from fresh oil.
Oil change due to thinning of the lubricating oil is necessary if the oil viscosity
falls by one viscosity class, or if the flash point has dropped below 185 °C. If a
laboratory test cannot be performed, the viscosity can be determined approx-
imately as described below:
Fresh oil samples which exhibit one viscosity class higher and one lower than
the oil in the engine are dripped, together with the used oil, onto an inclined
glass or metal plate at the same temperature. You can determine from the
flow rate whether the used oil has higher or lower viscosity than the fresh oil.
Water in the lubricating oil If a laboratory test for determining the water content is not possible, a drop of
the used oil is applied to a hot plate. If there is water is in the oil it will evapor-
ate quickly and disappear with an audible noise upon overcoming the capillary
force force (crackle test). The water content in the oil should be no more than
0.2%. In the case of water content >0.5 %, an oil change is required and, if
not possible, the water content is to be reduced to <0.2% by centrifuging
carefully and/or temporary heating of the oil. Water in the oil promotes,
amongst other things, corrosion of the polished running gear components
and the formation of oil sludge, i.e. increased viscosity.
Increased water content in lubricating oil is often caused by insufficient tank
and crankcase ventilation. It is therefore necessary to drain the oil sludge and
water from the lowest point of the service and reservoir tanks at regular inter-
vals.
Air in the lubricating oil Air emulsion (oil has white appearance) or severe surface foaming appears if
there are leaks on the intake side of the pump, through which air reaches the
oil. This compromises, amongst other things, the formation of a hydrodynamic
lubrication condition in the bearing and promotes ageing of the oil.
Oil Treatment
Oil Treatment The filter installed in the main flow has the task of holding back the particles of
dirt, up to an established width of mesh. The main load is borne by the auto-
matic filter fitted, in all operational configurations and on all types of engine.
Depending on the application, an indicator filter, designed as double filter, can
also be fitted downstream of the automatic filter. It is required especially in
marine systems with single engine operation, as stipulated in the classifica-
tion.
If the correct components are selected, and if the system is serviced in an op-
2020-12-08 - de
timum way, maintenance of the filter(s) at the intervals as per the diesel engine
will be adequate.
The separator performs the task of clearing the particles of dirt from the lub-
ricating oil. The dirt caused by engine operation, such as soot, abrasion
Lubricating oil
products etc. is eliminated from the system by the separator.

In contrast to the lube oil filter, the lube oil separator works in bypass. The
design criterion in this case is the recirculation of the lube oil content within
the time period specified by the diesel engine manufacturer with the corres-
ponding approximate value.
2 (3) General, M010.000.002-01-0002

The automatically self-draining separators currently available on the market,

recommended for use in the systems described, are highly optimised on a hy-
draulic level, in the separation process, as well as on a control technology
level, so that, when selected and used correctly, a balance between the in-
gress and removal of impurities is maintained. A minimum requirement on the
operator, by the manufacturer of the diesel engine, is the synchronous opera-
tion of the lube oil separator and the diesel engine.
Oil Change
A definitive prediction of the expected useful life of the oil cannot be since the
engine manufacturers generally do not know the quality of the fuel or lubricant
oil to be used, the operational conditions under which the engine runs, and
also whether proper oil maintenance can be assumed.
An oil change is necessary if the chemical-physical parameters of the oil filling
have changed in such a way that the lubrication, cleaning and neutralisation
characteristics are no longer adequate. This can only be ascertained by full
analysis.
The parameters specified in Table 1 must be observed.
In an oil change, all the lubricating oil must be drained from the system at the
operating temperature. If the main pipe systems cannot be fully drained, the
entire system must be cleaning with flushing oil before fresh oil is added.
27021599510920843
2020-12-08 - de
Lubricating oil
General, M010.000.002-01-0002 3 (3)

27021599510920843
2020-12-08 - de
Lubricating oil
General, M010.000.002-01-0002
Lubricating oil
Carrying out the spot test
Summary
Collating and assessing operating media parameters, maintaining the consist-
ency within the permitted range. Spot tests allow the evaluation of important
characteristics with little effort. They are useful as supplements to lubricating
oil and fuel analyses. They cannot, however, substitute them.
The work includes: Preparation and assessment of spot test.
Work Sequence (during the lube oil test)

Immerse a cleaned rod (glass or wire), which should taper to a point, in the
lubricating oil at the operating temperature.
Drip the oil adhering to the rod onto the filter paper and let it dry for a few
hours at room temperature.
Compare the filter paper with the tests shown on the reverse.
Evaluation of the Lube Oil Drip Test

The spot test on filter paper indicates the degree of contamination, the pres-
ence of water or fuel and the current dispersing power of the detergent. Con-
clusions can be drawn from this information on the condition of the oil filling.
The spot test must not be regarded as a substitute for an oil analysis. If the
spot test appears abnormal compared to images made using earlier oil
charges that spent the same amount of time in the engine, this indicates irreg-
ularities, e.g. poor combustion, fuel or water leakage, insufficient oil mainten-
ance, etc. Fig. 1 shows what used doped (HD) oils look like. The lubricating oil
spot shown in sample 1 is slightly contaminated, the oil shown in sample 5
shows has been used up and an immediate oil change is required. If the oil
spot has the same appearance as sample 4, a comprehensive analysis is re-
quired to establish beyond doubt the condition of the oil filling.
Doped lubricating oils contain active ingredients that hold combustion
residues in suspension in a finely distributed form and/or prevent these from
accumulating in the engine (effect of the dispersant). The dirt particles are
smaller than the capillaries in the paper which explains why the flow effect is
more pronounced at the outer edges. When the dispersion effect reduces, dirt
particles join together and block the capillaries. The centre of the spot turns a
2020-12-08 - de
dark colour. If the edge has a radial appearance, this indicates that the lubric-
ating oil contains water or fuel.
The oil samples for the spot tests must be taken from the oil circuit at the spe-
cified intervals (also see maintenance schedule) and at the same point when
Lubricating oil
the engine is running and affixed inside a notebook.

In order to be able to compare the spot tests the same filter paper must be
used. The spot tests shown were carried out using the filter paper specified
above.
General, M010.000.002-02-0001 1 (2)

Figure 1: Spot tests of doped lubricating oils - Sample 1: slightly contaminated - Sample 4: analysis re-
quired - Sample 5: oil change required
Fuel drop test

The spot test on filter paper gives an indication of the type of the fuel, i.e.
whether distillate or blended fuel. In the case of residual fuels, the compatibil-
ity of the blended components can be determined from the appearance of the
spot test. It is recommended that the spot tests from each new bunkering be
kept in a book.
9007201001646091
2020-12-08 - de
Lubricating oil
2 (2) General, M010.000.002-02-0001

Coolant
inspecting
Summary
Acquire and check typical values of the operating media to prevent or limit
damage.
The fresh water used to fill the coolant circuits must satisfy the specifications.
The coolant in the system must be checked regularly in accordance with the
maintenance schedule.
The following work/steps is/are necessary:
Acquisition of typical values for the operating fluid,
evaluation of the operating fluid and checking the anticorrosive agent concen-
tration.
Tools/equipment required
Equipment for checking the The following equipment can be used:
fresh water quality ▪ The MAN Energy Solutions water testing kit, or similar testing kit, with all
necessary instruments and chemicals that determine the water hardness,
pH value and chloride content (obtainable from MAN Energy Solutions or
Mar-Tec Marine, Hamburg).
Equipment for testing the When using chemical additives:
concentration of additives ▪ Testing equipment in accordance with the supplier's recommendations.
Testing kits from the supplier also include equipment that can be used to
determine the fresh water quality.
Testing the typical values of water

Short specification
Typical value/property Water for filling Circulating water
and refilling (without additive) (with additive)
Water type Fresh water, free of foreign matter Treated coolant
1)
Total hardness ≤ 10 dGH ≤ 10 dGH1)
pH value 6.5 – 8 at 20 °C ≥ 7.5 at 20 °C
Chloride ion content ≤ 50 mg/l ≤ 50 mg/l2)

Table 1: Quality specifications for coolants (short version)
2020-12-08 - de
1)
dGH German hardness
1 dGH = 10 mg/l CaO
= 17.8 mg/l CaCO3
= 0.178 mmol/L
2)
1 mg/l = 1 ppm
Coolant
General, M010.000.002-03-0001 1 (2)

Testing the concentration of rust inhibitors

Short specification
Anti-corrosion agent Concentration
Chemical additives In accordance with quality specification in volume 010.005 Engine – Operating Instruc-
tions 010.000.023-14
Antifreeze In accordance with quality specification in volume 010.005 Engine – Operating Instruc-
tions 010.000.023-14
Table 2: Concentration of coolant additives
126100791313331083
Testing the concentration of The concentration should be tested every week, and/or according to the
chemical additives maintenance schedule, using the testing instruments, reagents and instruc-
tions of the relevant supplier.
Chemical anti-corrosion agents can only provide effective protection if the
concentration is precisely maintained. Respectively, the concentrations re-
commended by MAN Energy Solutions (quality specifications in volume
010.005 Engine – Operating Instructions 010.000.023-14) must be main-
tained under all circumstances. These recommended concentrations may de-
viate from those specified by the manufacturer.
Testing the concentration of The concentration must be checked in accordance with the manufacturer's
anti-freeze agents instructions or the test can be outsourced to a suitable laboratory. If in doubt,
consult MAN Energy Solutions.
Regular water samplings Small quantities of lube oil in coolant can be found by visual check during reg-
ular water sampling from the expansion tank.
Testing Regular analysis of coolant is very important for safe engine operation. We
can analyse fuel for customers at MAN Energy Solutions laboratory PrimeSer-
vLab.
To ensure the safety of the team and to obtain a representative sample,
sampling should be carried out as per Work Card M10.000.002-07.
126100791313331083
2020-12-08 - de
Coolant
2 (2) General, M010.000.002-03-0001

Coolant system
cleaning
Summary
Remove contamination/residue from operating fluid systems, ensure/re-estab-
lish operating reliability.
Coolant systems containing deposits or contamination prevent effective cool-
ing of parts. Contamination and deposits must be regularly eliminated.
This comprises the following:
Cleaning the system and, if required,
removal of limescale deposits,
flushing the system.
Cleaning
The coolant system must be checked for contamination at regular intervals.
Cleaning is required if the degree of contamination is high. This work should
ideally be carried out by a specialist who can provide the right cleaning agents
for the type of deposits and materials in the cooling circuit. The cleaning
should only be carried out by the engine operator if this cannot be done by a
specialist.
Oil sludge Oil sludge from lubricating oil that has entered the cooling system or a high
concentration of anticorrosive agents can be removed by flushing the system
with fresh water to which some cleaning agent has been added. Suitable
cleaning agents are listed alphabetically in the table entitled Cleaning agents
for removing oil sludge. Products by other manufacturers can be used provid-
ing they have similar properties. The manufacturer's instructions for use must
be strictly observed.
Manufacturer Product Concentration Duration of cleaning procedure/temperature
Drew HDE - 777 4 – 5% 4 h at 50 – 60 °C
Nalfleet MaxiClean 2 2 – 5% 4 h at 60 °C
Unitor Aquabreak 0.05 – 0.5% 4 h at ambient temperature
Vecom Ultrasonic 4% 12 h at 50 – 60 °C
Multi Cleaner
Table 1: Cleaning agents for removing oil sludge
Lime and rust deposits Lime and rust deposits can form if the water is especially hard or if the con-
2016-09-08 - de
centration of the anticorrosive agent is too low. A thin lime scale layer can be
left on the surface as experience has shown that this protects against corro-
sion. However, limescale deposits with a thickness of more than 0.5 mm ob-
Coolant system
struct the transfer of heat and cause thermal overloading of the components
being cooled.
Rust that has been flushed out may have an abrasive effect on other parts of
the system, such as the sealing elements of the water pumps. Together with
the elements that are responsible for water hardness, this forms what is
known as ferrous sludge which tends to gather in areas where the flow velo-
city is low.
General, M010.000.002-04-0001 1 (3)

Products that remove limescale deposits are generally suitable for removing
rust. Suitable cleaning agents are listed alphabetically in the table entitled
Cleaning agents for removing limescale and rust deposits. Products by other
manufacturers can be used providing they have similar properties. The manu-
facturer's instructions for use must be strictly observed. Prior to cleaning,
check whether the cleaning agent is suitable for the materials to be cleaned.
The products listed in the table entitled Cleaning agents for removing limes-
cale and rust deposits are also suitable for stainless steel.
Manufacturer Product Concentration Duration of cleaning procedure/temperature
Drew SAF-Acid 5 – 10 % 4 h at 60 – 70 °C
Descale-IT 5 – 10 % 4 h at 60 – 70 °C
Ferroclean 10 % 4 – 24 h at 60 – 70 °C
Nalfleet Nalfleet 9 - 068 5% 4 h at 60 – 75 °C
Unitor Descalex 5 – 10 % 4 – 6 h at approx. 60 °C
Vecom Descalant F 3 – 10 % ca. 4 h at 50 – 60 °C

Table 2: Cleaning agents for removing lime scale and rust deposits
In emergencies only Hydrochloric acid diluted in water or aminosulphonic acid may only be used in
exceptional cases if a special cleaning agent that removes limescale deposits
without causing problems is not available. Observe the following during ap-
plication:
▪ Stainless steel heat exchangers must never be treated using diluted hy-
drochloric acid.
▪ Cooling systems containing non-ferrous metals (aluminium, red bronze,
brass, etc.) must be treated with deactivated aminosulphonic acid. This
acid should be added to water in a concentration of 3 – 5 %. The temper-
ature of the solution should be 40 – 50 °C.
▪ Diluted hydrochloric acid may only be used to clean steel pipes. If hydro-
chloric acid is used as the cleaning agent, there is always a danger that
acid will remain in the system, even when the system has been neutral-
ised and flushed. This residual acid promotes pitting. We therefore recom-
mend you have the cleaning carried out by a specialist.
The carbon dioxide bubbles that form when limescale deposits are dissolved
can prevent the cleaning agent from reaching boiler scale. It is therefore abso-
lutely necessary to circulate the water with the cleaning agent to flush away
the gas bubbles and allow them to escape. The length of the cleaning pro-
cess depends on the thickness and composition of the deposits. Values are
provided for orientation in the table entitled Cleaning agents for removing
limescale and rust deposits.
Following cleaning The cooling system must be flushed several times once it has been cleaned
2016-09-08 - de
using cleaning agents. Replace the water during this process. If acids are
used to carry out the cleaning, neutralise the cooling system afterwards with
suitable chemicals then flush. The system can then be refilled with water that
Coolant system
has been prepared accordingly.
2 (3) General, M010.000.002-04-0001

Only carry out cleaning procedure with cooled engine

Only begin the cleaning procedure when the engine has cooled down.
Hot engine parts may not come into contact with cold water. After re-
filling the cooling system, open the venting pipes. Blocked venting
pipes prevent the air from escaping and may cause thermal overload
of the engine.
Danger of chemical burns

From cleaning agents poisonous gases and fumes can develop, which
may cause light to severe person injuries.
• Wear protective clothing
• Provide adequate ventilation
• Do not inhale developed gases and fumes
• Observe Safety Data Sheets or Operating Instructions of the relevant
manufacturer
The applicable instructions for disposing of cleaning agents or acids are to be

observed.
27021599511822731
2016-09-08 - de
Coolant system
General, M010.000.002-04-0001 3 (3)

27021599511822731
2016-09-08 - de
Coolant system
General, M010.000.002-04-0001
Engine/Components
preservation
Summary
These work instructions describe the relevant measures which, if properly ap-
plied, can help to protect metal surfaces of engines and their components
that are subject to corrosion and avoid corrosion damage that could impair
proper functioning. The necessary scope of the corrosion protection depends
on the type of the component to be preserved, the expected environmental
conditions during transport and storage and the likely time span until further
use.
Preparing surfaces
Any coating on a surface must be fully hardened before further corrosion pro-
tection can be applied. Coated surfaces to which a preserving agent is to be
applied must be clean, dry and grease and oil free. In addition to that, un-
coated metal surfaces in danger of corrosion must be bright metal and free
from rust. Otherwise, the surfaces must be appropriately de-rusted, cleaned,
dried and de-greased. Prepared surfaces must be protected against corrosive
environmental conditions such as salty sea air or industrial atmospheres. The
contamination of bright metal surfaces with sweat should also be avoided.
Suitable gloves must therefore be worn when handling these components. If it
is uncertain whether a metal surface is free from salt, it must be cleaned with
a suitable agent before corrosion protection is applied. After preparation of the
surface, the required corrosion protection must be applied directly and
without significant delay.
Selection of corrosion protection

Step 1: Determining the corrosion protection group depending on the application.
See table Corrosion protection group.
Step 2: Determining the corrosion protection measure for a corrosion protection
group (e.g. agent d).
See table Anti-corrosion measure.
Step 3: Determining the anti-corrosion agent (e.g. Rivolta K.S.P. 204 non VOC for
agent d).
See table Anti-corrosion agent.
2018-10-16 - de
Engine/Components
Application of anti-corrosion agents

Manufacturer information must always be observed when applying an anti-
corrosion agent. Generally, all necessary information is summarised in the
product data sheet or in the technical information for each product. If ques-
tions remain about the application, it will be necessary to ask the manufac-
turer. The dosage and thickness of the coat of the anti-corrosion agent to be
applied must be obtained from the product information and adapted accord-
ing to the specific application conditions.
General, M010.000.002-05-0007 1 (7)

The required anti-corrosion agent may present a danger for health and the en-
vironment. For application, transport, storage and disposal, the relevant per-
son in charge must become acquainted with the information contained the
relevant safety data sheet and observe this information.
Volatile Phase Corrosion Inhibitor (VCI)

The use of VCI products represents a special type of corrosion protection. VCI
refers to a process in which a corrosion-inhibiting material evaporates from of
a substrate material inside a draught-free package, creates a saturated active
ingredient atmosphere and forms a monomolecular protective layer on the
surface of the metal. Typical VCI substrates are plastic films and film bags
containing the active ingredient, pulp-based materials such as paper and
card, foams or oils in various viscosities. If pulp and plastic-based VCI sub-
strates are used exclusively for preservation, the active ingredient will dissipate
after the packaging is opened and the component can be put to its further
use without any residue. It is, however, no longer protected from corrosion.
Generally, when using VCI products, the manufacturer information on storage,
application and shelf life must be observed. For effective corrosion protection
with VCI materials, the following points must be taken into particular consider-
ation:
▪ Only new, intact VCI material may be used. The use of recycled material is
not permitted. VCI materials that have been removed from their original
packaging must be used within a maximum of three months.
▪ If using VCI films, the film strength must be fit for purpose.
▪ It must be ensured that only VCI products that are suitable for the material
to be protected are used. See table Anti-corrosion agent.
▪ No hand or body sweat must come into contact with the bright metal sur-
faces. When handling components, suitable gloves must be worn.
▪ Only dry, clean and corrosion-free components may be preserved and
packaged.
▪ When packing the component, its temperature must not differ from the
ambient temperature; otherwise, there is a risk of condensation build-up.
▪ To improve the effectiveness of VCI film packaging, working with addi-
tional VCI substrates inside the packaging is recommended. For example,
the component to be protected can be wrapped in VCI paper first and
then packaged in VCI film. This ensures a smaller distance between the
VCI substrate and the metal surface and the VCI substrate will be equally
distributed in the packaging.
▪ VCI chips are suitable for enclosed spaces in the interior of engines or
components. The amount of VCI substrates to be applied depends on the
volume of the cavities. When using VCI substrate materials in interior
2018-10-16 - de
spaces, adequate signage must be attached to ensure that the materials

Engine/Components
are removed before further application or commissioning.

▪ Inside VCI film packaging, no materials that can hold moisture may be
used, e.g. wood, corrugated cardboard or untreated fibrous materials.
These materials must also not be in contact with any metal surfaces or
the internal atmosphere when closing off interior spaces of engines or
components.
▪ The VCI protective atmosphere can only build up within closed packaging.
Therefore, the film must be closed in such a way that conditions within the
packaging are free from draughts for the required preservation time.
▪ The volume of air contained inside a VCI film package must be kept as
small as possible.
2 (7) General, M010.000.002-05-0007

▪ After closing the package, manufacturer information regarding waiting

time and temperatures must be observed, so that the VCI atmosphere
can form and a protective effect is ensured.
▪ Reliable preservation with VCI film packaging requires that the film is not
damaged during the intended duration of the process. This can be
achieved, for example, by choosing a suitable load carrier or by using pro-
tective outer packaging or a label.
▪ It must be ensured that components packaged in VCI film are transported
and stored in a way that provides maximum protection against the ele-
ments.
▪ After forming a VCI protective atmosphere within the packaging or an in-
terior space, ensure that further transport/storage takes place at a tem-
perature in the range from -20 to +50°C. If temporary deviations from this
range occur, ensure that the film packaging remains sealed and is not
mechanically stressed.
▪ For VCI packaging that is transported and stored in fluctuating ambient
temperatures, condensation build-up is to be expected. The use of desic-
cants in VCI packaging can have a negative effect under certain circum-
stances. It is recommended to cut a small slit at the lowest point of the
packaging, so that any accumulated water can escape.
▪ VCI film packaging can be applied in such a way that re-sealing is pos-
sible after partial removal, or re-packing after short-term removal - e.g. for
a quality inspection. In particular when additional VCI substrates are ad-
ded, a protective atmosphere can form again after sealing.
▪ In order to ensure that there is a protective atmosphere even if the VCI
packaging is damaged, additional VCI protection in the form of corrosion
protection oil can be applied if possible.
Packaging and protection against moisture

If engines or components with preserved metal surfaces in danger of corro-
sion are not stored exclusively in a closed warehouse, a suitable covering or
packaging must be used in order to protect the components from moisture
and weather influences. Before packaging a preserved component, any
solvents must be fully evaporated out of the corrosion protection.
Moisture on surfaces may also develop if the temperature falls below the dew
point. This may for example occur if unpackaged, cold components are
brought into a warm warehouse. If falling below the dew point cannot be
avoided, the metal surface must be dried quickly and the preserving agent re-
applied.
In case of oversea transport and a preservation time exceeding 12 months,
the use of desiccants in conjunction with welded aluminium composite foil is
2018-10-16 - de
suitable, forming a barrier for moisture and water vapour. The amount of de-
Engine/Components
siccant to be used depends on the volume of cavities in the packaging. Addi-

tionally, a stable protective packaging (e.g. a wooden crate) must be used to
protect the aluminium foil from mechanical damage. The required materials
are not listed in the table Anti-corrosion agent of this standard. Other use of
desiccants may have a negative effect under some circumstances and is only
permitted in special cases.
General, M010.000.002-05-0007 3 (7)

Removing anti-corrosion agents

Before further use of a preserved component or before commissioning of a
preserved engine, the corrosion protection must be removed. The operating
manual must be observed when doing this. Anti-corrosion agent that are
marked as compatible with operating materials do not need to be completely
removed. It is sufficient if large excesses or deposits in the engine interior are
removed. See table Anti-corrosion agent.
Re-preservation
After the estimated duration of preservation has elapsed, or if corrosion be-
comes noticeable, the preservation must be renewed. If there are no specific
guidelines stating otherwise, the same provisions as for the initial preservation
also apply to subsequent preservations.
Corrosion protection groups

In the case of special applications that are not covered by this table, or in the
event of uncertainty, consult MAN Energy Solutions.
Corrosion pro-
tection group:
Short-term production interruption and internal transportation 1
Storage of individual parts and subassemblies (e.g. logistics warehouse) up to 12 months 2
Transport and storage under max. moder- Individual parts up to 6 months 1

ately corrosive ambient conditions (e.g.
up to 12 months 2
shipping within Europe)
up to 24 months 3
Turbocharger up to 12 months 5
Engines and engine subassem- up to 3 months 6

blies
up to 12 months 7
Transport and storage under highly corros- Individual parts up to 12 months 3

ive ambient conditions (e.g. sea transport)
up to 24 months 4
Turbocharger up to 12 months 5
Engines and engine subassem- up to 12 months 7

blies
2018-10-16 - de
Table 1: Corrosion protection groups

Engine/Components
Anti-corrosive measures
Corrosion pro- Anti-corrosive measure:
tection group:
1 Processed metal surfaces: Agent d, in special cases (e.g. crack inspections) agent b.
Blasted metal surfaces without coating: Agent d.
4 (7) General, M010.000.002-05-0007

2 Processed metal surfaces and blasted metal surfaces without coating: agent d, additional VCI pack-
aging with agent l.
Without VCI packaging, agent e or agent g are also possible.
3 Processed metal surfaces and blasted metal surfaces without coating: agent m and an additional
VCI packaging with agent l.
4 Interiors that are difficult to access:agent m.

Processed metal surfaces and blasted metal surfaces without coating: agent f and additional pack-
aging with aluminium composite foil and desiccants.
5 Interiors: agent m or agent b and subsequent closing.

Bright metal surfaces on the exterior: agent f.
Bores and threads on the exterior: agent h.
Turbochargers not mounted on the engine: VCI packaging with agent l.
6 Interiors of coolant systems: agent c.

Interiors of the fuel system: agent b.
Closed interiors to which lubricating oil is applied during operation: agent m.
Gas pipe system interior: VCI substrate based on pulp – agent l.
Cavities, moving parts and tension rod bolt connections on the exterior: agent h.
Other bright metal surfaces on the exterior: agent f.
Painted surfaces on the exterior: agent g or m.
7 Like corrosion protection group 6, but painted exterior surfaces: Agent f

Table 2: Anti-corrosive measure
Anti-corrosion agent
Agent b Agent c Agent d
Brief description: Corrosion protection oil Water-soluble corrosion Synthetic corrosion protec-
based on mineral oil, VOC- protection concentrate as tion oil, VOC-free
free addition to coolant
Type of application: Pump spray bottle Purging Pump spray bottle

Airless application Airless application
Immersion Immersion
Rinsing
Painting
Removability: Neutral cleaner Neutral cleaner Neutral cleaner

Alkaline tenside based Alkaline tenside based Alkaline tenside based
cleaner cleaner cleaner
Diesel fuel Diesel fuel
2018-10-16 - de
Petroleum Petroleum
Engine/Components
Test fuel Test fuel
Media compatibility: Fuel Cooling water Lubrication oil

Lubrication oil
Areas of application and Preservation of the fuel sys- Preservation of the cooling Preservation of bright metal
notes: tem, preservation of bright water system surfaces
metal surfaces
General, M010.000.002-05-0007 5 (7)

Preferred anti-corrosion Fuchs Anticorit RPO 1001 BASF Glysacorr P 113 Bremer & Leguil Rivolta
product to be applied: K.S.P. 204 non VOC
MAN PrimeServ Protect
Table 3: Anti-corrosion agent
27021618202843915
Agent e Agent f Agent g
Brief description: Solvent-containing pre- Solvent-containing pre- Solvent-containing corro-

serving wax with wax-like serving wax with anti-slip sion protection oil
dry layer dry layer
Type of application: Airless application Airless application Airless application

Painting Painting Painting
Removability: Alkaline tenside based Diesel fuel Alkaline tenside based

cleaner Petroleum cleaner
Diesel fuel Test fuel Diesel fuel
Petroleum Petroleum
Test fuel Test fuel
Media compatibility: Lubrication oil -- Lubrication oil
Areas of application and Surface preservation Surface preservation Surface preservation

notes:
Preferred anti-corrosion Valvoline Tectyl 400 C Fuchs Anticorit BW 366 Valvoline Tectyl 511-M
products to be applied (K19)
Valvoline Tectyl 846-K-19
Valvoline Tectyl 846
27021618202843915
Agent h Agent l Agent m
Brief description: Solvent-containing corro- VCI anti-corrosion agent Tixotropes, synthetic corro-
sion protection grease sion protection oil, VOC-
free
Type of application: Painting Volatile phase corrosion Airless application

protection within draught- Filling
free closed packaging and
interior spaces.
Removability: First wipe, then: The corrosion protection Neutral cleaner

Alkaline tenside based dissipates without residue. Alkaline tenside based
cleaner cleaner
2018-10-16 - de
Diesel fuel
Diesel fuel
Engine/Components
Petroleum
Petroleum Test fuel
Test fuel
Media compatibility: -- In all cases. Lubrication oil
6 (7) General, M010.000.002-05-0007

Areas of application and Preservation for cavities as Observe material compatib- Surface preservation by
notes: well as for moving parts ility according to the moistening and volatile
and bolted connections product data sheet! Vari- phase corrosion protection
ations: within draught-free closed
R - protects cast iron, steel, packaging and interior
chrome, aluminium and tin. spaces.
Not suitable for non-ferrous
metals. Amount required:
RY - like R, but neutral with 245 g/m3
respect to non-ferrous
metals.
M - like R but longer forma-
tion phase.
U - protects steel, zinc,
chrome, tin, copper, brass,
bronze and aluminium. Cast
iron is only protected in the
case of direct contact.
Amount required:
Chips – 0.5 m2/m3
Paper - fully wrap the part
Oil - 300 ml/m3
Preferred anti-corrosion Carlofon Pasta Branopac Branofol VCI film Bremer & Leguil Rivolta
products to be applied Dinol Dinitrol Pasta Branopac Branorost VCI K.S.P. VCI
paper
Branopac Branorost VCI
chips
Branopac Branorol VCI oil
27021618202843915
2018-10-16 - de
Engine/Components
General, M010.000.002-05-0007 7 (7)

27021618202843915
2018-10-16 - de
Engine/Components
General, M010.000.002-05-0007
Taking an operating material sample
Summary
In order to ensure consistent quality and, as a result, that different operating
material samples can be compared, the following work steps must be fol-
lowed.
Choosing the sampling point
Taking the sample
Labelling the sample bottle
Choosing the sampling point

The choice of the sampling point depends on the type of operating material
and the local conditions. The sampling point must always be the same for
comparable values. This is particularly important for regular monthly sampling.
The sampling point can be:
▪ upstream or downstream of a separator,
▪ in the tank (always ensure that any sediment is drained beforehand),
▪ at the engine inlet (in the clean oil side or the fuel filter upstream of the en-
gine – the filtered side).
Taking the sample

When taking the sample, observe the following items:
▪ Wear personal protective equipment.
▪ Inform the plant operating personnel that the sampling is taking place.
▪ The sample bottle must be new, clean and dry and suitable for the oper-
ating material.
▪ The contents of the sample bottle must be at least 200 ml. In the case of
special operating materials, PrimeServLab must be consulted beforehand.

▪ Only send the required amount to the PrimeServLab.
▪ The sampling point must be thoroughly flushed. At least two litres of the
operating material must be drained before the sample can be taken. For
sampling points with long pipelines, a larger amount must be drained. The
drained operating material should be reused or recycled.
▪ Quickly fill the sample bottle and seal it.
▪ Clean the equipment used to take the sample.
2020-12-10 - de
▪ Correctly label the sample.
Labelling the sample bottle

It is essential that you correctly label the sample for the correct evaluation of
the results. Care must be taken to ensure that the label is attached to the
sample so that it doesn’t become contaminated by the operating material
during delivery.
The following information must appear on the label:
▪ Plant number and name
General, M010.000.002-07-0001 1 (2)

▪ Engine number and operating values (if available, operational hours of the
fluid and last top-up)
▪ Date and time
▪ Precise location that the sample was taken from
▪ Type of operating material
▪ Reason for sample
▪ Additional information
▪ Name of the person taking the sample, in case of questions
49083287179
2020-12-10 - de
2 (2) General, M010.000.002-07-0001


51354082315
1 (1)

Galvanised Bearings
assessing
Summary
Carry out the work in good time in accordance with the maintenance sched-
ule; check the components’ quality/wear condition. Bearing shells must be
checked on a regular basis. Usually, only the loaded bearing shell is checked.
From the wear condition and appearance of the bearing shell running surface,
conclusions can be drawn regarding the load conditions, the lubricating oil
maintenance etc.
The work/work steps include: Measuring of components and assessing sur-
face/wear condition.
Relevant Working Instructions

Measure crankshaft web clearance 010.030.010-12
General
1 Anti-corrosion layer
2 Running layer
3 Nickel dam
4 Bearing metal
5 Steel support shell
Figure 1: Galvanised Bearings - Structure
Galvanised bearings (compound bearings) are used for the crankshaft bear-
ings and big-end bearings of four-stroke engines, which are made from a
2013-07-26 - de
steel support shell, a bearing metal layer of leaded bronze or aluminium tin
Galvanised Bearings
bronze and a galvanised running layer.

The soft running layer has better running in and emergency running properties
than the leaded bronze or aluminium tin bronze layer. This running layer must,
therefore, remain serviceable for as long as possible and no additional work is
permitted. Since every bearing must adapt itself after refitting, bearings which
are running correctly should be opened up as little as possible.
Galvanised bearings have a long service life if the lubricating oil is carefully
filtered and separated. This means that cleaning the filters and separators,
and checking the oil, are very important.
General, M010.000.003-01-0001 1 (8)

Damaged bearing shells must always be replaced in pairs (upper and lower
shell).
After refitting worn bearing shells, or after replacement, the bearing caps must
be felt with a manual temperature sensor carefully, after approx. 30 min. idling
and at the end of run-in period, to detect any unacceptable increase in tem-
perature (compare to the adjacent bearings).
Undersized bearings (with smaller diameter) ready for installation can be sup-
plied for reworked crankshaft pins.
Wear Limits
Bearing shells, the running surface of which show wear of more than 30%
must be replaced. Bearing shells, the running surface of which show wear of
approx. 20% are also to be replaced, if, at the same time, extensive overhaul
work is being performed on the engine.
Figure 2: Degree of Wear of the Running Surface
Bearing shells which have already been in service for 30 000 operational
hours should, in general, be replaced when the engine is being overhauled.
If the bearing shells already show signs of wear on the bearing metal running
layer after approx. 5000 operational hours or the running surface is worn by
about 20%, this indicates dirt accumulation and insufficient cleaning of the
lubricating oil.
Bearing Illustrations
In the following pictures the dismantled bearing shells can be assessed, and
they also give an indication of reuse possibility or whether replacement with
new bearings is required.
Normal Contact Pattern with Existing Running Layer
2013-07-26 - de
Galvanised Bearings
Figure 3: Normal Contact Pattern
The mainly grey running surface in the main load area is smooth and reflects
slightly. The bearing can be used again.
2 (8) General, M010.000.003-01-0001

Normal Contact Pattern with Partially Worn Running Layer
Figure 4: Partially Worn Running Layer
After the running layer is worn out a reddish brown contact pattern is seen in
lead bronze bearings. With aluminium tin bronze bearings a variation is seen
between the lighter and darker zone. The lighter zone indicates a fresh con-
tact pattern, the darker zone is created by surface oxidation which does not
adversely affect performance. The bearing can be reused and must only be
replaced once the aforementioned features listed under 'wear limits’ are evid-
ent.
Mirror effect on both edges of the bearing
Figure 5: Mirror effect
The bearing becomes slightly rounded by the running-in process. Slight mir-
roring on the edges of the bearings will normally disappear after a longer run-
ning time. The bearing can be reused, provided figure 6 (edge loading) is not
applicable.
Edge Loading (on one side or both sides)
Figure 6: Edge loading
A bearing which only carries load on the edges is not permitted. Possible
causes could be deviations in the pin geometry or incorrect location of the
2013-07-26 - de
bearing bore, which must be corrected. The bearing must be replaced if the
Galvanised Bearings
edge loading is significant.

Load on the One Side
Figure 7: Load on the One Side
General, M010.000.003-01-0001 3 (8)

A one sided contact pattern may be seen in the case of external bearings and
is also acceptable provided the crank web deflection is in order (cause:
Weight of the flywheel or of the vibration damper). One sided load is not per-
mitted for intermediate bearings. In this case the causes, e.g. pin gyration, de-
formation of the bearing support, uneven tie rod preload, dirt on back of the
bearing, must be remedied. If there is pronounced one-sided load then the
bearing must be changed.
Load Marks on the Bearing Shell Joint (on one side or both sides)
Figure 8: Load Marks on the Bearing Shell Joint
When pronounced load marks occur near the bearing joint face, there is a
danger that the crank journal on the parting lines could break away from the
lubricating film. For this reason, a bearing should be exposed by approx. 10°,
calculated from the joint face. Should load marks still appear close to the joint
face, then the cause must be remedied. In the event of load marks on only
one side, the back of the bearing should be checked for dirt or oil carbon. In
addition, the bearing support could be misaligned. If there are load marks on
both sides see figures 20 (cold shuts on the back of the bearing) and 21
(bearing spread). Bearings with heavy loading close to the joint face should be
replaced.
Scoring and Embedding of Foreign Bodies in the Running Layer
Figure 9: Scores and Foreign Bodies in the Running Layer
Hard dirt particles, carried by the circulating oil, make scores through the run-
ning layer and often get embedded. Depending on the hardness of the foreign
bodies the bearing journal may become scored. Light scores, which do not
break through the running layer are not dangerous. The bearings can continue
to be used. Scores which are wider than 1 mm interfere with the structure of
the wedge-shaped lube oil film. Bearings with several wide scores in the lower
2013-07-26 - de
shells of the crankshaft bearing or the upper shell of the big-end bearing,
Galvanised Bearings
which reach the lead bronze or aluminium tin bronze layer, must be changed,
especially if the scores are very close to the bearing edge. If wide scores are
seen in the bearing shells, the surface of the bearing journal must be checked.
Depending on the situation, the pin should be smoothed or reworked using
emery cloth or an oil stone, or mechanically with a portable regrinding device
(Specialist firms). The cause of scoring must be remedied. The complete lube
oil circuit, including separator, lube oil filter and lube oil pipes between the filter
and engine must be checked (scale, weld beads etc.). If other bearings are
supplied with oil from this bearing, they should definitely be checked.
Cracks in the Running layer
4 (8) General, M010.000.003-01-0001

Figure 10: Cracks
The odd crack in the running layer is not dangerous to the bearing. The bear-
ing should only be replaced if there is a notable build-up of cracks in the
loaded zone.
"Bark Beetle"
Figure 11: Bark Beetle
When the accumulation of a lot of small cracks becomes recognisable in the

loaded zone of the running layer (often paving stone type) as result of material
fatigue, disintegration or erosion of the crack areas (similar to the bark beetle
on trees) the bearing should be changed.
Peeling of the Running Layer
Figure 12: Peeling of the Running Layer
If the running layer has begun to peel at points on the surface, then the bear-
ing must be replaced. Only in the case of small individual areas of damage
(smaller than 2 cm2) can the bearing continue to be used, provided the bind-
ing of the remaining running layer immediately adjacent to the area of damage
is good condition (check carefully with a sharp tool, e.g. a pocket knife).
Running Layer Heavily Smudged
2013-07-26 - de
Galvanised Bearings
Figure 13: Smudging of the Running Layer
General, M010.000.003-01-0001 5 (8)

If the soft running layer is smudged over a large area (creep deformation) and
if it has possibly already been penetrated in the middle, this implies insufficient
oil, which could possibly be caused by insufficient prelubrication before the
start. The cause of insufficient oil must be remedied and the bearing must be
replaced.
Rough Running of the Bearing Metal Layer
Figure 14: Rough Running
Bearings with very rough bearing metal should be replaced, particularly be-
cause of increased pin wear. Moreover, the bearing journal must be
smoothed.
Spallings on the bearing metal layer
Figure 15: Spallings
Bearings with spallings on the bearing metal layer must be replaced. The
bearing journal must be checked, smoothed or reworked.
Overheating of the Bearing Metal Layer
Figure 16: Overheating of the Running Layer
If the bearing metal shows overheating characteristics (blue-violet) or even

net-shaped heat cracks, the bearing must be replaced. The bearing journal
2013-07-26 - de
must undergo a magnetic crack inspection. If any cracks are apparent, the
Galvanised Bearings
bearing journal must be reground until it is "crack free", taking the surface
quality, ovality and taper into account. If no cracks or hardening have been
detected, smoothing of the pin is sufficient.
Electroerosion
6 (8) General, M010.000.003-01-0001

Figure 17: Electroerosion
If generator installations are not sufficiently earthed, this can lead to stray elec-
trical currents and possibly to electro-erosion in the bearing. The running layer
will be roughened as if cracked. The cracks sometimes appear at an angle to
the running direction. In more severe cases of erosion, the journal surface is
also visibly rough. The cause of the damage must be determined and
remedied. The bearing must be replaced and, where necessary, the journal
smoothed or reworked.
Corrosion
Figure 18: Corrosion
Signs of running surface corrosion are surface discolouration as a result of

chemical changes in the bearing material and corrosive, usually localised, ma-
terial removal. The lubricating oil should be examined for contamination by
water, acids etc. If the corrosion is advanced, the bearing must be replaced.
The bearing journal, which is also often attacked, must be smoothed or re-
worked.
Cold shuts on the bearing shell joint
Figure 19: Cold shuts on the bearing shell joint
Cold shuts or pitting rings on the joint faces of the bearing shell indicate relat-
2013-07-26 - de
ive movement, due to the loss of preload or inadequate bearing protrusion.

Galvanised Bearings
The causes of the damage must be remedied. In less serious cases, when re-
fitting the bearing shells, ensure that only the cold welded material which has
deposited is carefully removed. Moreover, the back of the bearing is to be
checked for cold shuts (see figure 20). In serious cases (large amounts of ma-
terial application and removal) the bearing shells must be replaced.
Cold shuts on the back of the bearing
General, M010.000.003-01-0001 7 (8)

Figure 20: Cold shuts on the back of the bearing
Large numbers of cold shuts on the back of the bearing, which are spread
over more than 5% of the total area, are not acceptable. The bearing must be
replaced. Screw pretension, bearing protrusion, bearing spread (see figure 21)
and condition of the bearing locating bore must be checked. The bearing pro-
trusion can only be ascertained approximately on-site by loosening the bear-
ing bolts on one side. The cold shuts in the bearing locating bore must be
checked for cracks. If cracks are detected, the engine manufacturer must be
contacted. If no cracks have been detected, before the bearing is reas-
sembled surplus material in the bearing locating bore must be carefully re-
moved and, if the bearing is to be reused, any on the back of the bearing
must also be removed carefully.
Bearing Spread
D Bearing diameter
S Spread
Figure 21: Bearing Spread
Bearing shells must have a positive spread so that once built in they are per-
fectly positioned in the locating hole. The spread depends on the diameter of
the bearing and, when new, can be several millimetres. Even when bearings
are worn there should still be enough remaining spread so that when installing
the bearing in the bearing locating hole it is necessary to exert considerable
2013-07-26 - de
pressure on both joint surfaces. Bearing shells which can be very easily
Galvanised Bearings
placed in the bore (spread zero or negative) may not continue to be used. A
"spreading out" of the shell is not permitted.
9007201003918987
8 (8) General, M010.000.003-01-0001

Deep Groove Bearing

assessing
Summary
ule; check the components’ quality/wear condition. Bearing shells must be
checked on a regular basis. Usually, only the loaded bearing shell is checked.
From the wear condition and appearance of the bearing shell running surface,
conclusions can be drawn regarding the load conditions, the lube oil mainten-
ance etc.

General
The deep groove bearings used in the crankshaft and big-end bearings based
on aluminium or lead bronze have the structure as shown in figure 1.
The soft running layer has better running in and emergency running properties
than the bearing metal shell. This is why the running layer must remain func-
tional for as long as possible and any rework to the running layer should be
avoided. Since every bearing must adapt itself after refitting, bearings which
are running correctly should be opened up as little as possible.
Deep groove bearings, with careful filtering and separating the lube oil, have a
very long useful life. This means that cleaning the filters and separators, and
checking the oil, are very important.
If the bearing metal layer of the bearing shells is clearly visible after approx.
5,000 operational hours or 20% of the running surface is worn, this indicates
serious stress due to dirt particles and inadequate cleaning of the lube oil.
Bearing shells with advanced wear can be replaced individually (upper or
lower shell) or together.
After refitting worn bearing shells, or after replacement, the bearing caps must
be felt by hand, after approx. 30 min. idling and after approx. 5 hours with in-
creasing engine load, to detect any unacceptable increase in temperature
2012-08-21 - de
(compare to the adjacent bearings).

Deep Groove Bearing
Undersized bearings are available for reworked crankshafts. These are subject
to the same evaluation criteria as normal bearings.
General, M010.000.003-02-0001 1 (6)

1 Running layer (approx. 75%)

2 Bearing metal cross piece (approx. 25%)
3 Nickel dam (max. 5%)
Figure 1: Structure of a Deep Groove Bearing
Wear Criteria
In new condition the running surface accounts for approx. 75% galvanised
running layer and approx. 25% bearing metal cross pieces. The decisive
factor for wear in the deep groove bearing is the ratio width of the bearing
metal cross piece to the width of the groove and the extension of the worn
area. To assess the degree of wear of the running surface, a magnifying glass
with a magnifying power of 5 is required. For every assessment of the groove
condition, it is important to compare the running surface in the area with the
least load since the groove condition here is almost new.
An assessment of the bearing shells can be carried out with the aid of the im-
age sequence. It indicates whether a bearing can be reused or whether it
must be replaced.
1. No or little Wear. Continued Use

2012-08-21 - de
Deep Groove Bearing
Figure 2: Wear not critical
1. The groove geometry corresponds to the new condition. The running

layer is fully preserved within the grooves. Dark spots on the running layer
are mainly embedded particles of oily carbon deposits. (See figure left)
2 (6) General, M010.000.003-02-0001

Assessing: The ratio bearing metal cross piece to running layer is approx.
25% to 75%. Continued use!
2. The running layer is evenly worn approx. 0.005 mm out of the grooves.
The bearing metal cross piece shows no sign of wear. Dark spots on the
running layer are mainly embedded particles of oily carbon deposits. (see
figure right)
Assessing: Because of the wear of the running layer the bearing metal cross
pieces seem slightly wider. Continued use!
Figure 3: Wear not critical
3. Embedding of small impurities over the entire running surface. No major

modification of the bearing metal cross piece (see figure left)
Assessing: Continued use!
4. The running layer was dragged and spread over the bearing metal cross
pieces. The bearing metal cross pieces are partially concealed (see figure
right)
Assessing: Continued use!
2. Wear of bearing metal cross pieces. Replace depending on extent of wear

2012-08-21 - de
Deep Groove Bearing
Figure 4: Wear of Bearing Metal Cross Pieces
1. The bearing is worn to such an extent at some spots, that the ratio run-
ning layer groove to bearing metal cross pieces is approx. 50% to 50%.
The width of the bearing metal cross pieces has increased from 25%
(new condition) to 50 %. There is still running layer inside the grooves
(see figure left)
General, M010.000.003-02-0001 3 (6)

Assessing: The bearing is functional as long as the extension of the worn

parts does not reach the limits indicated in figure 6.
If wear is expected within the next maintenance interval as described in point
2, the bearing must be replaced for safety reasons.
2. The bearing metal cross pieces are worn locally. No grooves or running
layer present (see figure right)
Assessing: If the wear reaches the limits indicated in figure 6, the bearing
must be replaced.
3. Wear on running layer. Replace depending on extent of wear
Figure 5: Wear on running layer
1. Running layer outbreaks in the grooves through local overload (see figure
left)
Assessing: The bearing is functional as long as the extension of the worn
parts does not reach the limits indicated in figure 7.
If wear is expected within the next maintenance interval as described in point
2, the bearing must be replaced for safety reasons.
2. Empty grooves. In some areas, empty grooves become visible after
washing the broken running layer. Locally, the bearing metal cross pieces
may already be worn. (see figure right)
Assessing: If the wear reaches the limits indicated in figure 7, the bearing
must be replaced. 2012-08-21 - de
Deep Groove Bearing
4 (6) General, M010.000.003-02-0001

A max. 30% of shell circum- B max. 50% of shell circum-

ference ference
C max. 5% of shell circum- D max. 35% of shell circum-
ference ference
E max. 70% of shell width F max. 35% of shell width
G max. 20% of shell width H max. 10% of shell width
Wear ratio 50% to 50% Bearing metal cross
pieces worn
Figure 6: Extent of Wear
2012-08-21 - de
Deep Groove Bearing
General, M010.000.003-02-0001 5 (6)

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

ference ference
E max. 70% of shell width F max. 35% of shell width
K max. 10% of shell circum- L max. 40% of shell circum-
ference ference
M max. 40% of shell width N max. 30% of shell width
O max. 15% of shell width Bearing metal cross
pieces worn
Running layer outbreaks Empty grooves
Figure 7: Extent of Wear

1749369867
2012-08-21 - de
Deep Groove Bearing
6 (6) General, M010.000.003-02-0001

Bimetal Bearings (without a third layer)

assessing
Summary
ule; check the components’ quality/wear condition. The bearing shells (bi-
metal bearings) are used in crankshaft and big-end bearings as well as in the
camshaft bearings. They have to be checked or replaced according to the
maintenance schedule on a regular basis.

General
1 Bearing metal

2 Al - Binding layer
Figure 1: Bearing Structure
Roll-bonded bimetal bearings with the material combination steel/aluminium

alloy (AlSn20) are used both as main and big-end bearings and camshaft
bearings. Visible assessment of the extent of wear of a bimetal composite
bearing shell is not possible in normal wearing conditions (see figure below). In
contrast to trimetal composite bearings with galvanised running layer, bimetal
2016-09-15 - de
bearings contain no optical indicators which facilitate assessing the degree of

wear by the discolouration of the sliding surface. Assessment of the extent of
wear is only possible by measuring the thickness of the bearing shell wall and
comparing the current measured value with that of the initial condition. Meas-
uring bearing clearance does not produce any reliable indication of bearing
wear, since the acceptable wear values are measured in hundredth of a milli-
metre.
General, M010.000.003-03-0001 1 (3)

Assessment of Running Behaviour and Replacement Criteria
Figure 2: Measuring point for bearing shell thickness
Change the bearing shells if the following wear limits according to the data
sheet “Technical data: measurements, clearances, tolerances” are reached.
Measuring point for bearing shell thickness

Measure the bearing shell thickness (A) in the main load area or at 90°
to the joint face.
1. Contact pattern even over the entire bearing width

Figure 3: Contact Pattern Normal
1. Isolated, superficial dirt marks caused by foreign bodies do not influence

continued operational safety (see figure 3 - left).
2016-09-15 - de
Assessing: If the wall thickness is within the permitted wear value, the bearing
can continue to be used.
2. Running surface slightly scored. If the scores are only visible, but neither
measurable nor perceptible, the bearing can continue to be used. If the
wall thickness has reached the lowest tolerance value, the bearing shell
must be replaced (see figure 3 - right).
Assessing: If the scores are clearly perceptible or measurable, the bearing
shell must be replaced.
2 (3) General, M010.000.003-03-0001

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

2016-09-15 - de
Figure 5: Contact pattern with spallings
The loaded area of the bearing shell shows signs of bearing metal spallings
caused by fatigue of the sliding layer (see figure 5).
9007201004782859
General, M010.000.003-03-0001 3 (3)

9007201004782859
2016-09-15 - de
General, M010.000.003-03-0001
Tightening of bolted connections

Partial image
Explanations
The illustrations in Work Instructions 000.29 serve for identification of the parts
to be connected based on their location and adjacent parts. The illustrations
have identification numbers, for example 020-1, which are listed in numerical
order in Work Instructions 000.30. The identification numbers also indicate the
tightening torques and the corresponding Work Instructions.
27021632458808075

2019-06-03 - de
L48/60CR, M010.000.003-04-0029 1 (8)

2019-06-03 - de
Figure 1: Cross section of the engine
2 (8) L48/60CR, M010.000.003-04-0029


2019-06-03 - de
Figure 2: Crankshaft / counterweight / crankshaft vibration damper / cylinder head / charge air pipe / lub-
ricating oil and cooling water pump with attachment
L48/60CR, M010.000.003-04-0029 3 (8)

2019-06-03 - de
Figure 3: Piston / cylinder head bolts / camshaft thrust bearing / charge air pipe / exhaust pipe
4 (8) L48/60CR, M010.000.003-04-0029


2019-06-03 - de
Figure 4: Crankshaft extension / balancer mass for camshaft / turbocharger installation / crankcase cover /
charge air cooler installation
L48/60CR, M010.000.003-04-0029 5 (8)

2019-06-03 - de
Figure 5: High-pressure pump / high-pressure pipes / cabling / accumulator unit with installation
6 (8) L48/60CR, M010.000.003-04-0029


2019-06-03 - de
Figure 6: Inlet and outlet rocker arm with bearing / VVT drive
L48/60CR, M010.000.003-04-0029 7 (8)

2019-06-03 - de
Figure 7: Charge air cooler installation / attachment of turbocharger

27021632458808075
8 (8) L48/60CR, M010.000.003-04-0029


Table
Tightening torques

2019-06-03 - de
L48/60CR, M010.000.003-05-0029 1 (13)

2019-06-03 - de
2 (13) L48/60CR, M010.000.003-05-0029


2019-06-03 - de
L48/60CR, M010.000.003-05-0029 3 (13)

2019-06-03 - de
4 (13) L48/60CR, M010.000.003-05-0029


2019-06-03 - de
L48/60CR, M010.000.003-05-0029 5 (13)

2019-06-03 - de
6 (13) L48/60CR, M010.000.003-05-0029


2019-06-03 - de
L48/60CR, M010.000.003-05-0029 7 (13)

2019-06-03 - de
8 (13) L48/60CR, M010.000.003-05-0029


2019-06-03 - de
L48/60CR, M010.000.003-05-0029 9 (13)

2019-06-03 - de
10 (13) L48/60CR, M010.000.003-05-0029


2019-06-03 - de
L48/60CR, M010.000.003-05-0029 11 (13)

2019-06-03 - de
12 (13) L48/60CR, M010.000.003-05-0029


2019-06-03 - de
18014433203973899
L48/60CR, M010.000.003-05-0029 13 (13)

18014433203973899
2019-06-03 - de
L48/60CR, M010.000.003-05-0029
Tightening of bolt connections

General notes
Summary
Bolted connections must be tightened using different methods, depending on
the type and importance of their position. The methods are: tightening without
specifications, tightening to specific torque, tightening using specific turning
angle, tightening using hydraulic tensioners. Bolted connections should be
tightened using a torque wrench if at all possible. For especially important
connections, the values are specified in Work Instructions 010.000.003-05.
Guideline values for other bolt connections are stated here.
Relevant work instructions

Tightening screw connections, image excerpt 010.000.003-04
Tightening the screwed connections Table 010.000.003-05
Working and Safety Regulations 015.000.001-01
General notes
Tightening with standard tools

Different methods of tightening bolted connections are used depending on
the purpose of the connection and its significance. When there are no spe-
cifications for the tightening of bolted connections of average significance, use
normal ring spanners, socket wrenches or open-jaw wrenches without any
extensions.
Property damage due to reuse of self-locking hex nuts

The reuse of self-locking hex nuts may lead to material damage.
• Self-locking hex nuts must only be used once. They must be replaced
with new ones after each use.
Tightening to specific torque

Bolted connections for which a specific tightening torque is specified in Work
2020-09-04 - de
Instructions 010.000.003-04 and 010.000.003-05 must be tightened using a

torque wrench. The stipulated lubricant must be adhered to during assembly,
since different forces are exerted in the bolted connection at the same torque
value, depending on the lubricant used. Unless otherwise stated, the lubricant
must be applied to the thread and to the head/nut contact surface. The spe-
cifications from the manufacturer must always be adhered to.
Handling torque wrenches

If torque wrenches are also used to release bolted connections, it must be en-
sured that the maximum torque capacity of the wrench is not exceeded (risk
of damage). Extension pipes must not be used under any circumstances.
Torque wrenches must also be regularly checked for correct read-out/setting.
General, M010.000.003-07-0002 1 (4)

Guideline values for tightening torques

When tightening bolted connections other than those listed in Work Instruc-
tions 010.000.003-05: Working with torque wrenches, the following must be
observed:
▪ In addition to the tightening torque applied, the clamping force of a screw
connection depends on the lubricant used, the surface properties of the
support and thread, and the material combination. It is therefore essential
that these conditions are fulfilled in their entirety.
▪ Table 3 shows the tightening torques of the different threads in relation to
the coefficient of friction μ, i.e. depending on the chosen lubricant. The
torque values apply to a bolt material of strength category 8.8 and in util-
isation of approx. 87% of the yield point. Conversion factors must be used
for other strength classes, by which the tightening torque taken from the
table must be multiplied. The strength class is stamped on the bolt head.
Strength class 5.6 6.8 10.9 12.9
Conversion factor x 0.47 0.75 1.4 1.7

Table 1: Conversion factors for tightening torques depending on the strength
class of the bolts
The following applies approximately for the coefficient of friction µ:
μ = 0.08 for surfaces lubricated with G-N Plus or Molykote HSC Plus.
μ = 0.10 for oiled or phosphated and oiled surfaces, and when securing with
Loctite 243 and 222.
μ = 0.14 for surfaces without post-treatment, lightly oiled

Table 2: Coefficient of friction μ
Thread Tightening torque in Nm Thread Tightening torque in Nm

Rated di- Coefficient of friction μ Rated di- Coefficient of friction μ
mension mension
0.08 0.10 0.14 0.08 0.10 0.14
M5 4 5 6 M 24 473 551 686
M6 7 8 10 M 24x2 503 594 753
M8 17 20 24 M 27 694 813 1017

M 10 34 39 49 M 27x2 731 867 1103
M 12 59 68 84 M 30 945 1104 1379
M 14 93 108 134 M 30x2 1014 1205 1537

2020-09-04 - de
M 14x1.5 99 116 145 M 33 1271 1491 1870
M 16 141 165 205 M 33x2 1353 1611 2061
M 16x1.5 148 174 220 M 36 1640 1920 2403
M 18 196 228 282 M 36x3 1707 2017 2554
M 18x1.5 213 252 319 M 39 2113 2481 3117
M 18x2 205 240 300 M 39x3 2190 2594 3295
M 20 275 320 398 M 42 2623 3075 3856
M 20x1.5 295 350 445 M 42x3 2757 3272 4166
2 (4) General, M010.000.003-07-0002

M 20x2 285 335 422 M 45 3262 3734 4821
M 22 368 431 538 M 45x3 3414 4058 5178
M 22x1.5 393 466 594 M 48 3952 4638 5823
M 22x2 381 449 566 M 48x3 4184 4981 6367

Table 3: Tightening torques for bolts of strength class 8.8
Tightening to torsion angle, or to torque and torsion angle

Bolted connections, for the tightening of which a specific torsion angle is stip-
ulated, must first be tightened with a torque wrench to the prescribed torque,
or with an open-ended spanner, ring spanner or socket wrench until the nut
or bolt fits tightly. Secondly, the nut or bolt must be further tightened by the
stipulated torsion angle.
Tightening to the elongation of the bolt

The procedure in which the bolted connections were primarily, or exclusively,
tightened by reference to the elongation of the bolt/pressing of the parts to be
tensioned has been discarded in favour of other methods. The change in
length/compression ΔL is now only measured as a control measure, to sup-
plement clamping with hydraulic tensioners.
Tightening with hydraulic tensioners

Tightening bolted connections using hydraulic tensioners can also be used for
the largest bolts with a high level of reliability. The screw, bolt or axis is hy-
draulically extended and, after tightening or loosening the nut, relieved again.
See Work Instructions 015.000.001-01: Work and safety instructions for the
use of high-pressure tools/hydraulic tensioners.
Bolt tightening torques for not fully enclosed pipe clamps
Avoid deformation of pipelines

Bolted connections on not fully enclosed pipe clamps must be
tightened with reduced tightening torque. See Table 4.
Scope Not fully enclosed pipe clamps as per Figure 1.

2020-09-04 - de
General, M010.000.003-07-0002 3 (4)

Figure 1: Representative example
Table of tightening torques Pipe diameter M10 M12 M16

Diameter 60.3 – 20 Nm 25 Nm 35 Nm
diameter 76.1 Loctite 243 Loctite 243 Loctite 243
Diameter 82.5 – 45 Nm 65 Nm
diameter 168.3 Loctite 243 Loctite 243
Diameter 168.3 – 105 Nm

diameter 219.1 Loctite 243
Table 4: Valid for bolts with a strength class of 8.8 / 10.9 in conjunction with
Loctite 243
27021622605757067
Additional standards for Preferred pipe clamps according to standard:

pipe clamps ▪ R 508 part 3
▪ DIN 3015 parts 1 to 3
▪ DIN 3016
2020-09-04 - de
27021622605757067
4 (4) General, M010.000.003-07-0002

Surface examination
using penetration method
Summary
Inspection of components for cracks/surface defects. Evaluation regarding
usability/reworking possibilities/tightness. Surface inspections are carried out
on high quality and highly stressed components, in order to ensure their per-
fect condition, or to correctly classify existing damage.
The work/work steps include: Cleaning components and preparing for testing,
inspecting parts/components.
Tools/aids required
1 Wire brush - Inventory
1 Special cleaning agent - Inventory
1 Penetrant - Inventory
1 Developer - Inventory
1 Protective clothing - Inventory
Application areas
Surface inspections using the penetration method are based on the introduc-
tion of liquid media having a low surface tension and high capillary effect. They
can be seen in pores and cracks up to a size of approx. 0.25 μm, provided
they have a connection to the test surface. The penetration method can be
used for almost all materials and at a temperature range of approx. -5° to 50°
C. With special testing equipment, this method can also be used on surfaces
having temperatures up to 175° C. Surface defects (hereafter referred to as
faults) can be displayed independently of their type and direction as well as in-
dependently of the geometry of the test object. Other non-destructive test
methods can only be applied with restrictions under the requirements stated
above.
Fluorescent penetrating oils are used in a similar method. These require an
additional emulsifying process. The evaluation of surface faults is carried out
under UV light.
In all cases the manufacturer's instructions must be observed during use. The
2017-05-04 - de
following information illustrates the procedure and the main application op-
Surface examination
tions.
Work Sequence 1 - Precleaning of the Components to be Tested

Various cleaning methods can be applied, depending on the type and quality
of the component to be tested. Generally the surface to be tested must have
a polished metal finish, must be clean and free of grease. All types of coating
and deposits, such as galvanic coatings, rust and scale layers must be re-
moved. This is necessary so that the penetrant can fully wet the surface and
penetrate surface faults.
General, M010.000.003-08-0001 1 (7)

1 Mechanical (Wire brush) 3 Chemical (Degreasing us-

ing hot steam)
2 Mechanical (e.g. sand- 4 Chemical (Cleaning agent)
blasting)
Figure 1: Options for the precleaning of the components to be tested (Illustra-
tion source: Helling)
Work Sequence 2 - Introduction of the Penetrant

The penetrant can be applied to the component to be tested in various ways.
You must ensure that the test surface remains fully wet throughout the entire
penetration period. Adequate penetration duration depends on the character-
istics of the penetrant, the test temperature and the material of the compon-
ent to be tested. For castings, this is generally within a range 3 ... 5 minutes,
for homogeneous metals 10 ... 20 minutes.
2017-05-04 - de
Surface examination
1 Immersion bath 3 Spraying (spray can)

2 Brushing on 4 Spraying (Compressed air
gun)
Figure 2: Options for application of the penetrant
2 (7) General, M010.000.003-08-0001

Work Sequence 3 - Intermediate Cleaning of the Component Surface

The excess penetrant clinging to the component surface must be fully re-
moved. In doing so, you must ensure that the penetrant remains in position in
any faults that are detected. The cleaning method depends on the penetrant
used.
1 water soaked, non-fraying 3 Rinsing with water

cloth or sponge
2 Cleaning with a brush 4 Special cleaning agents
(compatible with the pen-
etrant)
Figure 3: Intermediate cleaning options
Work Sequence 4 - Drying of the Cleaned Component Surface

After removal of the excess penetrant, the component surface to be tested
must be dried as quickly as possible. In doing so, you must ensure that the
penetrant located in any faults does not dry in. The entire drying process can
be omitted if a wet developer with water is used as the carrying agent for the
development process.
2017-05-04 - de
Surface examination
General, M010.000.003-08-0001 3 (7)

1 Air drying 3 Compressed air (water

and oil free)
2 dry, non-fraying cloth 4 Warm air
Figure 4: Component drying options
Work Sequence 5 - Development Process

The developer must be applied as evenly as possible in a thin layer on the
component surface to be tested. In addition to wet developers based on wa-
ter or solvent, dry developers are also used. In general, the development dur-
ation corresponds to the penetration duration of the penetrant.
1 Water-based wet de- 3 Solvent-based wet de-

2017-05-04 - de
veloper (Immersion) veloper (compressed air

Surface examination
gun)
2 Solvent-based wet de- 4 Solvent-based wet de-
veloper (aerosol can) veloper (electrostatic/air-
less)
Figure 5: Options for the application of the developer
4 (7) General, M010.000.003-08-0001

Work Sequence 6 - Results Evaluation

The developer (white) draws the penetrant (red) out of any faults and shows
them as coloured bleed-outs. The size, type and shape of the bleedings allow
conclusions to be drawn as to the origin of the fault. Such fault indications are
shown as a schematic diagram in figure 7.
1 visual inspection 3 photograph

2 Documentation on trans- 4 Documentation by photo-
parency film graphs or video recording
Figure 6: Options for recording the test result
1 Cold cracks 6 Cluster porosity

2 Hot cracks 7 Spongy structure
2017-05-04 - de
3 Grinding cracks 8 Porosity (heavy bleeding)

Surface examination
4 Cracks (heavy bleeding) 9 Stress corrosion cracking

5 Porosity
Figure 7: Fault indications
General, M010.000.003-08-0001 5 (7)

Figure 8: Valve cone with stress cracks in the fillet
2017-05-04 - de
Surface examination
Figure 9: Valve cone with cracks in the valve seat armouring
6 (7) General, M010.000.003-08-0001

Recommended Manufacturers for Testing Chemicals (Special Cleaning Agents/

Penetrants/Developers)
Manufacturer Special cleaning agent Penetrant Developer
Tiede Tiede-PEN RL-40 Tiede-PEN PWL-1 Tiede-PEN DL-20
Bahnhofstraße 94-98
D-73457 Esslingen
MR Chemie GmbH MR 79 MR 68 NF MR 70
Nordstraße 61-63
D-59427 Unna
Brent GmbH ARDROX ARDROX ARDROX

Rostocker Straße 40 9PR88 9VF2 9D1B
D-41199 Mönchengladbach
Helling KG GmbH & CO. NPU VP 30 D 70

Sylvesterallee 2
D-22525 Hamburg
Table 1: Manufacturers/Testing Chemicals
9007201004993675
Figure 10: Testing Chemicals of Various Manufacturers (Special Cleaning

Agents/Penetrants/Developers Respectively)
2017-05-04 - de
Surface examination
9007201004993675
General, M010.000.003-08-0001 7 (7)

9007201004993675
2017-05-04 - de
Surface examination
General, M010.000.003-08-0001
Surface examination
using magnetic leakage flux method
Summary
Inspection of components for cracks/surface defects. Evaluation regarding
usability/reworking possibilities/tightness. Surface inspections are carried out
on high quality and highly stressed components, in order to ensure their per-
fect condition, or to correctly classify existing damage.
The work/work steps include: Cleaning components and preparing for testing,
inspecting parts/components.
Tools/aids required
1 Yoke magnetising equipment - Inventory
1 UV light source - Inventory
1 Magnetic powder (dry) - Inventory
1 Magnetic powder (in suspension) - Inventory
1 Special cleaning agent - Inventory
Application areas
Surface examinations, carried out according to the magnetic particle inspec-
tion method, cause ferromagnetic discontinuities and thus leakage fields in
the faulty areas of magnetised ferromagnetic materials which have been
flooded by a magnetic field. These go beyond the component surface. The
presence of a magnetic discontinuity or a leakage field is verified by the ap-
plication of fine ferromagnetic powder onto the component surface, the
powder being partially held by the magnetic leakage field. The magnetic
powder accumulation reveals the contour of the fault and generally indicates
the location, size, shape and extent of the field.
The magnetic powder is applied to the test surface as a dry powder or in a li-
quid suspension (water, oil, paraffin). These are ferromagnetic materials such
as iron, nickel and cobalt alloys. The ferromagnetic characteristics of these
materials disappear above a certain temperature, the so-called Curie point.
For most ferromagnetic materials this point is approx. 760° C.
The magnetic field in the component to be tested can be generated in several
2017-05-05 - de
different ways. Apart from coil magnetisation, self-magnetisation and induced

Surface examination
magnetisation, the most widespread magnetisation method is yoke magnet-

isation. In all cases the manufacturer's instructions must be observed during
use. The following information illustrates the yoke magnetisation procedure
and the basic application options.
General, M010.000.003-09-0001 1 (5)

Figure 1: AC yoke magnetising device (by Helling)
Yoke magnetisation
Figure 2: Field line path in yoke magnetisation
In yoke magnetisation we generally differentiate between two types of mag-

netisation. The magnetic field can be generated using a permanent magnet or
solenoid.
Preferentially, faults of this type are displayed whose longitudinal direction
runs at right angles to the connecting line between the magnetic poles (trans-
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verse to the field direction). It is therefore necessary to perform the test a

Surface examination
second time in a transverse direction (see figure 4/B and 4/C).
2 (5) General, M010.000.003-09-0001

A Component without faults (homogeneous magnetic field - no fault

display)
B Component with faults in the field direction (homogeneous mag-
netic field - no fault display)
C Component with faults transverse to the field direction (inhomo-
geneous magnetic leakage field - clear fault display)
Figure 3: Field lines in the magnetised component
The component to be tested must be cleaned and freed from all types of
coatings and covering which may impede the alignment of the magnetic
powder or which may lead to incorrect fault displays.
In general, narrow detachments, such as cracks and gaps, are indicated more
precisely than wide faults such as slag, porosity or blow holes. Faults lying be-
low the surface are indicated inaccurately, becoming increasingly obscure the
deeper they are. The magnetic powder test is therefore mainly used for de-
tecting surface faults or faults near the surface.
Application of the magnetic powder

The magnetic powder can be applied in a dry or wet process. Both proced-
ures differ in their application options and, in part, in their display sensitivity.
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Surface examination
Figure 4: Bead formation in the magnetic powder due to magnetic leakage

fields
General, M010.000.003-09-0001 3 (5)

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

First of all the cleaned component surface is given a visual inspection and
coated with a fast-drying special paint, if necessary, to achieve an improved
contrast with the magnetic powder. The application of the magnetic powder
and the magnetisation take place simultaneously. The time required for flush-
ing or spraying depends on the amount of powder applied per unit time, the
concentration of the suspension, the grain size, the shape of the component
surface to be tested and the size of the faults to be detected. In general, the
flushing or spraying must have been completed before the magnetic field is
deactivated in order not to destroy the powder beads formed over the faults.
Very fine separations, such as grinding and hardening cracks, can only be reli-
ably detected using the wet process with less concentrated magnetic particle
suspensions and a smaller grain size.
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Finally, the test area is examined for powder accumulation and the possible
Surface examination
fault indications are evaluated, marked and fixed if necessary. Depending on

the use of the component, test agent residues are removed and the compon-
ent is demagnetised.
4 (5) General, M010.000.003-09-0001

Magnetic Powder Indications

During the magnetic powder test, an image of the fault pattern is given by the
bead formation at the fault locations, but no information is provided as to the
fault depth. As already described, clear magnetic powder images are
provided of component surface faults, while faults underneath the component
surface only result in indistinct indications.
Figure 5: Valve cone with stress cracks in the fillet
False indications are a special problem in magnetic powder testing. These are
powder accumulations which occur in places that are not faulty. False dis-
plays occur, for example, at sharp cross section transitions or in cold-formed
areas. A certain amount of experience is required in such cases to be able to
differentiate between a false display and a genuine fault indication.
Demagnetisation
After magnetisation, residual magnetism remains in the test object, which can
lead to malfunctions, depending on the use of the component. To demagnet-
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ise, the component is subjected to an alternating magnetic field of decreasing

Surface examination
strength. Experience shows that the field strength may only decrease by max.
10 % with each alternation. At the beginning of the demagnetisation process,
the field strength must be selected to be greater or equal to the field strength
used for the test.
18014400259948299
General, M010.000.003-09-0001 5 (5)

18014400259948299
2017-05-05 - de
Surface examination
General, M010.000.003-09-0001
Elastomer Seals
storage, cleaning and fitting
Summary
Insert/replace components, process and install professionally. Elastomer seals
(rubber products) are to be stored properly and replaced during overhaul
work.
The work/work steps comprise: storage of components/auxiliary materials,
cleaning of components and correct installation.
Preliminary remarks
When servicing or carrying out overhaul work, the natural or artificial rubber
seals must be replaced. Undamaged seals, in perfect condition, may only be
reused in an emergency. It is recommended to immediately re-order seals
used, to ensure that they are to hand when needed.
The following sections are extracts from DIN 7716 and ISO 2230-1973.
Storage of Elastomer Seals

The life of rubber products is influenced by oxygen, ozone, heat, light, humid-
ity, solvents and mechanical load. The functionality of rubber seals at the time
of their installation is therefore dependent on factors such as correct storage.
The following indications should be noted in particular:
1. The store-room should be cool, dry, free from dust and moderately ventil-
ated.
2. The storage temperature should not be below -10 °C or above +25 °C.
Neoprene items (chloroprene rubber) should not be stored at temperat-
ures below +12 °C.
3. Rubber items in heated storage rooms should be protected from heat
sources. The distance between the heat source and the stored items
must be at least 1 m. If the rooms are heated by hot air, a greater dis-
tance is required (danger of drying out).
4. Rubber items should not be stored in humid rooms. Relative humidity
should be less than 65%.
5. Rubber items should be protected from direct sunlight and strong artifi-
cial light with a high UV content. The effects of ozone are particularly
2016-09-12 - de
damaging. You must therefore ensure that the storage location is not
within the proximity of fluorescent tubes or other light sources emitting ul-
tra-violet radiation. Because of the effects of ozone, rubber items should
also not be stored close to electrical installations, engines and generat-
Elastomer Seals
ors.
6. Rubber items should not be stored in the same storage room as
solvents, fuels, lubricants, slushing oils, chemicals, acids, disinfectants
and similar substances.
7. Rubber items must be tension-free, i.e. stored without strain, compres-
sion or deformation of any kind (e.g. O-ring seals should not be stored
hanging on hooks due to the danger of permanent deformation or the
development of cracks).
General, M010.000.003-10-0001 1 (2)

8. Rubber items with different compositions e.g. Perbunan and silicone rub-
ber should not come into contact with each other. This is particularly im-
portant for parts which have different colours. Also avoid contact with
copper and materials containing manganese.
9. Rubber items should be packed (shrink wrapped) in polyethylene plastic
bags or similar (foils should not contain any plasticisers). To avoid confu-
sion, the bag should be labelled with details of the elastomer type (e.g.
Perbunan, silicone) and the date of manufacture. Moreover, the bags
should be stored in cardboard containers to protect them from light. Ob-
serve points 6-7.
10.Newly delivered rubber items should be stored separately from those
already in storage to ensure that the older ones are used up first.
Cleaning
Rubber items are cleaned in warm soapy water and dried at room temperat-
ure. If necessary, seals which have been stored for a long period can be
cleaned in a 1.5% sodium bicarbonate solution. Any cleaning solution residue
should rinsed off with normal tap water (not sea water!).
Solvents such as trichloroethylene, carbon tetrachloride and hydrocarbons
must not be used for cleaning. Sharp utensils, wire brushes, emery paper etc.
are not suitable for cleaning either, since these will damage the seals.
Assembly
Generally accepted prin- The installation of rubber items requires particular care. The following points
ciples should be noted in particular during installation.
O-ring seals ▪ During installation, sealing rings should not be expanded by more than
30% of the inner diameter for a short period of time.
▪ Sealing rings should not be twisted during installation (take care with rings
of large diameter and small cross section). Some sealing rings have a cir-
cumferential line which must be visible continuously around the entire cir-
cumference.
▪ Sealing rings must not be slipped over sharp edges, threads, slots etc. If
necessary sharp edges should be covered.
▪ Sealing rings must not come into contact with corrosion-inhibiting wax
when other components pass over them. Cylinder liners must be free of
corrosion-inhibiting wax in the area where the sealing rings are installed.
The solvent used for cleaning must be completely dried off.
▪ The installation spaces of the sealing rings must be coated with a suitable
anti-seize agent.
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Radial sealing rings Sealing lips on radial shaft sealing rings must always be directed towards the
medium to be sealed.
Anti-seize agent Sealing rings and sealing ring grooves must be wetted with engine lubricating
Elastomer Seals
oil.
Unsuitable anti-seize agents

If unsuitable anti-seize agents are used, this can cause the seals to fail
prematurely.
18014400260227851
2 (2) General, M010.000.003-10-0001


51354106507
1 (1)

Working and Safety Regulations

Prepare Common-Rail engine for maintenance work
Summary
Provide the necessary knowledge to ensure safe work on a Common-Rail en-
gine.
To ensure safe work on a Common-Rail engine, some prerequisites are to be
provided.
The work includes:
Shut down the engine.
De-pressurise operating fluid systems.
Take safety precautions.
Technical data
Designation Information Value Unit
Pressure in the Common-Rail injection system Pressure > 1000 bar
Related work instructions

Disassembly, cleaning and assembly of purge valve 010.110.054-08
Preliminary information
Releasing high pressure in the common-rail injection system

properly
After an engine stop, it must be ensured that the common-rail injection
system, which is under high pressure during operation, is de-pressur-
ised before the engine fuel system is disconnected from the system
side. Otherwise, components may get damaged or serious personal in-
juries or damage to property may occur.
• It is absolutely mandatory to maintain the order of the steps given in the
following.
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Relieving the common-rail injection system

Relieving the high pressure present in the common-rail injection sys-
tem after engine operation to a low pressure level is initiated by the en-
gine control unit automatically two minutes after the engine has
stopped. In case of an emergency, the high pressure in the common-
rail injection system can be relieved manually by operating the Emer-
gency Stop switch before said two minutes have elapsed.
General, M010.000.004-02-0001 1 (3)

Work Sequence - Preparing the Common-Rail engine for maintenance work

Initial situation
Perform tasks in the order specified!

It is absolutely mandatory to carry out the below steps in the order
specified. Ignoring the order of the steps specified in the following
leads to serious personal injuries or damage to property.
Work steps 1. Stop engine.
Current state of the operating media, i.e. air and fuel

• 10-30 bar air supply to engine is open and accessible
• Shut-off valves on fuel supply and fuel outlet lines are open
2. Check the current state of the operating media, i.e. air and fuel. Refer to
the note.
3. Operate the Emergency Stop on the engine (this way, the high pressure
in the common-rail injection system is reduced to the low-pressure level).
4. Check on the engine control display whether the pressure in the com-
mon-rail system is reduced to the low-pressure level. If the pressure in
the common-rail system is not reduced to the low-pressure level (approx.
12 – 14 bar), the pressure can be relieved by opening the flush valve
mechanically. See work instructions 010.110.054-08.
Danger caused by inadvertent engine rotation!

Operating the Emergency Stop stops the running engine.
Operating the Emergency Stop safely prevents the engine from start-
ing.
The pressed Emergency Stop does not prevent the engine from rotat-
ing if the engine start is activated simultaneously. Inadvertent or unin-
tended rotation of the engine may lead to crushing of limbs or severe
fatal injuries.
• While working on the engine, the starting air pipe must be shut off and
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bled
5. Shut off the starting air pipe, bleed it and thus secure the engine against
starting.
6. Separate the engine fuel system from the system-side fuel system. For
this purpose, close the shut-off valve in the fuel supply line and close the
shut-off valve in the fuel return line.
7. Open the corresponding discharge valves of the fuel supply system. By
doing this, the engine fuel system is de-pressurised and is drained via the
leakage pipe.
2 (3) General, M010.000.004-02-0001

8. Using the pressure control devices (engine control display, pressure

gauge,...) on the engine, check whether the engine fuel system is really
de-pressurised.
9. Secure the drive shaft against rotating by engaging the turning gear.
9007201239175691
10.Disconnect the voltage supply / voltage generation.

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General, M010.000.004-02-0001 3 (3)

9007201239175691
2017-06-12 - de
General, M010.000.004-02-0001

when working on the fuel admission system
General remarks for work on the Common-Rail System

Possible consequences of Contamination of the fuel system (engine and system side) can damage com-
contamination in the fuel ponents of the Common-Rail system and cause them to fail. This can cause
system individual cylinders to fail or cause the engine to stop if the pressure in the
Common-Rail system drops.
For this reason, the following notes must be observed in the entire fuel sys-
tem.
Cleanliness at the work- Careful attention must be paid to workplace cleanliness during maintenance
place work on the entire fuel system because of tight assembly tolerances and high
operating pressures.
Attention must be paid to the absolute cleanliness of the sealing faces when
disassembling or assembling high-pressure groups like high-pressure pipes,
high-pressure pumps and Common-Rail accumulator units.
Contamination in the entire fuel system must be avoided.
Sealing of connections in Specially provided protection caps are to be used during maintenance work
the fuel system to close open pipe and pipe ends in the entire fuel system (high-pressure
groups, high-pressure pumps, Common-Rail accumulator units and high-
pressure fuel pipes, fuel admission pipes) in order to avoid dirt penetration in
the fuel system as far as possible. For proper fitting the protection caps, see
Correct execution of main- ▪ Always pay attention to the procedures described in the Work Instructions
tenance work for maintenance of the fuel system.
▪ Check seal faces for cleanliness before reassembly. Assemble high pres-
sure groups with stipulated torque.
▪ Only remove assembly parts from the packaging or remove caps shortly
before assembly. Apart from this, ensure that between the removal of as-
sembly parts from the packing and assembly that no dirt gets onto the as-
sembly parts.
▪ Only place the components of the fuel system on especially clean working
surfaces.
▪ After maintenance work on the Common Rail system , a pressure test of
the entire system is to be recommended in order to ensure there are no
leakages at the pipe connections and system components.
9007201239241739
2015-06-23 - de
General, M010.000.004-03-0001 1 (1)

9007201239241739
2015-06-23 - de
General, M010.000.004-03-0001

Securing the crankshaft and components linked to it against movement
Summary
Provide the necessary knowledge to ensure safe work on the crankshaft and
components linked to it.
Before starting work in the crankcase or on components, which also rotate
together with the rotating crankshaft, make sure that the crankshaft cannot be
turned/the engine cannot be started.
Causes
There could be unintended rotation of the crankshaft and movement of the
components coupled to it:
▪ In case of marine propulsion systems, due to the ship's motion or due to
water flow against the propeller in the case of a stationary ship;
▪ in generator units due to operating faults when the mains voltage is
present;
▪ due to unintended or negligent starting of the engine;
▪ due to the unintended or negligent actuation of the engine turning gear.
Safety measures
▪ Close/secure against opening the shut-off valves of the starting air and
control air vessels. Open the drain cocks in the air pipes/on filters. Open
the relief valves on the main starting valve.
▪ Engage the turning gear, lock it and secure against the start up.
▪ Fix an instruction plate to operating devices which are used to start the
engine.
▪ In the case of generator units and shaft-driven generators:
– Secure generator switch (especially in asynchronous generators)
against switching on. Wherever possible, also open the fuses / secur-
ing elements.
– Fix warning sign.
▪ In ship main engines with variable-pitch propeller:
– Set the climb gradient with the engine at rest to zero thrust, not to
zero.
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▪ In case of single engine systems with fixed or variable-pitch propeller:

– Apply the aforesaid measures. No other measures are necessary.
▪ In case of multi-engine installations with reduction gear(s), where work is
carried out on one engine, while the other one is running:
– When using elastic couplings, their rubber elements should be re-
moved.
– When using elastic couplings with intermediate rings, the latter must
be removed, and the resultant free space must never be bridged un-
der any circumstances. Released coupling parts should be supported
if necessary.
General, M010.000.004-04-0001 1 (2)

– If clutches are used between the engine and gear, they should be
completely removed. It is not sufficient to switch off /open the coup-
ling and to cut off the switchgear’s compressed air/ oil.
– If clutches are used in the gearing, the elastic couplings are to be par-
tially removed as described in the first two subparagraphs.
▪ In case of engines with a mechanical dredging pump drive on the second
drive side, where work is carried out on the dredge pump gear or on the
dredge pump, while the engine is running, proceed as described above.
9007203355579659
2020-05-26 - de
2 (2) General, M010.000.004-04-0001

Work and safety regulations

when turning the running gear
Summary
Impart necessary knowledge. Ensure hazard-free turning of the running gear.
In order to safely turn the running gear without hazards, work and safety in-
structions must be observed.
Information is provided on:
Safety instructions
Safe turning of the running gear
Safety requirements
l Engine stopped
l Operating media system isolated/depressurised
l Power supply/generation interrupted
Safety instructions
When turning the running gear, various dangers occur depending on the situ-
ation. Depending on the situation, the safety instructions described below
must be adhered to.
Danger to life when turning with an open crankcase

If the running gear is turned while persons are within the crankcase,
the person’s limbs may be crushed and severe injuries resulting in
death may be caused.
• Do not carry out work in the crankcase during the turning operation
• Cover any opened crankcase windows
• Prior to the start of the turning operation, pay attention to acoustic and
optical signals
• The turning operation must be carried out by at least two persons. One
person implements the turning operation and the second person con-
stantly ensures that nobody is in the crankcase or enters the crankcase
2017-06-29 - de
hazard area.
M010.000.004-05-0001 1 (4)
Pressure in the combustion chamber

When turning the running gear, pressure will build up in the combus-
tion chamber if the inlet and exhaust valves are closed. Depending on
the running gear position, the piston may be at TDC after stopping the
turning operation. The residual pressure in the combustion chamber
can set the running gear in motion, or cause unforeseen disruptions
when removing combustion chamber components. This can lead to
persons being crushed and injured.
• Only commence work 1 minute after the end of the turning operation
• Open the indicator valve before removing the combustion chamber
components
Damage due to turning with attached tools

In the case of some maintenance work, turning must not occur if tools
are attached as otherwise damage may result. In order to prevent
damage, reference is made to the dangers at the respective points in
the relevant work instructions. Relevant work instructions with at-
tached tools can be, for example:
• Working with attached hydraulic tensioning tools
• Working with fitted rope guide
• Working with attached locating clamp
• Working with attached sensor
• Working with attached support for removal and fitting of the cylinder
liner
Damage due to turning with detached components

In the case of some maintenance work, turning must not occur if cer-
tain components are detached as otherwise damage may result. In or-
der to prevent this damage, reference is made to the dangers at the re-
spective points in the relevant work instructions. For example, corres-
ponding situations can be:
• If the crankshaft gearwheel is removed

• During overhaul work on the control drive that requires interruption of
the control drive between the crankshaft and the camshaft
2017-06-29 - de
Note for 48/60CR - engines
2 (4) M010.000.004-05-0001
Damage due to excessive turning

If the running gear of a 48/60CR- engine is turned by more than 6
crankshaft revolutions (corresponds to 3 camshaft revolutions), the
high pressure pump drive with installation bolt (201.023) must be
raised up. Otherwise, further turning of the running gear can cause
damage to the high pressure pump drive.
If the high pressure pump drive with installation bolts(201.023) is
raised, the running gear can be turned more than 6 crankshaft revolu-
tions (corresponds to 3 camshaft rotations).
• Raise the high pressure pump drive with installation bolts (201.023) in
the case of more than 6 crankshaft revolutions. See Work Instructions
M010.110.020-01
Work sequence – turning the running gear

Initial situation Turning the running gear is required as part of maintenance work.
Observe manufacturer's Operating Manual

Before commissioning the turning gear, the manufacturer’s Operating
Manual must be read and observed.
Turning gear has its own power connection

The power supply to the engine has been interrupted in accordance
with the safety requirements in these work instructions. Since the turn-
ing gear has its own power connection, the power supply to the engine
can remain switched off during the turning operation.
Damage due to connected propeller

If the ship’s propeller is connected during the turning operation, dam-
age to the turning gear may occur due to rotational movements of the
ship’s propeller and the resulting forces on the turning gear.

In the case of engines that drive generators, the generators remain
2017-06-29 - de
connected and rotate during the turning operation.

• Ship’s propellers must always be disconnected during the turning oper-
ation
• If necessary, manual lubrication of the generator bearings must be ef-
fected to reduce the friction torque in the generator bearings.
Work steps 1. Engage the turning motor according to the description in the manufac-
turer's documentation. See Volume 010.210... 010.260 Engine compon-
ents - 010.260.030 Electric turning gear.
M010.000.004-05-0001 3 (4)
Danger of crushing
When turning the engine over, the body parts in the bore may be
crushed due to carelessness.
• During the turning the presence of persons in the area of moving parts
is prohibited.
Danger of crushing due to overrun of running gear

After completion of the turning operation from full speed (release of the
button on the turning motor remote control), the design of the system
means that the running gear will overrun by a maximum of 3°. Body
parts may be crushed if an attempt is made to touch parts that are still
moving.
• Do not touch moving parts while the running gear is overrunning
• Let the running gear come to a standstill before conducting further
work
22659876747
2. Turn the running gear.

3. Disengage the turning motor according to the description in the manufac-
turer's documentation. See Volume 010.210... 010.260 Engine compon-
22659876747
ents - 010.260.030 Electric turning gear.
2017-06-29 - de
4 (4) M010.000.004-05-0001
Work and safety specifications

Depressurise the compressed air system
Summary
Communicate necessary knowledge. Depressurise the compressed air sys-
tem.
The compressed air system must be shut off and depressurised before start-
ing maintenance work on the engine.
Information is communicated on:
Safety specifications
Depressurising the compressed air system using the main starter valve
Safety requirements
l Cut off starting air
l Engine stopped
l Starter air distributor/distribution system switched off
l Control air supply cut off
l Engine cooled down (room temperature)
Personnel and time requirements

Number Qualification Duration in h
1 Qualified Personnel 0,25
Required tools/aids
1 Open-jaw and ring spanner (set) - Inventory
Warning messages
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58/64;51/60;48/60;32/40, M010.000.004-06-0001 1 (3)

Severe to deadly injuries due to the crank mechanism rotating

unexpectedly
Pressure can build up in the supply lines due to potential leaks on the
shut-off devices. This pressure may lead to the crank mechanism ro-
tating unexpectedly. Severe/fatal injuries to limbs may occur due to
crushing/severing.
• Shut off the supply of starter air upstream of the engine
• Open the drain valve/ball valve for condensate upstream of the engine
• Secure the connecting shaft against cranking
• Open the ball valve on the main starter valve
Hearing damage due to a high sound level when compressed

air escapes
Compressed air may escape suddenly when operating the shut-off
devices. The resulting sound level may lead to hearing damage.
• As a general rule, wear the following during work on compressed air
lines:
• hearing protection,
• protective goggles and
• protective gloves.
Work sequence 1 - Depressurising the compressed air system

1. Disconnect the supply line from the starter air supply system using the
shut-off device.
2. Carefully open the drain valve/ball valve for condensate upstream of the
engine, evacuate the compressed air and leave it open for the duration of
the maintenance work.

3. Open the ball valve on the main starter valve and leave it open for the
duration of the maintenance work.
4. Carefully open the control air system drain valve/ball valve for condensate
2020-03-25 - de
upstream of the engine, evacuate the pressure and leave it open for the
duration of the maintenance work.
5. At the start of the maintenance work, check whether the compressed air
has been fully evacuated.
Work sequence 2 - Supplying the compressed air system with compressed air
1. Close the condensate drain valve/ball valve in the control air system.
2. Close the ball valve on the main starter valve.
3. Close the drain valve/ball valve for condensate upstream of the engine.
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4. Open the supply line shut-off device to ensure starter air supply.

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51354098443
1 (1)

Charge air cooler/Crankcase differential pressure

measure
Summary
Collecting operating data, ensuring/restoring operating safety, enabling/sup-
porting economic operation. Differential pressure measurements support, in
addition to the details in the maintenance schedule, the determination of the
most suitable cleaning intervals of charge air coolers and they enable the as-
sessment of operating data.
The work includes: Measurement by means of a digital pressure gauge, and
measurement by means of a U-tube pressure gauge.
Tools/aids required
1 Digital pressure gauge "Digima-Premo" 009.090 Option
1 Case 009.090-1 Option
1 9V battery 009.090-2 Option
1 Plug-in charger 009.090-3 Option
2 Teflon hose 009.090-4 Option
4 Quick-fitting coupling 009.090-5 Option
2 Hose plug-in nipple 009.090-6 Option
2 Filter 009.090-7 Option

1 U-tube pressure gauge/ water-filled PVC hose - Inventory
1 Measuring tape - Inventory
Preliminary remarks
Contamination of the charge air cooler reduces the cooling effect and has a
negative effect on the operating values of the engine. In addition to the recom-
mended cleaning intervals in the maintenance schedule, the measurement of
differential pressure helps to determine the most suitable time for cleaning and
to evaluate the operating data. The measurement can be done with a digital
differential pressure gauge or a U-tube pressure gauge.
2016-09-19 - de
General, M010.000.005-01-0001 1 (6)

Measuring devices/Measuring points

1 On/Off button 6 Zero button

2 Measuring range selector 7 Indicating display
button with LED
3 Information area 8 „lo bat“ - display indica-
tion
4 Attenuation button with 9 Battery tray
LED
5a Pressure connection (+) 10a Output port for printer (+)
5b Pressure connection (-) 10b Output port for printer (-)
Figure 1: Measuring device "Digima-Premo" made by DR, special instruments
2016-09-19 - de
2 (6) General, M010.000.005-01-0001


2016-09-19 - de
11 Charge air cooler casing A Measuring connection downstream the

charge air cooler
12 Charge air cooler B Measuring connection upstream the
charge air cooler
Figure 2: Measuring connections (upper: V32/40; lower: V48/60B)
General, M010.000.005-01-0001 3 (6)

Safety Instructions
Load measuring device with dry gases only

If you work with water, make sure that the hose line prevents the in-
gress of any liquids into the sensor. Use a hydrophobic filter in the
supply line, if necessary. These filters allow a gas exchange, however
they cut off the water column in case of a fault.
Normally, p2 > p1 for differential pressure measurements. If p2 < p1, the sign
of the measured value is negative. With relative pressure measurements, p1=
ambient pressure, p2 = measuring pressure.
The hose couplings on the engine and on the hoses in front of the measuring
device are self-locking.
Measurement with digital pressure gauge

One-off preparations Fit the hose plug-in nipple and quick-fit coupling on both ends of the teflon
hoses. Cut the hose approx. 30 cm in front of the coupling, and connect both
ends to the connections on the water repellent filter. Also use this hose for
connection p1!
Work steps 1. Blow out the measuring connections. In order to do so, connect the hose
plug-in nipple with nom. Ø 8 mm temporarily to the coupling at the en-
gine side.
2. Connect teflon hoses with filter to measuring points A and B. The locking
rings of the hose couplings must engage.
3. Press "On/Off" button (1).
4. Connect the measuring device and press measuring range selector but-
ton (2). In information area (3), the actual measuring range is indicated.
5. Pulsating pressures lead to unstable indications. In this case, press atten-
uation button (4). The activated attenuation is indicated by the red LED.
6. Turn off measuring device. Remove measuring hoses from the measuring
points (lift the locking ring to do so).
7. Compare measured value with reference value and evaluate. The pres-
sure differential in the as-new condition can be taken from the engine ac-
ceptance test record. The intercooler is, at the latest, to be cleaned when
the pressure differential has reached the maximum value (see 010.005
2016-09-19 - de
Engine – operator’s manual, section 3.5).

Additional information If the battery or accumulator voltage is too low, a pre-warning "lo bat" will ap-
pear in indication display (7). Replace the battery if this message appears.
The recording instrument outputs 10a/10b provide a DC voltage of 1 mV/digit
(maximum 2 V) which is proportional to the measured value.
4 (6) General, M010.000.005-01-0001

Overload of measuring device

Make sure, that the measuring device is not overloaded. The maximum
pressure is indicated on the sticker on the device bottom. For multir-
ange devices the value of high range is applicable. If the specified
maximum pressure is exceeded, the built-in sensor will be damaged ir-
reparably.
Measurement with U-tube pressure gauge

Work Steps 1. Blow by the measuring connections as described above.
2. Fit hose nipples, which are mounted on the measuring connections on
the engine, to both ends of the PVC hose having 8 mm inner diameter.
3. Fill hose with water until the water column is approx. 300 mm high on
both sides.
4. Grasp hose ends and connect to the couplings of the measuring points
at the same time.
5. Measure water level h and evaluate the result as described above.
Δh 100 mm WS = 10 mbar differential pressure Charge air cooler/Crankcase differential pressure

A Connection after charge air cooler
B Connection in front of charge air cooler
Figure 3: Differential pressure measurement with U-tube pressure gauge
2016-09-19 - de
Checking the crankcase pressure

A measuring connection is also located on the crankcase (approx. in the
middle of engine on the exhaust side). The crankcase pressure can be meas-
ured here on connection p2, relative to the atmosphere. When evaluating the
measured values, the following must be considered: the wear condition of the
piston, piston rings and cylinder liners, a potential sealing air transition from
the bearings of the turbocharger to the running gear area, the function of the
crankcase vent valve and other factors.
General, M010.000.005-01-0001 5 (6)

13 Cylinder crankcase C Measuring point

Figure 4: Measuring point on crankcase (figure shows engine V35/44G)

27021599514813963
2016-09-19 - de
6 (6) General, M010.000.005-01-0001



51354090379
1 (1)


using hydraulic tools
Summary
Impart necessary knowledge, ensure safe use of high-pressure tools. The hy-
draulic tensioning device, high pressure hose, hydraulic cylinders and the high
pressure pump are tools which can be used safely despite the high pressure
they are operated with, provided that the operating instructions are adhered
to.
Please observe:
Safety instructions,
Proper use,
Repair instructions.
Safety instructions
To safely use high-pressure tools (hydraulic tensioners, high-pressure hoses,
hydraulic cylinders and high-pressure pumps), adhere to the following safety
instructions. Furthermore, the safety instructions in the work instructions and
the operating instructions supplied by the manufacturer apply.
▪ Only trained and instructed personnel may carry out work on and with
high-pressure tools.
▪ Wear personal protective equipment during work.
▪ Before each load change, the high-pressure tools must undergo visual in-
spection. Only use tools in perfect working order. Overhaul or replace
faulty/dubious components.
▪ It is forbidden to stand in the axial direction of the hydraulic tensioner and
hydraulic cylinders.
▪ If possible, keep a safe distance from high-pressure tools and high-pres-
sure hoses.
▪ Remove dirt on the contact faces of engine parts or tools. Check threads
and clean if necessary.
▪ Screw the locking ring (fluted threaded ring) up to the stop after engaging Working and Safety Regulations
the hose coupling.
▪ Seal hose couplings with protective caps.
▪ Do not kink high pressure hoses, the minimum bending diameter is 400
mm.
▪ Use the stipulated tensioning values and lubricants.
2019-04-08 - de
▪ Slowly raise the pressure control valve. Do not exceed the specified pres-
sure.
▪ No impacts on loaded screws, nuts and high-pressure tools.
▪ After each tensioning process, ensure that the piston is reset. Description
in the Work Instructions for the hydraulic tensioners.
▪ No source of ignition in the workplace. Risk of fire when using anti-corro-
sion oil.
▪ When loosening hydraulically tightened bolts, the stipulated tensioning
pressure must not be exceeded by more than 5 %.
▪ When checking hydraulically tightened bolts, the release pressure may be
max. 7 % below and max. 5 % above the stipulated tensioning pressure.
General, M015.000.001-01-0001 1 (2)

If the release pressure is too low (max. 7 % below the stipulated value), de-
termine the cause (carelessness during tightening, wear, strong setting of the
bolted connection).
If the release pressure is 10% or more below the stipulated value, notify MAN
Energy Solutions Augsburg, who will help you find the best approach for de-
fining the necessary control measures.
If the release pressure is too high (tensioning pressure plus 5 % is insufficient
for release), eliminate the cause as far as possible (bolted connection dam-
aged/corroded/blocked by paint, tensioning tool damaged/incorrectly fitted).
Once remedial action has been taken and the connection still cannot be re-
leased, the tensioning pressure may then only be increased further to release
the connection with the verifiable consent of MAN Energy Solutions Augsburg
(as there is a danger of bolt elongation or deformation of components). As an
alternative, the nut can be split and replaced together with the bolt.
Intended use
The high-pressure tool is designed exclusively for the activities described in
the work instructions.
The units are not intended for any other use.
Repair instructions
Storage and maintenance ▪ Store tools at 15 to 25° C.
▪ Protect plastic seals from light.
▪ Keep dust, dirt, chemicals and liquids away from tools.
▪ Ventilate presses and high-pressure hoses for storage.
▪ Do not kink the high-pressure hoses. Close open couplings.
▪ Use original replacement parts.
▪ Check the pump pressure gauge before beginning work.
Recording the load cycles Maintain the load cycles of the individual hydraulic tensioners in the opera-
tional data.
Maintenance intervals Before each load cycle Visual inspection for damage and wear (thread,...)
After 100 load cycles Visual inspection for damage and wear (thread,...)
magnetic crack test of all components
After 2500 load cycles Decommission

36028798769772299
Overhauling the hydraulic The hydraulic tensioners must be dismantled when the high-pressure seals
2019-04-08 - de
tensioners are due to be replaced. We recommend having the hydraulic tensioner over-
hauled by MAN Energy Solutions or one of the authorised service subsidiaries.
36028798769772299
2 (2) General, M015.000.001-01-0001

High pressure hoses

use
Summary
High-pressure hoses are necessary to create a connection between the high-
pressure pump and hydraulic tensioners.
This document contains information on the following:
Technical data
Preliminary remarks
Opening the non-return valve
Tools/aids required
1 High-pressure hose 009.330 Standard
1 High pressure hose 009.306 Standard
1 Opener 009.026 Standard
Relevant Work Instructions

Technical data
Max. working pressure (sudden loading) Pressure 900 bar
Max. working pressure (constant loading) Pressure 1800 bar
Minimum burst pressure Pressure 4500 bar
Preliminary remark
When using high pressure hoses, observe the following items.
▪ The high pressure hoses should be subject to a visual inspection before
use. Defective or damaged high pressure hoses must be replaced imme-
2020-04-29 - de
diately.
High pressure hoses
▪ When coupling, ensure that the coloured warning ring is completely

covered by the seal sleeve. See Fig. 3.
– In addition, the couplings with the threaded ring must be secured
against unintentional loosening.
▪ During use the protection caps must be connected with each other.
▪ After use, the protection caps should be fitted to the nipple and coupling.
▪ The high pressure hoses should be subject to a pressure test every 2
years.
– The test pressure is 1.5 times that of maximum working pressure.
General, M015.000.002-01-0001 1 (3)

▪ High pressure hoses should be replaced every 6 years.

– Observe the manufacturing data on the high pressure hose.
Opening the non-return valve

Initial situation The high-pressure hoses are decoupled while under pressure. The pressur-
ized high-pressure hoses cannot be coupled together with the high-pressure
pump or the hydraulic tensioner.
Work steps 1. Place opener (009.026) over nipple (2) and secure them with star knob
(6). See Figure 2.
2. Screw in the star knob (5) and thus open the integrated non-return valve.
3. Turn star knob (5) back.
4. Turn star knob (6) back and remove the opener from the nipple (2).
1 Protective cap 3 Coupling

2 Nipple 4 Protective cap
Figure 1: High-pressure hose
2020-04-29 - de
2 Nipple 6 Star knob

High pressure hoses
5 Star knob
Figure 2: Fitted opener
2 (3) General, M015.000.002-01-0001

counter After coupling, the col- clockwise After coupling, the col-
clockwise oured warning ring can oured warning ring can
no longer be seen be seen
Figure 3: Coloured warning ring
36028798778982155
2020-04-29 - de
High pressure hoses
General, M015.000.002-01-0001 3 (3)

36028798778982155
2020-04-29 - de
High pressure hoses
General, M015.000.002-01-0001
High-pressure pump
use
Summary
The high-pressure pump generates the pressure for tightening and releasing
large bolted connections with a hydraulic tensioner. It is operated using com-
pressed air and generates pressures of up to 1500 bar with small feed
volumes.
This document contains information on the following:
Technical data
Structure/operating principle
Commissioning
Decommissioning
Maintenance
Operating faults
1 High-pressure pump 009.342 Standard
1 Anti-corrosion agent, 5 l 009.774 Standard

Using high-pressure hoses 015.000.002-01
Technical data
High-pressure pump Pressure range 0 - 1500 bar
Hydr. tensioner Test pressure 1500 bar
Compressed air connection Pressure 7 - 15 bar
Oil filling Volume 5 L
Slushing oil Quality
2020-04-24 - de
High-pressure pump Dimension 431x317 mm

High-pressure pump
x405
High-pressure pump Weight 30,5 kg
Structure/operating principle
For tightening and releasing large bolted connections, the following is re-
quired:
▪ The high-pressure pump
▪ Special, pressure-resistant hose lines
General, M015.000.003-01-0004 1 (6)

▪ Hydraulic tensioners
The high-pressure pump requires a relatively low fluid volume (if required, at a
pressure of up to 1500 bar) by the pluggable hose lines to one or more hy-
draulic tensioners.
If the piston of the hydraulic tensioner is engaged to the thread of the screw,
the fluid raises the piston within the casing. The screw is stretched and the
hydraulic tensioner rests against the component surrounding the screw.
The high-pressure pump is operated using compressed air. The air is routed
to a piston via control elements. This piston can be supplied from either side.
Each of these sides is equipped with a piston of a smaller diameter. These
pistons suck in slushing oil from the supply surrounding them, or route slush-
ing oil to the distributor on the opposite side. As soon as the piston reaches
an end position, the air flow is directed to the other side of the piston by a pi-
lot valve, and the pumping and suction action is repeated. The effective air
pressure is normally reduced so that a pressure of 1500 bar can be produced
on the hydraulic side. An outlet pressure of 1500 bar must not be exceeded.
Commissioning
Work steps 1. Check the oil level in the high-pressure pump on the oil level indicator (5).
Open the oil filler neck (1) if necessary. Refill anti-corrosion agent. Only fill
in anti-corrosion agent using the filling sieve.
2. Connect the high-pressure pump to the hydraulic tensioner via the high-
pressure hose.
When connecting the high-pressure hose and the hydraulic tensioners,
make sure that they have been bled as appropriate and completely filled
with slushing oil. Otherwise, it may not be possible to achieve the re-
quired release/tensioning pressure of the screw.
3. Set the shut-off valve to position II – OUT OF SERVICE.
4. Connect the compressed-air line to the hose connection (6).
5. Adjust the pressure control valve (C) so that the pressure gauge (7) for
compressed-air supply indicates about 1 bar.
6. Open the relief valve (B) (counter-clockwise) to relieve the oil side of the
high-pressure pump.
7. Ensure that the high-pressure hose is connected properly and close off
unused hose connections (4) with blind plugs (lock the sliding sleeve of
the coupling with the stop ring).
8. Set the shut-off valve (A) to position I – OPERATIONAL.
9. Close the relief valve (B) (clockwise).
2020-04-24 - de
10.Gradually turn the pressure control valve (C) for air pressure clockwise
High-pressure pump
until the required pressure is displayed on the oil pressure gauge (3). This
occurs after a delay that is proportional to the size of the hydraulic ten-
sioner.
The high-pressure pump operates until the set oil pressure is reached.
Leakage losses are compensated for by additional pump action.
2 (6) General, M015.000.003-01-0004

Shutdown
Risk of accident due to slushing oil suddenly being ejected

When opening a quick-connect coupling that is under pressure, slush-
ing oil may suddenly be ejected from the high-pressure hose, causing
injuries to personnel.
• Before opening a quick-connect coupling, make sure that the oil pres-
sure gauge is at zero.
Work steps 1. Set the shut-off valve to position II – OUT OF SERVICE. Bleed the air side
of the high-pressure pump.
2. Open the relief valve (B) (anti-clockwise). This depressurises the oil side of
the high-pressure pump (oil pressure gauge (3) drops to zero). Bear in
mind that the drop in pressure in the high-pressure hose occurs at a
slower rate. For this reason, it is necessary to leave the high-pressure
hose connected to the high-pressure pump for approx. 3 minutes with
the relief valve open after the pressure has been released. Otherwise, in-
ternal pressure may remain in the high-pressure hose, locked in by the
hose coupling. For troubleshooting, see Work Instructions
015.000.002-01.
WARNING Risk of accident due to slushing oil suddenly being ejected.
3. Undo the quick-acting coupling on the high-pressure hose.
Adjusting the pressure control valve

When several bolted connections are tensioned one after the other at
the same pressure, the pressure control valve (C) remains at the set
value. Re-adjustments are not necessary.
4. Leave the high-pressure hose on the hose connection (4) and force the
anti-corrosion agent out of the hydraulic tensioner. For a description of
the procedure, see the work instructions for the relevant hydraulic ten-
sioner.
5. Disconnect the high-pressure hose.
2020-04-24 - de
Maintenance
High-pressure pump
The components and connections of the high-pressure pump should be

checked regularly for leaks and overhauled if necessary. The set of wear parts
(2) for the high-pressure pump and pressure control valve (C) is fastened be-
hind the side panel.
Prior to every start, check the oil level on the oil level indicator (5) and add oil if
necessary. Never run high-pressure pump without oil, otherwise air may be
sucked in. Around once a year, the oil must be drained off and fresh slushing
oil must be added. Always clean the oil chamber when changing oil.
General, M015.000.003-01-0004 3 (6)

To drain the compressed-air filter in the compressed-air controller (C), the side
panel must be removed and the screw plug at the bottom of the compressed-
air controller must be screwed in by a few revolutions so that the water can
drain off. Tighten the locking screw afterwards. See the operating instructions
from the manufacturer.
Operating faults
Compressed-air part ▪ The high-pressure pump operates only at pressures above 1.5–2 bar.
Cause: Excessive friction with the pilot valve seal.
Corrective action: Lubricate or replace the O-rings on the pilot valve.
▪ The high-pressure pump operates slowly or not at all.
Cause 1: Compressed-air side is leaking.
Corrective action:Replace the O-rings.
Cause 2: The bleed valves have frozen up.
Corrective action: Warm up the high-pressure pump to approx. 20°C.
▪ The high-pressure pump does not generate any pressure or stays in
dead-centre position.
Cause: Compressed-air side is frozen up or unit is defective.
Corrective action: Replace the O-rings on the pilot valve or replace the air
pistons.
▪ Condensate is being ejected from the bleed valve silencer.
Cause: The compressed-air filter is full of water.
Corrective action: Drain the compressed-air filter.
Hydraulic part ▪ The high-pressure pump is in operation but does not generate any supply.
Cause 1: Air in the suction pipe.
Corrective action: Bleed the hydraulic system.
Cause 2: The intake filter is blocked.
Corrective action: Clean the intake filter.
▪ Slushing oil is being ejected from the silencer.
Cause: The piston seal has been worn down and is leaking.
Corrective action: Replace the seal.
2020-04-24 - de
High-pressure pump
4 (6) General, M015.000.003-01-0004

1 Oil filler neck with basket 6 Hose coupling (com-

strainer pressed air)
2 Set of wear parts 7 Compressed-air pressure
gauge
3 Oil pressure gauge A Shut-off valve
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4 Hose coupling (hydraulic B Relief valve

High-pressure pump
tensioner)
5 Oil level indicator C Pressure control valve
Figure 1: High-pressure pump, type HP25, by GERUS
General, M015.000.003-01-0004 5 (6)

A Shut-off valve C Pressure control valve

B Relief valve
Figure 2: Functional diagram of the high-pressure pump
36028798778992523
2020-04-24 - de
High-pressure pump
6 (6) General, M015.000.003-01-0004

Dial gauge (measuring device)

checking the screw elongation
Summary
The measuring device is used to determine the screw elongation in compar-
ison to a reference value. This is to ensure that particularly important screws
are tightened correctly with a hydraulic tensioner.
The work sequences include the following:
Measurement of the screw elongation Δl
Required tools/aids
1 Magnetic measuring stand 009.446 Standard
1 Dial gauge 009.444 Standard
1 Tommy bars (set) - Inventory

Preliminary remark
In case of threaded connections, which are clamped hydraulically, measure-
ment of the screw elongation against a reference value is particularly import-
ant. This is to ensure that the necessary pretension actually exists in the form
of elongation of the screw and compression of the engine parts to be
clamped. This is not guaranteed if the tensioner is blocked or the tension
pressure is partly or fully dissipated by friction.
Work sequence – measuring the screw elongation Δl

Serious injury may occur if the hydraulic tensioners fail

The high working pressure involved in the use of hydraulic tensioners
2021-03-05 - de
can cause powerful forces to be released in the axial direction in the

event of failure and cause severe personal injuries.
• It is forbidden to stand in the axial direction of hydraulic tensioners.
• If possible, keep a safe distance from high-pressure tools and high-
pressure hoses.
General, M015.000.004-01-0005 1 (4)

Preliminary remark A prerequisite for correct tightening of a screw connection is a pressure indic-
ator with an accurate read-out. If in doubt, compare the pressure indicator
with a comparison pressure indicator.
Before fitting the hydraulic tensioner, check that the piston is fully retracted
(stroke = zero), and reset the piston if necessary.
Initial situation Screw connection released, hydraulic tensioner is fitted and ready to operate.
Work steps 1. Start the high-pressure pump and tighten the screw to charging pressure
with the hydraulic tensioner (1). See Work instructions 010.000.003-05.
2. Fit the measuring device.
– Place the dial gauge (009.444) into the bore in the cover of the hy-
draulic tensioner (1) and fix it with the stud screw (3). See Fig. 1.
– Attach magnetic test stand (009.446) to hydraulic tensioner (1) and
position dial gauge into magnetic test stand. See Fig. 2.
3. Reset dial gauge to “0”.
4. Increase the tensioning pressure up to the prescribed end value. See
Work instructions 010.000.003-05.
5. Using a tommy bar, tighten the nuts until hand-tight.
6. Release the pressure.
7. Increase the pressure to pre-tensioning pressure. Make sure to tension
the screws with the prescribed tensioning pressure. The measurement of
the screw elongation ∆l is only intended for inspection purposes.
8. Indication on the dial gauge is equivalent to screw elongation Δl. Read off
the value, convert to millimetres and compare it with the setpoint value.
See Work Instructions 010.000.003-05.
If major deviations from setpoint value occur, repeat tensioning and
check hydraulic tensioners (1), bolted connections and pressure indicat-
ors if necessary.
10.Remove the measuring device.
11.Remove the hydraulic tensioner (1).
2021-03-05 - de
2 (4) General, M015.000.004-01-0005

1 Hydraulic tensioner 3 Stud bolt

2 Thrust piece
Figure 1: Hydraulic tensioner (example arrangement)

2021-03-05 - de
General, M015.000.004-01-0005 3 (4)

1 Hydraulic tensioner 2 Thrust piece

Figure 2: Hydraulic tensioner (example arrangement)
63050396760554379
2021-03-05 - de
4 (4) General, M015.000.004-01-0005

Hydraulic tensioner
use
Summary
Hydraulic tensioners are used for extending screws according to the compon-
ents to be connected. In this condition, nuts can be tightened or loosened
without applying force.
The work sequence includes the following:
Releasing a screw
Tensioning a screw
Tools/aids required
1 Tensioning nut 030.539 Standard
1 Hydraulic tensioner 009.664 Standard
1 Single ended open-jaw wrench 50 000.569 Standard

Using high-pressure pump 015.000.003-01
Dismantling and assembling hydraulic tensioners 015.000.030-02
Technical data
Hydr. tensioner Nominal pres- 1000 bar
sure
Thread size Dimension M33x2 mm
2020-05-04 - de
Hydr. tensioner Effective piston 41,09 cm²

Hydraulic tensioner
area
Hydr. tensioner Effective stroke 5 mm
General, M015.000.030-01-0001 1 (4)

Warning message

• Safety provisions in Work Instructions 015.000.001-01 must be ob-
served.
Preliminary remark
The screw is expanded relative to the components to be connected using the
piston and casing of the hydraulic tensioner, supplemented by a pressure
shim and tensioning nut. To do this, press anti-corrosion agent behind the
pistons using the high-pressure pump. When the pressure is high enough, the
screw nut is accessible and can be loosened or adjusted according to spe-
cifications.
As with high-pressure hoses, hydraulic tensioners must be completely filled
with slushing oil before use. Hydraulic tensioners must be vented if necessary.
Leak tightness must be checked occasionally.
Tensioners Single tensioners are used separately or in combination with others.
Tandem tensioners are always used as a unit.
Release To undo the screw connection, the pistons of the hydraulic tensioner must be
unscrewed by a specified angle from the hand-tight position. Otherwise there
is a danger that the screw and the hydraulic tensioner are still tensioned to the
extent that the hydraulic tensioner cannot be removed, even though the nut
may be released.
Tightening Hand-tighten the nut before tensioning the screw connection. The piston of
the hydraulic tensioner must be screwed on so that the casing and thrust
piece are blocked.
Work Sequence 1 - Releasing a bolt

Preliminary remark A prerequisite for correct releasing of a screw connection is a pressure indic-
2020-05-04 - de

Hydraulic tensioner
Initial situation Screw thread has been cleaned.
Work steps 1. Check tensioning nut (3) on piston of the hydraulic tensioner (2) for tight-
ness using a single open ended spanner (000.569). If the tensioning nut
is loose, retighten it with torque. See Work Instructions 015.000.030-02.
2. Place the thrust piece (5) over the nut (4).
3. Screw the hydraulic tensioner (2) onto the screw (6). Make sure that the
thrust piece is centrally aligned (5) by the hydraulic tensioner.
2 (4) General, M015.000.030-01-0001

4. Turn the hydraulic tensioner (2) back by the turn-back angle. See Work
Instructions 010.000.003-05. See Figure 1/X.
5. Connect the high-pressure hose (009.306) to the hydraulic tensioner (2)
and high-pressure pump (009.342), and secure it. See Work Instructions
015.000.002-01.
WARNING It is forbidden to stand in the axial direction of hydraulic ten-
sioners.
6. Put the high-pressure pump into operation and close the gap during un-
screwing. See Work Instructions 015.000.003-01.
7. Pump up the hydraulic tensioner (2) until the nut (4) can be released using
the tommy bar (7). The release pressure must not be more than a max-
imum of 7% below or a maximum of 5% above the tensioning pressure.
See Work Instructions 010.000.003-05 and 015.000.001-01.
8. Using a tommy bar (7), turn the nut (4) back by the turning-back angle
through the opening in the thrust piece (5). See Work Instructions
010.000.003-05.
9. Release the pressure. See Work Instructions 015.000.003-01.
10.Disconnect the high-pressure hose from the hydraulic tensioner (2) and
the high-pressure pump. See Work Instructions 015.000.002-01.
11.Unscrew the hydraulic tensioner (2) from the screw (6). Take off the thrust
piece (5).
Work Sequence 2 - Tensioning a bolt

Initial situation Nut is screwed on and hand-tight. Screw thread has been cleaned.
Work steps 1. Check tensioning nut (3) on piston of the hydraulic tensioner (2) for tight-
ness using a single open ended spanner (000.569). If the tensioning nut
is loose, retighten it with torque. See Work Instructions 015.000.030-02.
2. Place the thrust piece (5) over the nut (4).
3. Screw the hydraulic tensioner (2) onto the screw (6). Make sure that the
thrust piece is centrally aligned (5) by the hydraulic tensioner. See Fig-
ure 1/Y.
2020-05-04 - de
015.000.002-01.
Hydraulic tensioner

sioners.
5. Start the high-pressure pump. See Work Instructions 015.000.003-01.
6. Tighten the screw (6) with the specified tensioning pressure. See Work
Instructions 010.000.003-05.
7. Tighten the nut (4) hand-tight through the cut-out in the thrust piece (5)
using a tommy bar (7).
General, M015.000.030-01-0001 3 (4)

9. Disconnect the high-pressure hose from the hydraulic tensioner (2) and
piece (5).
1 Compression spring 5 Thrust piece X Released

2 hydraulic tensioner 6 Bolt Y Under tension
3 Tensioning nut 7 Tommy bar
4 Nut A Hole for Tommy bar
Figure 1: Hydraulic tensioner
2020-05-04 - de
54043197501766539
Hydraulic tensioner
4 (4) General, M015.000.030-01-0001

Hydraulic tensioner
disassembly and assembly
Summary
Hydraulic tensioners must occasionally be disassembled and reassembled,
e.g. in order to check them for leaks. In case leaks are discovered on hy-
draulic tensioners, the seals must be replaced.
Hydraulic tensioners must be vented when being disassembled. When in use,
they must be completely filled with slushing oil.
Tools/aids required
1 Tension nut 030.539 Standard
1 Mounting device 009.663 Standard
1 Pin extractor 009.621 Standard
1 Open-jaw wrench and ring spanner (set) 009.231 Option
1 Torque wrench 60-320 Nm 008.183 Standard
1 Tool holder 008.180 Standard
1 Reversible ratchet 12.5 008.023 Standard
1 Pliers for locking rings A 10-25 002.121 Option
1 Extension piece 12.5x75 001.908 Option
1 Screw driver insert 12x12.5 001.857 Option
1 Hexagon screw driver 12 000.299 Option
1 Lubricant (PrimeServGrease assembly paste) - Option
1 Slushing oil - Inventory

2020-06-16 - de

Hydraulic tensioner

Using hydraulic tensioner 015.000.030-01
General, M015.000.030-02-0001 1 (8)

Technical data
sure
area
Tool No./Spare Part No.

Item Designation Tool No.
- Hydraulic tensioning tool, complete 009.664
1 Hydraulic nipple 009.664-12
2 Threaded piece 009.664-11
3 Angle piece 009.664-10
4 Set screw 009.664-19
5 Locking ring 009.664-18
6 Cover 009.664-8
7 Valve spring 009.664-25
8 High-pressure seal 009.664-28
10 Piston 009.664-2
12 Parallel pin 009.664-35
13 Casing 009.664-3
14 Piston 009.664-1
16 Casing 009.664-4

2020-06-16 - de

Hydraulic tensioner
- Stroke-limiter valve, complete 009.627
20 Ball 009.627-3
21 Bolt 009.627-2
2 (8) General, M015.000.030-02-0001

Preliminary remark
Just like high-pressure hoses, hydraulic tensioners must be completely filled
with slushing oil before use. They must be bled if required. Leak tightness
must be checked occasionally.
The hydraulic tensioner must be disassembled if high-pressure seals are be-
ing replaced or if any damage has been identified. In case of dismantling, all
high-pressure seals must be replaced. Due to the high working pressures and
the critical clearances and surfaces, additional repair measures and interven-
tions are not recommended. If required, we recommend having the hydraulic
tensioner overhauled by MAN Energy Solutions or one of the authorised ser-
vice subsidiaries.
Work Sequence 1 - Disassembling the hydraulic tensioner

Work steps 1. Screw the hexagon socket screws (23) into the hydraulic tensioner. See
Figure 2/I.
2. Pull out parallel pins (12) using the pin extractor tool (009.621). See Fig-
ure 2/II
3. Unscrew tensioning nut (030.539) with single ended open-jaw spanner
(000.569). If the piston (14) also turns when unscrewing the tensioning
nut, brace the piston with a hexagon screwdriver (000.299). See Fig-
ure 3/III.
4. Mount the opener (009.622) to the hydraulic nipple (1). Open the non-re-
turn valve in the hydraulic nipple.
5. Fit the mounting device (009.663) to the hydraulic tensioner. See Fig-
ure 3/II
6. Press the piston (14) out of the casing (13) without tilting by turning the
hex screw (25).
7. Remove the piston (14) from the casing (13) using the mounting device.
See Figure 2/IV.
8. Remove the casing (16) from the piston (14). See Figure 2/V.
9. Remove the mounting device and the opener.
10.Remove the locking ring (5) from the piston (14) using circlip pliers
(002.121).
11.Remove the angle piece (3) from the piston (14). See Figure 2/VI.
12.Carefully unscrew the hexagon socket screws (23), unscrew the set
screw (4), remove the cover (6), and take off the parallel pin (17) and valve
2020-06-16 - de
springs (7) from the piston (14).

Hydraulic tensioner
13.Press the piston (10) out of the casing (13).

14.Remove high-pressure seals (8, 9, 11, 15 and 18).
15.Clean all the components and check them for damage. Replace if neces-
sary.
General, M015.000.030-02-0001 3 (8)

Work Sequence 2 - Assembling the hydraulic tensioner

served.
Initial situation All parts are cleaned, checked and renewed where necessary.
Work steps 1. Apply a thin coating of lubricant to all metallic mating surfaces on the pis-
tons (10 and 14) and casings (13 and 16). Ensure that the threads, high-
pressure seals (8, 9, 11 and 15) and grooves do not come into contact
with the lubricant.
2. Install new high-pressure seals (8, 9, 11 and 15) in casing (13 and 16) or
piston (10). Take care that sealing lips are not damaged. Make sure the
sealing lips are in the correct position. See Figure 2/VI and Figure 3/I.
3. Press the piston (10) into the casing (13).
4. Fit the piston (14) on the casing (16) and press in. See Figure 2/V.
5. Fit the piston (14) on the casing (13), and press in as far as possible.
6. Insert the valve springs (7) into the piston (14).
7. Insert the parallel pin (17) into the piston (14).
8. Screw the stud bolt (4) into the cover (6) and place the cover onto the
piston (14).
9. Secure the cover (6) with hexagon socket screws (23).
10.Insert new high-pressure seals (18) into the angle piece (3). Take care
that sealing lips are not damaged. Attention must be paid to the correct
position of the sealing lips. See Figure 3/I.
11.Place the angle piece (3) on the piston (14). Take care not to damage the
sealing lips of the high-pressure seals (18).
12.Fit the locking ring (5) in the ring groove using the locking ring pliers
(002.121).
13.Mount the opener (009.622) on the hydraulic nipple (1) and screw in the
2020-06-16 - de
star knob (26). Open the non-return valve in the hydraulic nipple. See Fig-
Hydraulic tensioner
ure 3/II
14.Fit the mounting device (009.663) to the hydraulic tensioner.
15.Press the piston (14) all the way into the casing (13) by turning the
nut (24). Ensure that the piston does not tilt in the casing.
16.Remove the mounting device and the opener.
17.Screw the tensioning nut (030.539) onto the piston (14) and tighten with
a torque of 250 Nm. See Figure 3/III.
18.Insert the parallel pins (12) into the relevant bore holes. Make sure to do
this with the thread outside so that it can be removed again.
4 (8) General, M015.000.030-02-0001

19.Unscrew the hexagon socket screws (23).

20.Clamp casing (13) with protective jaws into a vice so that the hydraulic
nipple (1) is pointing upwards.
21.Connect and lock the high-pressure hose (009.306) to the hydraulic ten-
sioner and high-pressure pump (009.342). See Work Instructions
015.000.002-01.
sioners.
22.Start the high-pressure pump. See Work Instructions 015.000.003-01.
23.Disconnect the high-pressure hose from the hydraulic tensioner.
24.Mount the opener on the hydraulic nipple (1). Open the non-return valve
in the hydraulic nipple. Wait until the piston (14) has fully reset and slush-
ing oil is emerging free of bubbles.
25.Remove the opener and release the hydraulic tensioner from the vice.
26.Screw the hydraulic tensioner onto a suitable screw.
27.Connect the high-pressure hose to the hydraulic tensioner, and secure it.
sioners.
28.Start the high-pressure pump and pump up the hydraulic tensioner with
the tensioning pressure required for this screw. The piston (14) should
extend by approx. 2/3 of the effective stroke. See Work Instructions
010.000.003-05.
29.Hold pressure for 5 minutes.
30.Check the hydraulic tensioner for any apparent leaks.
– If no leaks are detected, continue with work step 31.
– If leaks are detected, repeat work sequence 1.
31.Release the pressure.
32.Disconnect the high-pressure hose from the hydraulic tensioner and the
high-pressure pump.
33.Remove the hydraulic tensioner.
2020-06-16 - de
Hydraulic tensioner
General, M015.000.030-02-0001 5 (8)

1 Hydraulic nipple 12 Parallel pin

2 Threaded piece 13 Casing
3 Angle piece 14 Piston
4 Set screw 15 High-pressure seal
5 Locking ring 16 Casing
6 Cover 17 Parallel pin
7 Compression spring 18 High-pressure seal
8 High-pressure seal 19 Compression spring
9 High-pressure seal 20 Ball
10 Piston 21 Bolt
11 High-pressure seal 22 Threaded piece
2020-06-16 - de

Hydraulic tensioner
6 (8) General, M015.000.030-02-0001

2020-06-16 - de
Hydraulic tensioner
3 Angle piece 11 High-pressure seal 16 Casing

5 Locking ring 12 Parallel pin 18 High-pressure seal
8 High-pressure seal 13 Casing 23 Hexagon socket bolt
M5x30
9 High-pressure seal 14 Piston
10 Piston 15 High-pressure seal I - VI Work Steps
Figure 2: Disassembling/assembling the hydraulic tensioner
General, M015.000.030-02-0001 7 (8)

24 Nut M10 26 Star knob I - III Work steps

2020-06-16 - de
25 M10x150 hex screw

Hydraulic tensioner
Figure 3: Disassembling/assembling the hydraulic tensioner

45035998247028747
8 (8) General, M015.000.030-02-0001

Hydraulic tensioner
use
Summary
Releasing a screw
Tensioning a screw
Tools/aids required

Technical data
sure
area
2021-02-25 - de

Hydraulic tensioner
General, M015.000.036-01-0001 1 (4)

Warning message

pressure hoses.
Preliminary remark
The screw is extended relative to the components to be connected using the
piston and casing of the hydraulic tensioner, supplemented by a thrust piece.
To do this, slushing oil is pressed underneath the piston using the high-pres-
sure pump. When the pressure is high enough, the screw nut is accessible
and can be loosened or adjusted according to specifications.
As is the case with the high-pressure hoses, hydraulic tensioners must be
completely filled with slushing oil before use. Hydraulic tensioners must be
vented occasionally. A tightness test must be carried out on the hydraulic ten-
sioner.
Release To release the screw connection, the piston of the hydraulic tensioner must
be turned back from the hand-tightened position by a specified angle. Other-
wise there is a danger that the screw and the hydraulic tensioner are still ten-
sioned to the extent that the hydraulic tensioner cannot be removed, even
though the nut may be released.
the hydraulic tensioner be screwed on so that the casing and thrust piece are
blocked.

2021-02-25 - de

Hydraulic tensioner
Work steps 1. Place the thrust piece (3) over the nut (5).
2. Screw the hydraulic tensioner (1) onto the bolt (4), Make sure that the
thrust piece is aligned to the middle (3) by the hydraulic tensioner.
Instructions 010.000.003-05. See Figure 1/I.
2 (4) General, M015.000.036-01-0001

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

tensioner (1) and high-pressure pump (009.342). See Work Instructions
015.000.002-01.
sioners.
5. Put the high-pressure pump into operation and close the gap (G) caused
by turning back. See Work Instructions 015.000.003-01.
6. Pump up hydraulic tensioner (1) until nut (5) can be released using
Tommy bar (2). The release pressure must not be more than a maximum
of 7% below or a maximum of 5% above the tensioning pressure in the
process. See Work Instructions 010.000.003-05 and 015.000.001-01.
010.000.003-05.
piece (3).

Initial situation Nut is installed and tightened by hand. Screw thread has been cleaned.
thrust piece is aligned to the middle (3) by the hydraulic tensioner. See
Fig. 1/II
015.000.002-01.
sioners.
2021-02-25 - de
Hydraulic tensioner
9. Unscrew the hydraulic tensioner (1) from the screw (4). Take off the thrust
piece (3).
General, M015.000.036-01-0001 3 (4)

1 Hydraulic tensioner 4 Screw I – II Work steps

2 Tommy bar 5 Nut
3 Thrust piece G Gap
Figure 1: Screw with attached hydraulic tensioner – Illustration I: releasing/Illustration II: tensioning
36028799009185547
2021-02-25 - de
Hydraulic tensioner
4 (4) General, M015.000.036-01-0001

Hydraulic tensioner
Summary
Tools/aids required
1 Fixing piece 009.622-1 Standard
2 Threaded piece 009.622-3 Standard
2 Assembly bolt 009.618 Standard
1 Installation and removal device 009.616 Standard
1 Bridge 009.616-1 Standard
1 Counter plate 009.616-2 Standard

2021-02-25 - de

Hydraulic tensioner
Technical data
sure
area
General, M015.000.036-02-0001 1 (10)



1 Piston 009.631-1
3 Cover 009.631-10
4 Casing 009.631-2
5* High-pressure sealing ring 009.631-16
6* Hydraulic nipple 009.631-7
7* Threaded piece 009.631-5
9* Stroke-limiter valve 009.625
10* Parallel pin 009.631-21
12 Set screw 009.631-11
- Set of spare parts 009.660
* together in spare parts packet.
Preliminary remarks
Hydraulic tensioners, like high-pressure hoses, must be completely filled with
slushing oil before use. They must be bled if necessary. Check for leakage oc-
casionally.
The hydraulic tensioner must be disassembled if the high-pressure seals are
to be replaced or in case of damage. For complete dismantling, all high-pres-
sure seals should expediently be replaced. Due to the high working pressures
and the critical clearances and surfaces, additional repair measures and inter-
ventions are not recommended. If required, we recommend having the hy-
draulic tensioner overhauled by MAN Energy Solutions or one of the author-
ised service subsidiaries.
2021-02-25 - de
Hydraulic tensioner
Work Sequence 1 - Dismantling the Hydraulic Tensioner

Work steps 1. Clamp the hydraulic tensioner with protective jaws on the casing (4) into
the vice with the piston (1) pointing upwards.
2. Insert assembly screws (009.618) through the cover (3) and screw them
into the piston (1) completely. See Figure 2.
3. Remove parallel pins (10) using the pin extractor (009.621). See Fig. 2/II
turn valve in the hydraulic nipple. See Figure 3/I and 5.
2 (10) General, M015.000.036-02-0001

5. Fit the installation and removal device (009.615/009.616) to the hydraulic

tensioner. While doing so, centre the counterplate (009.615-2/009.616-2)
on the piston skirt. See Fig. 3/II
6. Press the piston (1) out of the casing (4) without tilting by turning the hex
screw (13). See Figure 3/III.
7. Remove the piston (1) from the casing (4) using the installation and re-
moval device.
8. Remove the installation and removal device along with the opener.
9. Carefully unscrew the mounting screws and the set screw (12), remove
the cover (3) and take off the parallel pin (11) and valve spring (2) from the
piston (1). See Figure 4.
10.Detach the high-pressure seals (5 and 8).
sary.
Work sequence 2 - Assembling the hydraulic tensioner

pressure hoses.
Work steps 1. Inspect the new high-pressure seals (5 and 8) for damage.
2. Lubricate the high-pressure seal (5) with slushing oil, and place the seal
on the piston (1). Pay attention to the pressure side (F) here. See Fig. 4.
3. Lubricate the high-pressure seal (8) with slushing oil, and place it into the
appropriate groove in the casing (4). Pay attention to the pressure side (F)
here.
4. Thinly coat the running surfaces of the piston (1) and the casing (4) with
lubricant. Ensure that the high-pressure seals (5 and 8) and the grooves
for the high-pressure seals do not come in contact with the lubricant.
2021-02-25 - de
5. Clamp the casing (4) with protective jaws into a vice.

Hydraulic tensioner
9. Screw the set screw (12) into the cover (3) and place the cover onto the
piston (1).
10.Secure the cover (3) with assembly screws (009.618).
11.Mount the opener (009.622) to the hydraulic nipple (6). Open the non-re-
turn valve in the hydraulic nipple. See Fig. 6/I.
General, M015.000.036-02-0001 3 (10)

12.Fit the installation and removal device (009.615/009.616) to the hydraulic

on the piston crown.
13.Press the piston (1) all the way into the casing (4) by turning the hex
screw (13). Ensure that the piston does not tilt in the casing. See Fig. 6/II.
14.Insert the parallel pins (10) into the respective bore holes using a pin ex-
tractor tool (009.621). See Fig. 6/III.
15.Remove the installation and removal device along with the opener.
16.Unscrew the mounting screws.
015.000.002-01.
sioners.
in the hydraulic nipple. In doing so, wait until the piston (1) fully retracts
and slushing oil emerges without any bubbles. See Fig. 5.
23.Remove the opener and release the clamping device from the vice.
sioners.
45035998263929739
the tensioning pressure required for this screw. The piston (1) should ex-
tend by approx. 2/3 of the effective stroke. See Work Instructions
010.000.003-05 and 015.000.003-01.
– If leaks are detected, repeat Work Sequence 1.
2021-02-25 - de

Hydraulic tensioner
high-pressure pump.
4 (10) General, M015.000.036-02-0001

1 Piston 6 Hydraulic nipple

2 Valve spring 7 Threaded piece
3 Cover 8 High-pressure seal
4 Casing 9 Stroke-limiter valve
5 High-pressure seal A Effective stroke
2021-02-25 - de
Hydraulic tensioner
General, M015.000.036-02-0001 5 (10)

1 Piston 4 Casing I – II Work steps

Figure 2: Hydraulic tensioner – Piston removal
2021-02-25 - de
Hydraulic tensioner
6 (10) General, M015.000.036-02-0001

4 Casing 7 Threaded piece I – III Work steps

2021-02-25 - de
6 Hydraulic nipple 13 Hex screw M10x240

Hydraulic tensioner
General, M015.000.036-02-0001 7 (10)

1 Piston 8 High-pressure seal

2021-02-25 - de
2 Valve spring 9 Stroke-limiter valve

Hydraulic tensioner

4 Casing 11 Parallel pin
5 High-pressure seal 12 Set screw
6 Hydraulic nipple F Pressure side
7 Threaded piece
Figure 4: Hydraulic tensioner, disassembled
8 (10) General, M015.000.036-02-0001

1 Piston
6 Hydraulic nipple
7 Threaded piece
Figure 5: Hydraulic tensioner – Opener
2021-02-25 - de
Hydraulic tensioner
General, M015.000.036-02-0001 9 (10)

1 Piston 5 High-pressure seal 10 Parallel pin

2021-02-25 - de
3 Cover 6 Hydraulic nipple 13 Hex screw M10x240

Hydraulic tensioner

Figure 6: Hydraulic tensioner – Piston installation
45035998263929739
10 (10) General, M015.000.036-02-0001

Hydraulic tensioner
use
Summary
Releasing a screw
Tensioning a screw
Tools/aids required

Technical data
sure
area
2021-02-25 - de

Hydraulic tensioner
General, M015.000.037-01-0001 1 (4)

Warning message

pressure hoses.
Preliminary remark
The screw is extended relative to the components to be connected using the
piston and casing of the hydraulic tensioner, supplemented by a thrust piece.
To do this, slushing oil is pressed underneath the piston using the high-pres-
sure pump. When the pressure is high enough, the screw nut is accessible
and can be loosened or adjusted according to specifications.
sioner.
Release To release the screw connection, the piston of the hydraulic tensioner must
be turned back from the hand-tightened position by a specified angle. Other-
wise there is a danger that the screw and the hydraulic tensioner are still ten-
sioned to the extent that the hydraulic tensioner cannot be removed, even
though the nut may be released.
blocked.

2021-02-25 - de

Hydraulic tensioner
thrust piece is aligned to the middle (3) by the hydraulic tensioner.
Instructions 010.000.003-05. See Figure 1/I.
2 (4) General, M015.000.037-01-0001


015.000.002-01.
sioners.
5. Put the high-pressure pump into operation and close the gap (G) caused
by turning back. See Work Instructions 015.000.003-01.
6. Pump up hydraulic tensioner (1) until nut (5) can be released using
Tommy bar (2). The release pressure must not be more than a maximum
of 7% below or a maximum of 5% above the tensioning pressure in the
process. See Work Instructions 010.000.003-05 and 015.000.001-01.
010.000.003-05.
piece (3).

Initial situation Nut is installed and tightened by hand. Screw thread has been cleaned.
thrust piece is aligned to the middle (3) by the hydraulic tensioner. See
Fig. 1/II
015.000.002-01.
sioners.
2021-02-25 - de
Hydraulic tensioner
9. Unscrew the hydraulic tensioner (1) from the screw (4). Take off the thrust
piece (3).
General, M015.000.037-01-0001 3 (4)

1 Hydraulic tensioner 4 Screw I – II Work steps

2 Tommy bar 5 Nut
3 Thrust piece G Gap
Figure 1: Screw with attached hydraulic tensioner – Illustration I: releasing/Illustration II: tensioning
36028799009191947
2021-02-25 - de
Hydraulic tensioner
4 (4) General, M015.000.037-01-0001

Hydraulic tensioner
Summary
Tools/aids required
1 Fixing piece 009.622-1 Standard
2 Assembly bolt 009.618 Standard

2021-02-25 - de

Hydraulic tensioner
Technical data
sure
area
General, M015.000.037-02-0001 1 (10)



1 Piston 009.632-1
3 Cover 009.632-10
4 Casing 009.632-2
6* Hydraulic nipple 009.632-7
7* Threaded piece 009.632-5
9* Stroke-limiter valve 009.625
10* Parallel pin 009.632-21
12 Set screw 009.632-11
- Set of spare parts 009.660
* together in spare parts packet.
Preliminary remarks
casionally.
2021-02-25 - de
Hydraulic tensioner
Work Sequence 1 - Dismantling the Hydraulic Tensioner

Work steps 1. Clamp the hydraulic tensioner with protective jaws on the casing (4) into
the vice with the piston (1) pointing upwards.
2. Insert assembly screws (009.618) through the cover (3) and screw them
into the piston (1) completely. See Figure 2.
3. Remove parallel pins (10) using the pin extractor (009.621). See Fig. 2/II
turn valve in the hydraulic nipple. See Figure 3/I and 5.
2 (10) General, M015.000.037-02-0001

5. Fit the installation and removal device (009.615/009.616) to the hydraulic

on the piston skirt. See Fig. 3/II
6. Press the piston (1) out of the casing (4) without tilting by turning the hex
screw (13). See Figure 3/III.
7. Remove the piston (1) from the casing (4) using the installation and re-
moval device.
8. Remove the installation and removal device along with the opener.
9. Carefully unscrew the mounting screws and the set screw (12), remove
the cover (3) and take off the parallel pin (11) and valve spring (2) from the
piston (1). See Figure 4.
10.Detach the high-pressure seals (5 and 8).
sary.
Work sequence 2 - Assembling the hydraulic tensioner

pressure hoses.
Work steps 1. Inspect the new high-pressure seals (5 and 8) for damage.
2. Lubricate the high-pressure seal (5) with slushing oil, and place the seal
on the piston (1). Pay attention to the pressure side (F) here. See Fig. 4.
3. Lubricate the high-pressure seal (8) with slushing oil, and place it into the
appropriate groove in the casing (4). Pay attention to the pressure side (F)
here.
4. Thinly coat the running surfaces of the piston (1) and the casing (4) with
lubricant. Ensure that the high-pressure seals (5 and 8) and the grooves
for the high-pressure seals do not come in contact with the lubricant.
2021-02-25 - de
5. Clamp the casing (4) with protective jaws into a vice.

Hydraulic tensioner
9. Screw the set screw (12) into the cover (3) and place the cover onto the
piston (1).
10.Secure the cover (3) with assembly screws (009.618).
11.Mount the opener (009.622) to the hydraulic nipple (6). Open the non-re-
turn valve in the hydraulic nipple. See Fig. 6/I.
General, M015.000.037-02-0001 3 (10)

12.Fit the installation and removal device (009.615/009.616) to the hydraulic

on the piston crown.
13.Press the piston (1) all the way into the casing (4) by turning the hex
screw (13). Ensure that the piston does not tilt in the casing. See Fig. 6/II.
14.Insert the parallel pins (10) into the respective bore holes using a pin ex-
tractor tool (009.621). See Fig. 6/III.
15.Remove the installation and removal device along with the opener.
16.Unscrew the mounting screws.
015.000.002-01.
sioners.
in the hydraulic nipple. In doing so, wait until the piston (1) fully retracts
and slushing oil emerges without any bubbles. See Fig. 5.
23.Remove the opener and release the clamping device from the vice.
sioners.
45035998263936139
the tensioning pressure required for this screw. The piston (1) should ex-
tend by approx. 2/3 of the effective stroke. See Work Instructions
010.000.003-05 and 015.000.003-01.
2021-02-25 - de

Hydraulic tensioner
high-pressure pump.
4 (10) General, M015.000.037-02-0001

1 Piston 6 Hydraulic nipple

2 Valve spring 7 Threaded piece
3 Cover 8 High-pressure seal
4 Casing 9 Stroke-limiter valve
5 High-pressure seal A Effective stroke
2021-02-25 - de
Hydraulic tensioner
General, M015.000.037-02-0001 5 (10)

1 Piston 4 Casing I – II Work steps

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Hydraulic tensioner
6 (10) General, M015.000.037-02-0001


2021-02-25 - de
6 Hydraulic nipple 13 Hex screw M10x240

Hydraulic tensioner
General, M015.000.037-02-0001 7 (10)

1 Piston 8 High-pressure seal

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2 Valve spring 9 Stroke-limiter valve

Hydraulic tensioner

4 Casing 11 Parallel pin
5 High-pressure seal 12 Set screw
6 Hydraulic nipple F Pressure side
7 Threaded piece
Figure 4: Hydraulic tensioner, disassembled
8 (10) General, M015.000.037-02-0001

1 Piston
6 Hydraulic nipple
7 Threaded piece
Figure 5: Hydraulic tensioner – Opener
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Hydraulic tensioner
General, M015.000.037-02-0001 9 (10)

1 Piston 5 High-pressure seal 10 Parallel pin

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3 Cover 6 Hydraulic nipple 13 Hex screw M10x240

Hydraulic tensioner

Figure 6: Hydraulic tensioner – Piston installation
45035998263936139
10 (10) General, M015.000.037-02-0001

Hydraulic tensioner
use
Summary
Releasing a screw
Tensioning a screw
1 Nut 021.148 Standard

Dismantling and assembling hydraulic tensioner 015.000.040-02
Technical data
sure
Hydr. tensioner Effective piston 218 cm²
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area
Hydraulic tensioner
L51/60DF;L48/60CR, M015.000.040-01-0001 1 (4)

Warning message

pressure hoses.
Preliminary remark
The bolt is extended as required by the components to be fixed using the pis-
ton and casing of the hydraulic tensioner, supplemented by a thrust piece and
nut. This is done by pressing anti-corrosion oil below the pistons using the
high-pressure pump. When the pressure is high enough, the nut of the bolt is
released and can be loosened or adjusted according to specifications.
sioner.
Release To release the screw connection, the pistons of the hydraulic tensioner must
be unscrewed by a specified angle from the hand-tight position. Otherwise
there is a danger that the bolt and the hydraulic tensioner are still tensioned to
the extent that the hydraulic tensioner cannot be removed, even though the
nut may be released.
blocked.

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Hydraulic tensioner
Work steps 1. Clean the bolt thread (5).
2. Check proper fit of nut (3) on the hydraulic tensioner’s piston (1) using a
tommy bar. If the nut is loose, re-tighten it using the tommy bar.
3. Place the thrust piece (4) over the nut (7). See Fig. 1.
4. Screw the hydraulic tensioner (1) onto the bolt (5). Make sure that the
2 (4) L51/60DF;L48/60CR, M015.000.040-01-0001

015.000.002-01.
sioners.
7. Put the high-pressure pump into operation and close the gap (A) resulting
from turning the tensioners back. See Work Instructions 015.000.003-01.
8. Pump the hydraulic tensioner (1) until nut (7) can be released. Make a
note of the release pressure and compare it to the tensioning pressure.
The release pressure must not exceed 7% below or 5% above the ten-
sioning pressure. See Work Instructions 010.000.003-05 and
015.000.001-01.
9. Using a tommy bar (6), turn the nut (7) back through the opening in the
thrust piece (4) by the turning-back angle. See Work Instructions
010.000.003-05.
11.Disconnect the high-pressure hose from the hydraulic tensioner (1) and
the high-pressure pump.
12.Remove the hydraulic tensioner (1) and the thrust piece (4).

Initial situation The nut is fitted into place and hand-tight, the bolt thread is cleaned.
Work steps 1. Check proper fit of nut (3) on the hydraulic tensioner’s piston (1) using a
tommy bar. Re-tighten the nut if it is loose.
2. Place the thrust piece (4) over the nut (7). See Fig. 1.
3. Screw the hydraulic tensioner (1) onto the bolt (5). Make sure that the
015.000.002-01.
2021-02-26 - de

Hydraulic tensioner
sioners.
5. Start the high-pressure pump and tension the bolt (5) to the specified
tensioning pressure. See Work Instructions 010.000.003-05 and
015.000.003-01.
6. Using a tommy bar (6), tighten nuts (7) until hand-tight through the cut-
out in thrust piece (4).
L51/60DF;L48/60CR, M015.000.040-01-0001 3 (4)

9. Remove the hydraulic tensioner (1) and the thrust piece (4).
1 Hydraulic tensioner 5 Bolt A Gap

2 Disc spring 6 Tommy bar B Hole for Tommy bar ∅
12
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3 Nut 7 Nut C Bore for tommy bar ∅

10
Hydraulic tensioner
4 Thrust piece 8 Crankcase

Figure 1: Bolt with attached tensioner (illustration on the left: loosening/illustration on the right: tightening)
18014423016394507
4 (4) L51/60DF;L48/60CR, M015.000.040-01-0001

Hydraulic tensioner
Disassembly and assembly
Summary
1 Size 110 socket wrench 009.104 Standard
2 Strip (Nylon) - Inventory
1 Hammer (wood/plastic-) - Inventory
1 Combination pliers - Inventory
1 Screwdriver (Set) - Inventory

Use hydraulic tensioner 015.000.040-01
2021-02-26 - de
Hydraulic tensioner
Technical data
sure
Hydr. tensioner Effective piston 218 cm²
area
L51/60DF;L48/60CR, M015.000.040-02-0001 1 (8)


Item Designation Tool no.
– Hydraulic tensioning tool, complete 009.850
1 Hydraulic nipple 009.850-8
2 Sealing ring 009.850-7
3 Piston 009.850-3
5 Nut 009.850-5
6 O-ring 009.850-15
8 Casing 009.850-4
9 O-ring 009.850-17
11 O-ring 009.850-19
13 Casing 009.850-2
14 Dowel pin 009.850-21
15 Disc spring 009.850-20
16 Piston 009.850-1
Preliminary remarks
casionally.
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Hydraulic tensioner
Work Sequence 1 - Disassembling the hydraulic tensioner

Work steps 1. Clamp the hexagon screwdriver (000.302) in a vice.
2. Position the hydraulic tensioners with piston (16) on the clamped-in
hexagon screwdriver.
3. Unscrew the nut (17) using the tommy bar. See Fig. 2.
4. Place the hydraulic tensioner on a clean workbench.
5. Remove the dowel pins (14) and disc springs (15). See Fig. 1.
6. Connect the high-pressure hose (009.306) to the hydraulic nipple (1).
2 (8) L51/60DF;L48/60CR, M015.000.040-02-0001

7. Attach the opener (009.622) to the high-pressure hose. Push the non-re-
turn valve onto the high-pressure hose. See Work Instructions
015.000.002-01.
8. Remove the casing (13) from the piston (16).
9. Disconnect the high-pressure hose from the hydraulic nipple (1).
10.Remove the opener.
11.Position the hydraulic tensioners with piston (16) on the clamped-in
hexagon screwdriver.
12.Fit the socket wrench (009.104) onto the nut (5). Note that the screw
connection between nut/piston (16) has a left-hand thread.
13.Loosen the nut (5) by applying light strokes with a hammer. Unscrew and
remove the nut.
14.Remove the socket wrench.
15.Place the hydraulic tensioner on a clean workbench.
16.Remove piston (3) and casing (8) from piston (16).
17.Remove the high-pressure seals (7, 10 and 12) and the O-rings (6, 9 and
11).
sary.
19.Purge the oil bores in the piston (16) using compressed air.
Work Sequence 2 - Assembling the hydraulic tensioner

pressure hoses.
Burns caused by hot oil

When submerging the sealing ring in the hot oil bath or removing it
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from the hot oil bath there is a risk of burns and irreversible damage to
the skin and the tissue below.
Hydraulic tensioner
• Place the oil bath on a flat and stable surface

• Use suitable equipment for insertion/removal
L51/60DF;L48/60CR, M015.000.040-02-0001 3 (8)

Initial situation All parts are cleaned, checked and renewed where necessary. Hexagon
screwdriver is clamped in a vice.
Work steps 1. Check the new O-rings (6, 9 and 11) and the high-pressure seals (7, 10
and 12) to ensure they are not damaged.
2. Coat O-rings (6) with anti-corrosion oil and place them in the correspond-
ing groove. See Fig. 1.
3. Press together the O-rings (9 and 11) into a kidney shape and insert them
into the corresponding groove. See Figs. 1 and 3.
WARNING Burns caused by hot oil.
4. Place new high-pressure seals (7, 10 and 12) in an oil bath and heat
them to approx. 80 to 100°C.
5. Remove the high-pressure seals (10 and 12) from the oil bath, press
them together into a kidney shape, and insert them into the correspond-
ing groove.
6. Install the high-pressure seals (7) in the corresponding groove, proceed-
ing as follows:
– Remove the high-pressure seal (7) from the oil bath.
– Insert the high-pressure seal (7) on one side of the piston (3/16) into
the corresponding groove as far as possible, see Fig. 4.
– Position two strips (20) around the high-pressure seal (7), with spa-
cing of approx 120°
– Using the two strips (20), carefully pull the high-pressure seal (7) over
the piston edge and fully into the groove
– Remove the strips (20)
– Press the elongated high-pressure seal (7) into the groove using a
round piece of wood or a hammer handle.
7. Thinly apply lubricant to the running surface (F) of the pistons (3 and 16)
and the casing (13). Ensure that the high-pressure seals (7, 10 and 12)
and the grooves do not come in contact with the lubricant. See Fig. 5.
8. Press the piston (3) into the casing (8).
9. Mount the casing (8) and piston (3) together onto piston (16) and press
in.
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Hydraulic tensioner
hexagon screwdriver (000.302).

11.Screw on the nut (5) until it makes contact with the piston (16). Note that
the screw connection between nut/piston has a left-hand thread.
12.Fit the socket wrench (009.104) onto the nut (5).
13.Tighten the nut (5) using the socket wrench.
14.Remove the socket wrench.
15.Place the hydraulic tensioner on a clean workbench.
16.Connect the high-pressure hose (009.306) to the hydraulic nipple (1).
4 (8) L51/60DF;L48/60CR, M015.000.040-02-0001

17.Attach the opener (009.622) to the high-pressure hose. Push the non-re-
turn valve onto the high-pressure hose. See Work Instructions
015.000.002-01.
18.Push on the casing (13) until it makes contact with the piston (16). See
Fig. 1.
19.Disconnect the high-pressure hose from the hydraulic nipple (1).
21.Install the disc springs (15), ensuring to adhere to the correct order.
22.Insert the clamping pins (14) into the casing (13) to secure the disc
springs (15) in place.
23.Screw the nut (17) onto the piston (16) so that it is hand-tight.
hexagon screwdriver. Ensure that the hydraulic nipple (1) is facing up-
wards.
25.Use the dowel pin to screw on the nut (17) until fully fitted. See Fig. 2.
26.Connect the hydraulic hose to the hydraulic tensioner and the high-pres-
sure pump (009.342) and secure. See Work Instructions
015.000.002-01.
sioners.
30.Attach the opener to the high-pressure hose. Push the non-return valve
onto the high-pressure hose. In doing so, wait until the piston (16) fully re-
tracts and slushing oil emerges without any bubbles.
sioners.
the tensioning pressure required for this screw. The piston (16) should
extend by approx. 2/3 of the effective stroke. See Work Instructions
010.000.003-05 and 015.000.003-01.
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Hydraulic tensioner

high-pressure pump.
L51/60DF;L48/60CR, M015.000.040-02-0001 5 (8)

1 Hydraulic nipple 7 High-pressure seal 13 Casing

2 Sealing ring 8 Casing 14 Dowel pin
3 Piston 9 O-ring 15 Disc spring
4 Threaded piece 10 High-pressure seal 16 Piston
5 Nut 11 O-ring
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6 O-ring 12 High-pressure seal

Hydraulic tensioner
6 (8) L51/60DF;L48/60CR, M015.000.040-02-0001

13 Casing 17 Nut
15 Disc spring C Hole for Tommy bar ∅10
16 Piston
Figure 2: Hydraulic tensioner with nut fitted
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Hydraulic tensioner
Figure 3: Pressing an O-ring into a kidney shape
L51/60DF;L48/60CR, M015.000.040-02-0001 7 (8)

3 Piston
7 High-pressure seal
20 Strip
Figure 4: Pulling the high-pressure seal onto the piston
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Hydraulic tensioner
3 Piston 16 Piston F Running surface

13 Casing
Figure 5: Running surfaces on piston and casing to be coated with lubricant
36028821533309323
8 (8) L51/60DF;L48/60CR, M015.000.040-02-0001

1 Introduction
51323031947
1 (1)


010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas
51354049035
1 (1)


51354053003
1 (1)

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

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Figure 1: Cross section of the engine
L48/60CR, M010.005.000-01-0008 1 (5)

2016-11-10 - de
Figure 2: Longitudinal section of the engine
2 (5) L48/60CR, M010.005.000-01-0008

Overview of components - Designation

No. Designation PDS
2)
011 Oil sump 010.010.020
012 Cylinder crankcase 010.010.030
020 Crankshaft 010.030.010
0211) Main bearing 010.030.020

1)2)
023 Crankshaft extension 010.030.040
0271) Crankshaft vibration damper 010.030.030
030 Connecting rod 010.040.010
034 Piston 010.040.050
050 Cylinder liner 010.050.010
055 Cylinder head 010.060.020
0571) Safety valve 010.060.090
071a Covering on coupling end 010.020.010
071b1) Dead centre indicator 010.020.010
072 Covering on free end of engine 010.020.020
073 Covering of crankcase with relief valve / Splash-Oil 010.020.030
077 Camshaft covering 010.020.050
1001) Camshaft drive 010.090.060
102a Camshaft bearing 010.090.030
102b1) Camshaft thrust bearing 010.090.030
111 Rocker arm with bearings and cylinder head cover 010.100.020
1)
112a Push-rod with covering 010.100.030
112b1) Inlet and exhaust cam follower with bearing 010.100.030
113 Inlet valve 010.060.030

114 Exhaust valve 010.060.040
1)
125 Operating device 010.280.020
1431) Mounting of injection unit SaCoSone 010.120.040

2016-11-10 - de
1)
160 Starting air pilot valve 010.150.010
1611) Starting valve 010.060.070
162 Main starting valve 010.150.020
201 High-pressure pump drive 010.110.020
2021) Pump set VVT 010.110.030
204 High-pressure pump 010.110.050
209 Camshaft 010.090.020
221 Fuel injection valve 010.060.060
L48/60CR, M010.005.000-01-0008 3 (5)

No. Designation PDS

280a Charge air pipe 010.170.010
280b2) Air bypass pipe 010.170.050
280c1) Pressure transducer 010.170.050
286a Attaching parts for turbocharger 010.190.010
286b1) Attaching parts for washing device 010.190.010
289a Exhaust pipe 010.180.010
289b Covering of exhaust pipe 010.180.030
292 Covering of exhaust pipe before turbocharger 010.180.030
3002) Lube oil pump 010.220.010
302 Lube oil pump for cylinder lubrication 010.220.030
3021)2) Lube oil pump for valve seat lubrication 010.220.040
311 Crankcase venting 010.220.120
322 Charge air cooler 010.170.040

2)
350 Cooling water pump 010.230.010
010.230.020
4001)2) Pulse transmitter 010.290.010
4001)2) Pulse pick-up 010.290.010
403 Sensor 010.290.040
408 Monitoring of main bearing temperature 010.290.310

1)
409 Exhaust gas temperature monitoring 010.290.130
4131) Cabling on engine for splash-oil temperature monitoring 010.290.330

1)2)
413 Oil mist detector 010.290.330
416 Mounting of control unit SaCoSone 010.290.155

1)
419 Indicator valve 010.060.080
432 Starting air pipes 010.250.010

1)
432 Control pipes 010.250.020
434 Fuel pipes 010.250.070
436 High-pressure pipes 010.110.052

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437 Common Rail accumulator unit 010.110.054
440a Lubricating oil pipes 010.250.110
440b Hydraulic control system for VVT 010.250.110
442 Condensed water discharge 010.250.150
443a Cylinder lubrication 010.250.120
443b1)2) Valve seat lubrication 010.250.130

1)2)
444 Pipes to the operating medium module 010.250.170
4461) Pipes to the turbocharger 010.250.180
4 (5) L48/60CR, M010.005.000-01-0008

No. Designation PDS

447 Cooling water pipes 010.250.190
456 Gallery 010.310.020

010.310.030
489a1) Cable conduits with attachment 010.290.150
489b1) Warning sign 010.290.150
489c1) Cabling for VVT 010.290.150

Table 1: Subassembly designation
1972386571
1)
These sub-assemblies cannot be seen in the pictures
2)
1972386571
If installed

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L48/60CR, M010.005.000-01-0008 5 (5)

1972386571
2016-11-10 - de
L48/60CR, M010.005.000-01-0008

010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas
51353768715
1 (1)


51353777163
1 (1)

Flexible engine support

inspection
Summary
Execute the work in time according to the maintenance schedule, ensure the
correct execution of work, ensure / restore operational safety.
The work/work steps include: Inspection of threaded connections, inspection
of parts/components.
Safety requirements
l Engine stopped
l Drive shaft secured against rotating
Tools/aids required
1 Thrust piece 055.242 Standard
1 Torque wrench 750-2.000 Nm 008.005 Standard
1 Ratchet tool 008.023 Standard
1 Adapter 12.5x20 001.927 Standard
1 Adapter 20x12.5 001.923 Option
1 Universal joint 12.5 001.876 Option
1 Screwdriver insert 14x12.5 001.858 Standard
1 Socket spanner insert 55x25 001.804 Standard

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1 Socket spanner insert 36x20 001.779 Option

1 Tommy bar, 10 000.263 Standard
1 Contact thermometer - Inventory
1 Sliding caliper - Inventory
1 Grease (acid-free) - Inventory
L48/60CR, M010.010.030-01-0009 1 (9)


Tightening screw connections General remarks 010.000.003-07
Determining/checking the crankshaft flange position in rela- 010.030.010-11
tion to the driven flange
Preliminary remark
General If a re-alignment of the engine is necessary due to replacement of the elastic
elements (17) or the synthetic resin support (12), proceed according to the in-
stallation instructions on the drawing and the alignment instructions. Volume
000 “Plant information” - 000.100 drawings - “Elastic engine support” of the
respective plant
Maintenance The reference dimensions (A) must be determined as per the intervals spe-
cified in the maintenance schedule and compared with the original dimensions
(B, driven into the front sides of the cylinder crankcase base). Check all bolts
for secure fit. Inspect the synthetic resin support (12) for hazardous cracks
and chipping affecting stability. Inspect elastic elements (17) for mechanical
damage.
Work sequence 1 – Inspecting the cylinder crankcase
Risk to life due to work carried out in the cylinder crankcase!

During all work in the cylinder crankcase, there is a risk to life as a res-
ult of starting the engine and rotating/turning over the running gear.
• Close the shut-off valves of the starting air and control air vessels/se-
cure against opening
• Open the drain cocks in the air pipes/on filters
• Open decompression cock on the main starting valve
• Engage the turning gear, lock it and secure against being started up
2018-09-19 - de
• Fix an instruction plate to operating devices

• Observe working and safety instructions
Work steps 1. Carefully clean the cylinder crankcase (1) and oil sump (11) during over-
haul work and at every oil change.
2. Check the interior and the exterior of the cylinder crankcase (1) for
cracks.
2 (9) L48/60CR, M010.010.030-01-0009

Work sequence 2 - Checking the reference dimension (A)

Initial situation Engine cooled down to engine room temperature.
Influence of higher temperatures

Especially higher temperatures of the elastic elements influence the
reference dimension (A). Always take measurements at approximately
the same temperature conditions.
Work steps 1. Clean the top of the cylinder crankcase base on the four corners and top
of the four measuring points (6) on the top-plates (5). See fig. 2.
2. Measure and record temperatures of the elastic elements (18) using a
contact thermometer.
3. Determine and record the reference dimension (A).
4. Compare measured values with values stamped on the part (B) and de-
termine amounts of difference. See fig. 2.
5. Record differences and hours of operation of the engine in the engine log
sheets.
6. Determine the mean value of the differences.
7. Measure the radial offset of the crankshaft to the driven shaft. See work
instructions 010.030.010-11.
Permissible mean value of differences

The permissible value for the mean value of the differences and for the
radial offset depends on the installed, flexible coupling type. When the
permissible value is exceeded, the engine must be realigned (see
Alignment Instructions). We recommend having the realignment carried
out by MAN Energy Solutions personnel, or at a MAN Energy Solutions
support point.
Work sequence 3 - Checking the foundations

Inspecting and pre-tension-
ing the foundation bolts (10)
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Inspection of the foundation bolts

Inspection of the foundation bolts starts on the coupling side.
1. Remove protective caps (7) and covers (15).
L48/60CR, M010.010.030-01-0009 3 (9)

Prerequisite for correct check

A prerequisite for the correct check of a bolted connection is a pres-
sure gauge with an accurate read-out. If in doubt, compare the pres-
sure gauge with a comparison pressure gauge.
Before fitting the hydraulic tensioner, check that the piston is fully re-
tracted (stroke = zero), and reset the piston if necessary.
2. Clean the threads of foundation bolts (10).

3. Set thrust piece (055.242) over nut (8).
4. Screw the hydraulic tensioner (009.631) onto foundation bolt (10), ensur-
ing that the thrust piece is aligned with the hydraulic tensioner. See fig. 3
and 4.
5. Turn the hydraulic tensioner back through the turning-back angle. See
6. Connect high pressure hose (009.306) to the hydraulic tensioner and
high pressure pump (009.342).
Dangerous area in case of failure in axial direction

At a high working pressure, powerful forces can be released in the
axial direction in case of failure, when using hydraulic tensioners and
thus could cause severe personal injuries.
• Staying in the axial direction of hydraulic tensioners is prohibited.
• Safety regulation in the Work Instructions 015.000.001-01 must be ob-
served.
7. Put the high-pressure pump into operation and close the gap caused by
turning back. See Work Instructions 015.000.003-01.
8. Pump the hydraulic tensioner until nut (8) can be loosened.
Maximum release pressure

The pressure must be a maximum of 7% under or a maximum of 5%
over the tensioning pressure. See Work Instructions 010.000.003-05.
2018-09-19 - de
9. Record the release pressure and compare it with the tensioning pressure.
10.Using Tommy bar (000.262), turn nut (8) back through the cut-out in the
thrust pad. For turn-back angle see work instructions 010.000.003-05.
11.Lower pressure to pre-tensioning pressure of 250 bar and tighten the nut
(8) hand-tight using tommy bar.
12.Relieve the pressure, and uncouple the high pressure hose from the hy-
draulic tensioner.
14.Check/pre-tension the remaining foundation bolts (10) of the spring ele-
ment (4) in the same way (see step 3 to 13).
4 (9) L48/60CR, M010.010.030-01-0009

Inspecting hex bolts (19) 15.Check hex bolts (19) of the spring element (4) with the specified torque
and re-tighten if necessary. See fig. 2 and work instructions
010.000.003-05.
Tensioning the foundation 16.Set thrust piece (055.242) over nut (8).
bolts (10) 17.Screw the hydraulic tensioner (009.631) onto foundation bolt (10), ensur-
ing that the thrust piece is aligned with the hydraulic tensioner. See fig. 3
and 4.
18.Connect high pressure hose (009.306) to the hydraulic tensioner and
high pressure pump (009.342).

served.
19.Put the high pressure pump into operation, and tighten the foundation
bolt to the specified tensioning pressure. See work instructions
010.000.003-05 and 015.000.003-01.
20.Tighten nut (8) by hand through the opening in the thrust piece using
tommy bar (000.262).
21.Relieve the pressure, and uncouple the high pressure hose from the hy-
draulic tensioner.
23.Tension the remaining foundation bolts (10) of the spring element (4) in
the same way (see step 16 to 22).
24.Check/pretension the foundation bolts and hex bolts (10 and 19) of the
remaining spring elements (4) in the same way (see steps 3 to 23).
25.Grease the thread ends of the foundation bolts (10) for protection against
rust, and cover them with protection caps (7).
Checking the hexagon 26.Check hexagon socket bolts (17) on all spring elements (4) in line with the
socket bolts (17), hex nuts specified torque, and re-tighten if necessary. See fig. 2 and work instruc-
(16, 23, 27) and synthetic tions 010.000.003-07.
resin support (12)
Check hex nuts (16) on all spring elements (4) in line with the specified torque,
2018-09-19 - de
and re-tighten if necessary. See fig. 2 volume 000 “Plant information” -

000.100 drawings - “Elastic engine support” of the respective plant.
Check hex nuts (23) on all axial stop brackets (3) in line with the specified
torque, and re-tighten if necessary. See fig. 2 volume 000 “Plant information” -
Check hex nuts (27) on all vertical stop brackets (2) in line with the specified
torque, and re-tighten if necessary. See fig. 2 volume 000 “Plant information” -
27.Inspect the synthetic resin support (12) for hazardous cracks and chip-
ping affecting stability. See fig. 2.
28.Attach covers (15).
L48/60CR, M010.010.030-01-0009 5 (9)

1 Cylinder crankcase 3 Axial stop block 5 Top plate

2 Vertical stop block 4 Spring element
Figure 1: Flexible engine support
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6 (9) L48/60CR, M010.010.030-01-0009


2018-09-19 - de
L48/60CR, M010.010.030-01-0009 7 (9)

1 Cylinder crankcase 16 Hex nut

2 Vertical stop block 17 Hexagon socket bolt
3 Axial stop block 18 Elastic element
4 Spring element 19 Hex bolt
5 Top plate 20 Steel shim
6 Measuring point on top 21 Hex bolt
plate
7 Protective cover 22 Washer
8 Nut 23 Hex nut
9 Plate 24 Fixing plate
10 Foundation bolt 25 Hex bolt
11 Oil sump 26 Washer
12 Synthetic resin support 27 Hex nut
13 Hex bolt A Reference dimension
14 Washer B Reference dimension
stamped on the part dur-
ing commissioning
15 Cover
Figure 2: Elastic engine support - Illustrations/details of the figure
9 Plate 10 Foundation bolt

Figure 3: Elastic engine support - foundation bolts with attached tensioner
2018-09-19 - de
8 (9) L48/60CR, M010.010.030-01-0009

8 Nut 10 Foundation bolt

9 Plate
Figure 4: Foundation bolts with attached tensioner
18014416670304139

2018-09-19 - de
L48/60CR, M010.010.030-01-0009 9 (9)

18014416670304139
2018-09-19 - de
L48/60CR, M010.010.030-01-0009
Crankshaft bearing bolts and cross tie rod (main bearing)

Inspection
Summary
The crankshaft bearing bolts and cross tie rods must be checked at regular
intervals using hydraulic tensioners.
Safety requirements
l Engine stopped
1 Suspension fixture 021.150 Standard

1 Box spanner 009.067 Standard
1 Ratchet tool 001.521 Option
1 Tommy bar, 12 000.264 Option
1 Lifting tackle - Inventory
2021-03-04 - de
1 Rope - Inventory

L51/60DF;L48/60CR;L48/60B, M010.010.030-07-0019 1 (9)

Technical data
Hydraulic tensioner (009.850) including nut 68 kg
Weight
(021.148)
Thrust piece (021.149) Weight 14 kg
Warning message

pressure hoses.
Work Sequence 1 - Checking the cross tie rods

Preliminary remark A prerequisite for correctly checking a screw connection is a pressure indic-
Starting position Crankcase opened. Running gear is turned so that the bearing cap is easily
accessible. The protection caps on the cross tie rods are unscrewed.
Work steps 1. Clean the threads of the cross tie rods (11).
2. Fit the thrust pieces (055.241) over the nuts (10). See Figs. 2 and 3.
3. Screw the hydraulic tensioners (009.632) onto the cross tie rods (11). In
doing so, ensure that the thrust pieces are centrally aligned by the hy-
draulic tensioners.
4. Turn the hydraulic tensioners back by the turn-back angle. See Work In-
structions 010.000.003-05.
5. Connect the high-pressure hoses (009.306) to the hydraulic tensioners
2021-03-04 - de
and the high-pressure pump (009.342) and secure them. See Work In-
structions 015.000.002-01.
sioners.
6. Start the high-pressure pump and close the gap between the thrust
piece and the ring (12) created by turning back. See Work Instructions
015.000.003-01.
Inspection
2 (9) L51/60DF;L48/60CR;L48/60B, M010.010.030-07-0019

7. Pump up the hydraulic tensioners until the nuts (10) can be released.
Make a note of the release pressure and compare it to the tensioning
pressure. The release pressure must not be more than 7% below or 5%
above the tensioning pressure. See Work Instructions 010.000.003-05
and 015.000.001-01.
8. Set the high-pressure pump to the specified tensioning pressure. See
9. Tighten both nuts (10) by hand through the cut-out in the thrust pieces
using a tommy bar (000.264).
11.Disconnect the high-pressure hoses from the hydraulic tensioners and
12.Remove the hydraulic tensioners and thrust pieces.
13.Fit protective caps (14) on the threads of the cross tie rods (11).
Work Sequence 2 - Checking the crankshaft bearing bolts
Standing and movement under suspended loads

Improper transport of components and tools may result in accidents
causing serious injury or death.
• Use suitable transport equipment as well as suspension devices and
lifting tackles, and operate them as intended
• Do not stand under suspended loads
Initial situation Cooling water for fuel injection pump cooling system drained completely.
Work steps 1. Remove all piping, engine components and covering parts obstructing
the installation of the hydraulic tensioners.
2. Remove the protective caps (3).
3. Clean the threads of the crankshaft bearing bolts (5).
2021-03-04 - de
4. Attach suspension device (021.150) to thrust piece (021.149). Fasten the

cable (18) to the suspension device with the shackle (002.453) and sus-
pend it from the hoist. See Figure 4.
DANGER Standing and driving under suspended loads is prohibited.
5. Lift the thrust over the crankshaft bearing bolt (5) and place it over the
nut (4).
Inspection
6. Detach the suspension device.

7. Attach the suspension device to the second thrust piece. Fasten the
cable to the suspension device with the shackle and suspend it from the
hoist.
L51/60DF;L48/60CR;L48/60B, M010.010.030-07-0019 3 (9)


nut (4).
10.Check nuts (021.148) on hydraulic tensioners (009.850) for secure fit us-
ing the tommy bar (000.263). If the nut is loose, re-tighten it hand-tight
using the tommy bar.
11.Screw suspension device (009.050) into hydraulic tensioner. Fasten the
cable (18) to the suspension device with the shackle and suspend it from
the hoist. See Figure 5.
12.Lift the hydraulic tensioner over the crankshaft bearing bolt (5). Place the
hydraulic tensioner onto the crankshaft bearing bolt and tighten by sev-
eral turns.
13.Detach the suspension device.
14.Place the socket wrench (009.067) on the hydraulic tensioner. Fit the
ratchet (001.521) and screw the hydraulic tensioner completely onto the
crankshaft bearing bolt (5). See Figure 6.
15.Leave the hydraulic tensioner in place and remove remaining tools.
16.Mount the second hydraulic tensioner onto the second crankshaft bear-
ing bolt (5) in the same manner. See steps 11 to 15.
17.Turn the hydraulic tensioners back by the turn-back angle. See Work In-
structions 010.000.003-05.
18.Connect the high-pressure hoses (009.306) to the hydraulic tensioners
structions 015.000.002-01.
sioners.
19.Put the high-pressure pump into operation and close the gap resulting
from turning the tensioner back. See Work Instructions 015.000.003-01.
20.Pump up the hydraulic tensioners until the nuts (4) can be released. Make
a note of the release pressure and compare it to the tensioning pressure.
The release pressure must not be more than 7% below or 5% above the
015.000.001-01.
21.Set the high-pressure pump to the specified tensioning pressure. See
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22.Tighten both nuts (4) by hand through the cut-out in the thrust pieces us-
ing a tommy bar (000.264).
9007223790792971
Inspection
25.Unscrew the hydraulic tensioners with the socket wrench and detach
with the suspension device (009.050).
26.Detach thrust pieces with the suspension device (021.150).
27.Fasten protective covers (3) on crankshaft bearing bolts (5).
4 (9) L51/60DF;L48/60CR;L48/60B, M010.010.030-07-0019

28.Attach the removed piping, engine components and covering parts.
1 Hex bolt 10 Nut

2 Washer 11 Cross-tie rod
3 Protective cap 12 Ring
4 Nut 14 Protective cap
5 Crankshaft bearing bolt 15 Nut
8 Crankshaft bearing cover A Bolt projection
9 Crankcase
Figure 1: Crankshaft bearing bolt and cross tie rod
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Inspection
L51/60DF;L48/60CR;L48/60B, M010.010.030-07-0019 5 (9)

5 Crankshaft bearing bolt 11 Cross-tie rod

9 Crankcase 12 Ring
Figure 2: Crankshaft bearing bolt and cross-tie rod with hydraulic tensioners
fitted
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Inspection
6 (9) L51/60DF;L48/60CR;L48/60B, M010.010.030-07-0019

9 Crankcase
10 Nut
11 Cross-tie rod
12 Ring
13 O-ring
Figure 3: Cross-tie rod with fitted hydraulic tensioner
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4 Nut
5 Crankshaft bearing bolt
9 Crankcase
Inspection
18 Rope
19 Hex bolt
Figure 4: Suspending the thrust piece
L51/60DF;L48/60CR;L48/60B, M010.010.030-07-0019 7 (9)

18 Rope
Figure 5: Suspending the hydraulic tensioner
Figure 6: Screwing on/off the hydraulic tensioner

2021-03-04 - de
Inspection
8 (9) L51/60DF;L48/60CR;L48/60B, M010.010.030-07-0019

4 Nut
9 Crankcase
A Bolt projection
Figure 7: Crankshaft bearing bolt with attached hydraulic tensioner
9007223790792971
2021-03-04 - de
Inspection
L51/60DF;L48/60CR;L48/60B, M010.010.030-07-0019 9 (9)

9007223790792971
2021-03-04 - de
Inspection
L51/60DF;L48/60CR;L48/60B, M010.010.030-07-0019
Crankshaft bearing bolts and the cross tie rod (external bearing)
inspecting
Summary
The crankshaft bearing bolts and cross tie rods must be checked at regular
intervals using hydraulic tensioners.
Safety requirements
l Engine stopped
Required tools and auxiliary equipment

1 Foot board (for oil sump) 011.007 Standard

2020-11-24 - de

L48/60CR, M010.010.030-08-0006 1 (7)

Warning message

pressure hoses.
Work sequence 1 - Checking the cross tie rods

Work steps 1. Clean the threads of the cross-tie rods (5).
3. Screw the hydraulic tensioners (009.632) onto both cross tie rods (5). In
draulic tensioners.
structions 010.000.003-05.
and high-pressure pump (009.342) and secure them. See Work Instruc-
tions 015.000.002-01.
sioners.
015.000.003-01.
2020-11-24 - de
7. Pump up the hydraulic tensioners until the nuts (3) can be undone. Make
The release pressure must not be more than a maximum of 7% below or
a maximum of 5% above the tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.001-01.
inspecting
9. Tighten both nuts (3) through the cut-out in the thrust pieces using the
2 (7) L48/60CR, M010.010.030-08-0006


Work sequence 2 - Checking the crankshaft bearing bolts

Initial situation Control crankcase casing lid removed.
Work steps 1. Place the foot board (011.003 for a V oil pan or 011.007 for a normal oil
pan) in oil pan.
2. Clean the threads of crankshaft bearing bolts (8).
4. Screw the hydraulic tensioners (009.631) onto the crankshaft bearing
bolts (8). In doing so, ensure that the thrust pieces are centrally aligned
by the hydraulic tensioners.
structions 010.000.003-05.
tions 015.000.002-01.
sioners.
27021599753269387
piece and the crankshaft bearing cover (9) created by turning back. See
010.000.003-05 and 015.000.001-01.
10.Tighten both nuts (7) through the cut-out in the thrust pieces using the
2020-11-24 - de

14.Remove the foot board (011.003 or 011.007) from the oil pan.
inspecting
L48/60CR, M010.010.030-08-0006 3 (7)

1 Ring 6 Crankcase
2 O-ring 7 Nut
3 Nut 8 Crankshaft bearing screw
4 Protective cap 9 Crankshaft bearing cover
5 Cross-tie rod
Figure 1: Crankshaft bearing (external bearing)
2020-11-24 - de
inspecting
4 (7) L48/60CR, M010.010.030-08-0006

1 Ring 9 Crankshaft bearing

cover
Figure 2: Crankshaft bearing bolt and cross tie rod with attached hydraulic tensioners
2020-11-24 - de
inspecting
L48/60CR, M010.010.030-08-0006 5 (7)

1 Ring 5 Cross-tie rod

2 O-ring 6 Crankcase
3 Nut
Figure 3: Cross tie rod with attached hydraulic tensioner
2020-11-24 - de
inspecting
6 (7) L48/60CR, M010.010.030-08-0006

7 Nut 9 Crankshaft bearing cover

8 Crankshaft bearing screw
27021599753269387
2020-11-24 - de
inspecting
L48/60CR, M010.010.030-08-0006 7 (7)

27021599753269387
2020-11-24 - de
inspecting
L48/60CR, M010.010.030-08-0006

releasing and tensioning
Summary
Crankshaft bearing screws and cross tie rods must be released and ten-
sioned by means of tensioners during maintenance work.
Safety requirements
l Engine stopped
2 Magnetic measuring stand 009.446 Standard

1 Feeler gauge 000.451 Option
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1 Sliding calliper Form C - Inventory
1 Rope - Inventory

L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019 1 (14)


Dial gauge (Measuring device) - Checking bolt elongation 015.000.004-01
Technical data
Hydraulic tensioner (009.850) including nut 68 kg
Weight
(021.148)
Thrust piece (021.149) Weight 14 kg
Bolt protrusion (A) Dimension 190 mm
Warning messages


pressure hoses.
Work Sequence 1 - Releasing the cross tie rods

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Initial situation Crankcase opened. The crankshaft assembly is turned so that the bearing
cover is easily accessible. The protective caps on the cross tie rods are un-
screwed.
Work steps 1. Remove the protective caps (14).
2. Clean the threads of the cross tie rods (11).
2 (14) L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019

draulic tensioners.
structions 010.000.003-05.
structions 015.000.002-01.
sioners.
7. Put the high-pressure pump into operation and close the gap resulting
pressure. The release pressure must not be more than 7% below or 5%
above the tensioning pressure. See Work Instructions 010.000.003-05
and 015.000.001-01.
9. Using a tommy bar (000.264), turn both nuts (10) back by the turning-
back angle through the cut-out in the thrust pieces. See Work Instruc-
tions 010.000.003-05.
Work Sequence 2 - Releasing the crankshaft bearing bolts

Initial situation Cooling water for fuel injection pump cooling system drained completely.
Work steps 1. Remove all piping, engine components and covering parts obstructing
the installation of the hydraulic tensioners.
2021-03-04 - de


nut (4).
hoist.
L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019 3 (14)


nut (4).
eral turns.
structions 010.000.003-05.
structions 015.000.002-01.
sioners.
The release pressure must not be more than 7% below or 5% above the
015.000.001-01.
21.Using a tommy bar (000.264), turn both nuts (4) back by the turning-back
angle through the cut-out in the thrust pieces. See Work Instructions
010.000.003-05.
2021-03-04 - de


4 (14) L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019

Work Sequence 3 - Tensioning the crankshaft bearing bolts and cross tie rods
Initial situation Crankshaft bearing cover is lifted up until it touches the crankcase, all nuts are
screwed on and hand-tightened. Threads of crankshaft bearing bolts and
cross tie rods cleaned.
Work steps 1. Using the feeler gauge (000.451), check that the gap in the joint between
the crankshaft bearing cover (8) and the crankcase (9) is closed on both
sides (measures less than 0.05 mm).
2. Check the bolt projection (A) of the crankshaft bearing bolts (5). See
Technical Data. See Figs. 1 and 7.
draulic tensioners.
and secure them. See Work Instructions 015.000.002-01.
nut (4).
hoist.
10.Lift the thrust over the crankshaft bearing bolt (5) and place it over the
nut (4).
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eral turns.
L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019 5 (14)

19.Connect the high-pressure hoses to the hydraulic tensioners and secure
them. See Work Instructions 015.000.002-01.
20.Connect the high-pressure hoses for the cross tie rods (11) to the high-
pressure pump (009.342) and secure them. See Work Instructions
015.000.002-01.
sioners.
21.Start the high-pressure pump and tension the cross-tie rods (11) to the
specified pre-tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.003-01.
22.Tighten the nuts (10) through the opening in the thrust pieces using a
tommy bar (000.264) until hand-tight.
24.Disconnect the high-pressure hoses for the cross-tie rods (11) from the
high-pressure pump.
25.Connect the high-pressure hoses for the crankshaft bearing bolts (5) to
the high-pressure pump and secure them. See Work Instructions
015.000.002-01.
sioners.
26.Start the high-pressure pump and tighten the crankshaft bearing
screws (5) to the specified pre-tensioning pressure. See Work Instruc-
tions 010.000.003-05 and 015.000.003-01.
tommy bar until hand-tight.
29.Remove the high-pressure hoses for crankshaft bearing bolts (5) from the
high-pressure pump.
30.Connect the high-pressure hoses for the cross tie rods (11) to the high-
pressure pump and secure them. See Work Instructions
015.000.002-01.
2021-03-04 - de

sioners.
specified tensioning pressure. See Work Instructions 010.000.003-05
and 015.000.003-01.
34.Disconnect the high-pressure hoses for the cross-tie rods (11) from the
high-pressure pump.
6 (14) L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019

the high-pressure pump and secure them. See Work Instructions
015.000.002-01.
sioners.
tions 010.000.003-05 and 015.000.003-01.
37.Insert dial gauges (009.444) into the magnetic measuring stands
(009.446) and fasten them. See Work Instructions 015.000.004-01.
38.Place the magnetic measuring stands on the casing of the hydraulic ten-
sioners (009.850). See Figure 8.
39.Place the dial gauges on the pistons of the hydraulic tensioners. Make
sure that the measuring probe of the dial gauges is resting against the
piston of the hydraulic tensioners.
40.Set the dial gauges to zero.
sioners.
41.Start up the high-pressure pump, and tighten the crankshaft bearing
screws (5) to the prescribed tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.003-01.
sioners.
tions 010.000.003-05 and 015.000.003-01.
45.Read off the bolt elongation Δl on the dial gauges, note down the values
and compare them with the setpoint value. The measurement of the bolt
elongation Δl serves only as a check. See Work Instructions
010.000.003-05.
In case of significant deviations from the setpoint value, repeat the ten-
sioning process and check the hydraulic tensioners, screw connections
and the pressure indicator if required.
2021-03-04 - de

48.Detach the magnetic measuring stands and dial gauges.

51.Fasten protective covers (3) on crankshaft bearing bolts (5).
52.Attach the removed piping, engine components and covering parts.
L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019 7 (14)

53.Remove the hydraulic tensioners and thrust pieces from the cross tie
rods (11).
Work Sequence 4 - Tightening the cross tie rods

Initial situation Work sequence 4 describes the tightening of cross tie rods of the neighbour-
ing crankshaft bearings after installation of crankshaft bearing shells.
Nuts are hand-tightened, threads of cross tie rods are cleaned.
Work steps 1. Fit the thrust pieces (055.241) over the nuts (10). See Figs. 2 and 3.
draulic tensioners.
structions 015.000.002-01.
sioners.
4. Start the high-pressure pump and tension the cross-tie rods (11) to the
and 015.000.003-01.
5. Tighten both nuts (10) by hand through the cut-out in the thrust pieces
using a tommy bar (000.264).
7. Disconnect the high-pressure hoses from the hydraulic tensioners and
8. Remove the hydraulic tensioners and thrust pieces.
9. Fit protective caps (14) on the threads of the cross tie rods (11).
2021-03-04 - de
8 (14) L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019

1 Hex bolt 10 Nut

2 Washer 11 Cross-tie rod
3 Protective cap 12 Ring
4 Nut 14 Protective cap
5 Crankshaft bearing bolt 15 Nut
8 Crankshaft bearing cover A Bolt projection
9 Crankcase
Figure 1: Crankshaft bearing bolt and cross tie rod
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L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019 9 (14)

5 Crankshaft bearing bolt 11 Cross-tie rod

9 Crankcase 12 Ring
Figure 2: Crankshaft bearing bolt and cross-tie rod with hydraulic tensioners
fitted
2021-03-04 - de
10 (14) L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019

9 Crankcase
10 Nut
11 Cross-tie rod
12 Ring
13 O-ring
Figure 3: Cross-tie rod with fitted hydraulic tensioner
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4 Nut
9 Crankcase
18 Rope
19 Hex bolt M6 x 16
Figure 4: Suspending the thrust piece
L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019 11 (14)

18 Rope
Figure 5: Suspending the hydraulic tensioner
Figure 6: Screwing on/off the hydraulic tensioner

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12 (14) L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019

4 Nut
9 Crankcase
A Bolt projection
2021-03-04 - de
L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019 13 (14)

Figure 8: Hydraulic tensioner with magnetic measuring stand and dial gauge
attached
9007223790799371
2021-03-04 - de
14 (14) L51/60DF;L48/60CR;L48/60B, M010.010.030-09-0019

Summary
Crankshaft bearing screws and cross tie rods must be released and ten-
sioned by means of tensioners during maintenance work.
Safety requirements
l Engine stopped
Tools/aids required

2021-01-26 - de

L48/60CR, M010.010.030-10-0006 1 (8)

Warning message

pressure hoses.
Work Sequence 1 – Releasing the cross tie rods

Work steps 1. Clean the threads of the cross tie rods (5).
3. Screw the hydraulic tensioners (009.632) onto the cross tie rod (5). In do-
ing so, ensure that the thrust pieces are centrally aligned by the hydraulic
tensioners.
structions 010.000.003-05.
structions 015.000.002-01.
sioners.
015.000.003-01.
2021-01-26 - de
7. Pump up the hydraulic tensioners until the nuts (3) can be released. Make
015.000.001-01.
8. Using a tommy bar (000.264), turn bots nuts (3) back by the turning-back
010.000.003-05.
2 (8) L48/60CR, M010.010.030-10-0006

Work Sequence 2 – Releasing the crankshaft bearing bolts

Initial situation Control crankcase casing lid removed. Cross tie rods unloaded.
Work steps 1. Place the foot board (011.003 for a V oil pan or 011.007 for a normal oil
pan) in oil pan.
structions 010.000.003-05.
structions 015.000.002-01.
sioners.
piece and the crankshaft bearing cover (9) created by turning back. See
015.000.001-01.
9. Using a tommy bar (000.262), turn both nuts (7) back by the turning-back
010.000.003-05.
2021-01-26 - de

Work Sequence 3 – Tensioning the crankshaft bearing bolts and cross tie rods
Initial situation Foot board inserted in oil pan. All nuts are tightened by hand.
L48/60CR, M010.010.030-10-0006 3 (8)

the crankshaft bearing cover (9) and the crankcase (6) is closed on both
sides (measures less than 0.05 mm).
2. Clean the threads of the crankshaft bearing bolts (8) and cross-tie rod (5).
4. Screw the hydraulic tensioners (009.632) onto the cross-tie rod (5). In do-
tensioners.
5. Connect the high-pressure hoses (009.306) to the hydraulic tensioner,
and secure it. See Work Instructions 015.000.002-01.
8. Connect the high-pressure hoses to the hydraulic tensioners (009.361)
and secure. See Work Instructions 015.000.002-01.
9. Connect the high-pressure hoses for the cross-tie rods (5) to the high-
pressure pump (009.342) and secure. See Work Instructions
015.000.002-01.
sioners.
specified pre-tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.003-01.
13.Disconnect high-pressure hoses for cross-tie rods (5) from the high-pres-
sure pump.
the high-pressure pump and secure. See Work Instructions
015.000.002-01.
sioners.
15.Start up the high-pressure pump, and tighten the crankshaft bearing
screws (8) to the prescribed tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.003-01.
2021-01-26 - de

18.Remove high-pressure hoses for crankshaft bearing bolts (8) from the
high-pressure pump.
19.Connect the high-pressure hoses for the cross-tie rods (5) to the high-
pressure pump and secure. See Work Instructions 015.000.002-01.
sioners.
27021599753272587
4 (8) L48/60CR, M010.010.030-10-0006

and 015.000.003-01.
25.Remove the foot board (011.003 or 011.007) from the oil pan.
26.Fit protective caps (4) on the threads of the cross-tie rods (5).
1 Ring 6 Crankcase
2 O-ring 7 Nut
3 Nut 8 Crankshaft bearing screw
4 Protective cap 9 Crankshaft bearing cover
5 Cross-tie rod
Figure 1: Crankshaft bearing (external bearing)
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L48/60CR, M010.010.030-10-0006 5 (8)

1 Ring 9 Crankshaft bearing

cover
Figure 2: Crankshaft bearing bolt and cross-tie rod with attached hydraulic tensioners
2021-01-26 - de
6 (8) L48/60CR, M010.010.030-10-0006

1 Ring 5 Cross-tie rod

2 O-ring 6 Crankcase
3 Nut
Figure 3: Cross-tie rod with attached hydraulic tensioner
2021-01-26 - de
L48/60CR, M010.010.030-10-0006 7 (8)

7 Nut 9 Crankshaft bearing cover

8 Crankshaft bearing screw
27021599753272587
2021-01-26 - de
8 (8) L48/60CR, M010.010.030-10-0006

Cylinder head bolts

removing and installing
Summary
Insert/ replace components, ensure proper application. Cylinder head bolts
should be removed, if their O-rings are damaged. Cylinder head bolts should
also be removed, if cylinder liners need to be removed in tight fitting height
locations.
The work/work steps include: Dismantling of components, Installation of com-
ponents.
Tools/aids required
1 Bolt extractor 014.015 Option
1 Torque wrench 008.011 Standard
1 Adapter 25x20 001.924 Standard
1 Tommy bar 16 000.266 Option
1 Rope - Inventory
1 Side cutter - Inventory
1 Lubricating oil, clean - Inventory

Loosening and tightening the cylinder head bolts 010.060.020-02
Technical data
Cylinder head bolt - L 48/60 B Weight 33,5 kg
2018-12-12 - de
Cylinder head bolt - V 48/60 B Weight 29,5 kg

Cylinder head bolts
Protrusion (A) Dimension 50 mm
Preliminary remark
The Work sequences 1 and 2 describe the normal installation and removal of
the cylinder head bolts.
The Work sequences 3 and 4 describe the installation and removal of the cyl-
inder head bolts in tight space conditions (e. g low construction height for re-
moval of the cylinder liner).
General, M010.010.030-11-0003 1 (10)

Values for bolt tightening

Item Tightening torque and torsion angle Note
Tightening 1st stage 2nd stage 3rd + 4th Lubricant /
torque stage screw lock
Nm Nm Nm Nm
1 100
Work sequence 1 - Removing the cylinder head bolts

Initial situation Cylinder liner with backing ring removed.
Work steps 1. Check that the hex nuts (7) on the bolt extractor (014.015) are released.
2. Mount the bolt extractor on the cylinder head bolt (1). Pay attention to the
protrusion (A) in doing so. See fig. 2.
3. Tighten the hex nuts (7).
4. Insert the tommy bar (000.266) into the bolt extractor. See fig. 2.
5. Release and unscrew the cylinder head bolt (1).
6. Loop the cable around the tommy bar and the bolt extractor and sus-
pend it from the lifting tackle.
Standing and transport under suspended loads

7. Remove the cylinder head bolt (1) and place it carefully on a clean base.
8. Remove the cable, pull out the tommy bar, release the hex nuts (7) and
unscrew the bolt extractor.
9. Remove the remaining cylinder head bolts (1) in the same manner. See
points 2 to 8.
10.Remove O-rings (3 and 6) and ring (4) from cylinder head bolts (1).
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11.Clean the cylinder head bolts (1).

Cylinder head bolts
Work sequence 2 - Installing the cylinder head bolts

Initial situation Cylinder head bolts cleaned.
Work steps 1. Clean holes and threads in cylinder crankcase (5) carefully.
2. Lightly oil shank of the cylinder head bolt (1) with clean lubricating oil.
3. Push the new O-rings (3) and a new ring (4) over the thread onto the
shank of the cylinder head bolt (1). In doing so, be careful not to damage
the O-rings.
2 (10) General, M010.010.030-11-0003

4. Push a new O-ring (6) over the thread and insert it into the ring groove. In
doing so, be careful not to damage the O-ring. Oil the O-ring (6) with
clean lubricating oil.
5. Check that the hex nuts (7) on the bolt extractor (014.015) are released.
6. Screw the bolt extractor onto the cylinder head bolt (1). In doing so, en-
sure to observe projection (A) between the bolt extractor and the cylinder
head bolt (1). See Fig. 2.
8. Insert the tommy bar (000.266) into the bolt extractor. See Fig. 2.

pend it from the lifting tackle. Lift the cylinder head bolt (1) carefully.
10.Insert cylinder head bolt (1) in hole.
11.Remove the cable.
12.Screw in cylinder head bolt (1).
13.Withdraw the tommy bar.
14.Tighten cylinder head bolt (1) to the prescribed torque. See table “Values
for bolt tightening”.
15.Loosen the hex nuts (7) and unscrew the bolt extractor.
16.Apply clean lubricating oil to the mounting bore in the cylinder crankcase
(5) as well as the O-rings (3) and ring (4).
17.Slide O-rings (3) and ring (4) individually into the locating hole, ensuring
that O-rings are not twisted. See Fig. 1.
18.Install the remaining cylinder head bolts (1) in the same manner. See
points 2 to 17.
19.Tighten the cylinder head bolts after installing or attaching all engine com-
ponents. See Work Instructions 010.060.020-02
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Cylinder head bolts
Tensioning the cylinder head bolts

Before tensioning the cylinder head bolts, make sure that the cylinder
crankcase and the cylinder head bolts are at the same temperature.
This is especially important when replacing cylinder head bolts with
the engine at its operating temperature.
General, M010.010.030-11-0003 3 (10)

Work sequence 3 - Removal of the cylinder head bolts (for low dismantling height for
cylinder liner)
Initial situation Cylinder head is detached.
Work steps 1. Check that the hex nuts (7) on the bolt extractor (014.015) are released.
2. Screw the bolt extractor onto the cylinder head bolt (1). Pay attention to
the protrusion (A) in doing so. See fig. 2.
4. Insert the tommy bar (000.266) into the bolt extractor. See fig. 2.
5. Release and unscrew the cylinder head bolt (1). See fig. 3/I.

7. Lift the cylinder head bolt (1) until the O-rings (3) and the ring (4) are ex-
posed. See fig. 3/II.
8. Cut through the O-rings (3) using side cutters and remove.
9. Remove the cylinder head bolt (1) slowly. The ring (4) has to be moved
multiple times during removal.
10.Remove the O-ring (6) and ring (4) before finally removing the cylinder
head bolt (1). See fig. 3/III.
11.Remove the cylinder head bolt (1) completely and place carefully on a
clean base.
12.Remove the cable, pull out the tommy bar, release the hex nuts (7) and
unscrew the bolt extractor.
13.Remove the remaining cylinder head bolts (1) in the same manner. See
points 2 to 12.
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14.Clean the cylinder head bolts (1).

Cylinder head bolts
Work sequence 4 - Installation of the cylinder head bolts (with low dismantling height
for cylinder liner)
Initial situation Cylinder head bolts are cleaned, backing ring and cylinder liner are installed.
Work steps 1. Clean holes and threads in cylinder crankcase (5) carefully.
4 (10) General, M010.010.030-11-0003

3. Screw the bolt extractor onto the cylinder head bolt (1). In doing so, en-
sure to observe projection (A) between the bolt extractor and the cylinder
head bolt (1). See Fig. 2.

pend it from the lifting tackle. Lift the cylinder head bolt (1) carefully.
7. Lightly oil shank of the cylinder head bolt (1) with clean lubricating oil.
8. Insert cylinder head bolt (1) through hole in the backing ring (2). See
Fig. 4/I.
9. Push the new O-rings (3 and 6) and a new ring (4) over the thread onto
the shank of the cylinder head bolt (1). In doing so, be careful not to dam-
age the O-rings. See Fig. 4/I.
10.Lower the cylinder head bolt (1) slightly and insert the new O-ring seal (6)
in the ring groove, ensuring that this is tensioned evenly over the entire
circumference and is not twisted. Oil the O-ring with clean lubricating oil.
See Fig. 4/I.
11.Push O-rings (3) and ring (4) until they rest on backing ring (2). See Fig. 4/
I.
12.Again lower the cylinder head bolt (1) slightly and move the O-rings (3)
and ring (4) until they abut the backing ring (2).
13.Keep repeating point 12 until cylinder head bolt (1) is completely inserted
in cylinder crankcase (5).
14.Remove the cable.
15.Screw in cylinder head bolt (1). See Fig. 4/III.
16.Withdraw the tommy bar.
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17.Tighten cylinder head bolt (1) to the prescribed torque. See table “Values
Cylinder head bolts

18.Loosen the hex nuts (7) and unscrew the bolt extractor.
19.Apply clean lubricating oil to the mounting bore in the cylinder crankcase
(5) as well as the O-rings (3) and ring (4).
20.Slide O-rings (3) and ring (4) individually into the locating hole, ensuring
that O-rings are not twisted. See Fig. 1.
21.Install the remaining cylinder head bolts (1) in the same manner. See
points 3 to 20.
General, M010.010.030-11-0003 5 (10)

22.Tighten the cylinder head bolts after installing or attaching all engine com-
ponents. See Work Instructions 010.060.020-02
Tensioning the cylinder head bolts

Before tensioning the cylinder head bolts, make sure that the cylinder
crankcase and the cylinder head bolts are at the same temperature.
This is especially important when replacing cylinder head bolts with
the engine at its operating temperature.
36028803839306251
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Cylinder head bolts
6 (10) General, M010.010.030-11-0003

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Cylinder head bolts
1 Cylinder head bolt 4 Ring

2 Backing ring 5 Cylinder crankcase
3 O-ring 6 O-ring
Figure 1: Cylinder head bolt*
General, M010.010.030-11-0003 7 (10)

1 Cylinder head bolt

7 Hex nut M10
A Projection
(bolt extractor - cylinder head bolt)
Figure 2: Attaching the bolt extractor to the cylinder head bolt
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Cylinder head bolts
8 (10) General, M010.010.030-11-0003

1 Cylinder head bolt 4 Ring I-III Work steps

3 O-ring 6 O-ring
Figure 3: Removing a cylinder head bolt (low dismantling height for cylinder liner - Work Sequence 3) *
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Cylinder head bolts
General, M010.010.030-11-0003 9 (10)

1 Cylinder head bolt 4 Ring I-III Work steps

3 O-ring 6 O-ring
Figure 4: Installation of a cylinder head bolt (low dismantling height for cylinder liner - Work Sequence 4) *
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* The illustrations show a 48/60 B in-line engine

Cylinder head bolts
36028803839306251
10 (10) General, M010.010.030-11-0003


010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas
51353781387
010.020 Casing
1 (1)

010.020 Casing
51353785611
1 (1)

Casing on the coupling side

Removing and fitting
Summary
Insert/replace components, machine properly and mount them.
The casing on the coupling side is to be dismounted only for disassembly of
the outer crankshaft bearing cover.
The work/work steps include:
Dismantling components,
fitting components.
Safety requirements
l Engine stopped
l Driving shaft secured against turning
l Operating media systems closed/depressurised
l Engine secured against starting
Tools/aids required
2 Lifting eye bolt M16 000.143 Standard
1 Lifting tackle with rope - Inventory
1 Wood (to support underneath) - Inventory
1 Hexagon nut M10 - Inventory
1 Sealing compound (Silicone) - Inventory
1 Securing compound, Loctite 243 - Inventory

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Technical data
Covering half (L48/60B, L48/60CR, L51/60DF) Weight 73,5 kg
Covering upper part (L48/60B, L48/60CR, Weight 24,5 kg
L51/60DF)
Covering lower part (L48/60B, L48/60CR, 24,5 kg
Weight
L51/60DF)
Splash ring half (L48/60B, L48/60CR, Weight 10,5 kg
L51/60DF)
General, M010.020.010-01-0001 1 (6)


Covering half (V48/60B, V48/60CR, 84 kg
Weight
V51/60DF)
Covering upper part (V48/60B, V48/60CR, Weight 27,5 kg
V51/60DF)
Covering lower part (V48/60B, V48/60CR, 27,5 kg
Weight
V51/60DF)
Splash ring half (V48/60B, V48/60CR, Weight 12,5 kg
V51/60DF)

Nm Nm Nm Nm
26 200 XX
XX Tightened with Loctite 243 up to stop
Work Sequence 1 – Removal

Work steps 1. Remove all pipes obstructing the removal of the covering.
2. Remove discharge pipe (17) including seals (18).
3. Screw two lifting eye bolts (000.143) into upper part of the casing (4),
fasten rope with shackle (002.453) to lifting eye bolts and suspend from
lifting tackle.
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4. Remove two taper pins (9).

5. Unscrew hex nuts (1) and hex bolts (3) and remove hex bolts (2). Remove
the upper part of the casing.
6. Detach the tool.
7. Screw two lifting eye bolts (000.143) into upper part of the casing (21),
lifting tackle. Tension the rope.
8. Remove two taper pins (11).
9. Unscrew hex bolts (3) and detach the lower part of the casing.
10.Detach the tool.
2 (6) General, M010.020.010-01-0001

11.Screw two lifting eye bolts (000.143) into right half of the casing (22),
lifting tackle.
12.Remove taper pins (10, 20 and 23).
13.Unscrew hex nuts (5) and hex bolts (12 and 15) for right half of the casing
and remove hex bolts (6 and 19). Remove the right half of the casing.
14.Detach the tool.
15.Screw two lifting eye bolts (000.143) into right half of the casing (13),
lifting tackle.
16.Unscrew hex bolts (12 and 15) for left half of casing and remove left half
of casing.
17.Support the lower part of splash ring with suitable means (e.g. a wooden
block).
18.Unscrew hexagon socket bolts (26) and remove upper part of splash ring
(24).
19.Remove the lower part of splash ring (25); in doing so, pay attention to
parallel pin (27).
20.Clean all the individual parts; check the upper and lower parts of splash
ring for damage.
Work Sequence 2 – Fitting

27021604723331851
Work steps 1. Clean the contact area on cylinder crankcase (8).

2. Clean the crankshaft (7) around the splash ring area.

3. Fit the lower part of the splash ring (25) to the crankshaft, and support it
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by suitable means (e.g. wooden block), paying attention to the position of

the parallel pin (27).
4. Place the upper part of splash ring (24) onto crankshaft and the lower
part of splash ring.
5. Apply securing compound Loctite 243 to threads of hexagon socket
bolts (26), screw in and tighten to the specified torque. See table “Values
6. Remove the support for the lower part of the splash ring.
7. Screw lifting eye bolts (000.143) into right half of the casing (13), fasten
rope with shackle (002.453) to lifting eye bolts and suspend from lifting
tackle.
General, M010.020.010-01-0001 3 (6)

8. Coat contact areas on the left half of the casing with sealing agent Silic-
one Rhodorsil.
9. Attach left casing half, screw hex bolts (12 and 15) in loosely until con-
tact. In doing so, be careful not to damage the splash ring.
10.Detach the tool.
11.Attach the right half of the casing (22) in the same manner. See Points 7
to 10. In doing so, be careful not to damage the splash ring.
12.Loosely connect the right and left casing halves by means of hex nuts (5)
and hex bolts (6 and 19).
13.Affix the right and left casing halves by inserting two taper pins (20 and
23). Tighten hex nuts.
14.Affix casing halves to cylinder crankcase (8) using two taper pins (10),
tighten hex bolts (12 and 15).
15.Screw lifting eye bolts (000.143) into the lower part of the casing (21),
lifting tackle.
16.Coat contact areas on lower part of casing with sealing agent Silicone
Rhodorsil.
17.Attach lower part of casing, screw hex bolts (3) in loosely until contact.
18.Detach the tool.
19.Attach upper part of casing (4) in the same manner. See Points 15 to 18.
20.Insert hex bolts (2) and loosely screw on hex nuts (1) until contact.
21.Affix the upper and lower parts of the casing by inserting two taper pins
(9). Tighten hex nuts.
22.Fix the upper and lower parts of the casing to the cylinder crankcase us-
ing two taper pins (11). Tighten the hex bolts.
23.Attach discharge pipe (17) including seals (18) and align it. Screw in hex
bolts (16) and tighten them.
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4 (6) General, M010.020.010-01-0001

1 Hex nut 10 Taper pin 19 Hex bolt

2 Hex bolt 11 Taper pin 20 Taper pin
3 Hex bolt 12 Hex bolt 21 Covering lower part
4 Covering upper part 13 Left casing half 22 Right casing half
5 Hex nut 14 Oil sump 23 Taper pin
6 Hex bolt 15 Hex bolt 24 Upper part of splash
ring
7 Crankshaft 16 Hex bolt 25 Lower part of splash
ring
8 Cylinder crankcase 17 Drain pipe
9 Taper pin 18 Seal
Figure 1: Casing on coupling side (Figure shows L46/60B)

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General, M010.020.010-01-0001 5 (6)

7 Crankshaft
24 Upper part of splash ring
25 Lower part of splash ring
26 Hexagon socket bolt
27 Parallel pin
Figure 2: Splash ring (Figure shows L48/60B)
27021604723331851
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6 (6) General, M010.020.010-01-0001

51353794059
1 (1)

Crankcase cover
dismounting and attaching
Summary
Ensure correct execution of work, provide access to the drive chamber for
work.
Remove crankcase cover.
removing the components,
fitting the components.
Safety requirements
l Engine stopped
l Voltage supply / voltage generation interrupted
Tools/aids required
1 Cross handle 001.891 Option
1 Socket spanner insert 24x12.5 001.757 Option
1 Depth gauge - Inventory
Technical data
Crankcase cover: V engine Weight 32 - 74 kg
Crankcase cover: L engine Weight 25 - 58 kg
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Reference dimension (L) Dimension 17,6 mm

Crankcase cover
48/60CR;48/60B, M010.020.030-01-0001 1 (8)

Preliminary remark
Explosion hazard
When opening the crankcase cover, hot components, oil mist gener-
ated in the crankcase and inflowing oxygen may form an explosive
mixture.
• Carry out any work on the engine only after a period of 20 minutes after
engine stop

Nm Nm Nm Nm
3 20 O
O Lube oil, clean
Work Sequence 1 - Detaching a crankcase cover

Preliminary remark Depending on the engine type, there are different crankcase covers attached
to the engine. The following Work Steps describe the removal procedure of
the crankcase cover with the splash-oil temperature monitoring attached.
Work Steps 1. Remove the resistance thermometer (6) and place safely to one side. See
Fig. 1.
2. Slacken the hexagon nuts (3) and twist the retaining bow (2). See Figs. 1
and 2.
3. Carefully remove the crankcase cover (5) and place on a support surface.
Work Sequence 2 - Attaching a crankcase cover

Preliminary remark Depending on the engine type, there are different crankcase covers attached
to the engine. The following Work Steps describe the procedure for fitting a
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crankcase cover with splash-oil temperature monitoring attached.

Initial situation Crankcase cover detached.
Crankcase cover
Work steps 1. Check the sealing ring (13) for damage, replace it if necessary. See Fig. 2.
2 (8) 48/60CR;48/60B, M010.020.030-01-0001

Fitting a new sealing ring

Before fitting a new sealing ring, clean the groove in the crankcase
cover. Stick the sealing ring into the groove using metal adhesive Loc-
tite 307 (follow the manufacturer's instructions). When fitting the seal-
ing ring into the groove observe position of joint (B). See fig. 3.
• In-line engine.... Joint above
• V engine.... Joint behind plate
2. Lubricate the thread of stud bolts (4) and contact area of hex nuts (3) with
clean lube oil.
Fitting the crankcase cover to the cylinder crankcase

When fitting the crankcase cover to the cylinder crankcase, there is a
danger of limbs being crushed.
• Do not reach into the contact surface area of crankcase cover and cyl-
inder crankcase when fitting
• During installation, hold the crankcase cover on the lateral grip re-
cesses
3. Fit the crankcase cover (5) on the dowel pins (7), and attach it to the cyl-
inder crankcase (9).
4. Turn back the retaining bows (2).
5. Screw in the hexagon nuts (3) and tighten to the prescribed torque. See
table “Values for bolt tightening”.
Risk of injury from stud bolts breaking

Incorrectly installed cup springs or re-tightening of the hex nuts will
cause the studs to break.
In case of breaking of the stud bolts, forces are released in axial direc-
tion, potentially leading to personal injury and material damage.
• It is prohibited to tighten / re-tighten the hex nuts with a higher torque
• The cup springs must be installed in the specified positions
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• The reference dimension (L) must not be undershot

Crankcase cover
Arrangement of cup springs

The correct arrangement of the cup springs is shown in fig. 5.
6. Determine the reference dimension (L) for each retaining bow (2). See Fig.
2.
48/60CR;48/60B, M010.020.030-01-0001 3 (8)

Undercutting of control dimension

If the control dimension is undercut, repeat the tightening operation,
replace cup springs (12) if necessary.
7. Install the resistance thermometer (6). See Fig. 1.
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Crankcase cover
4 (8) 48/60CR;48/60B, M010.020.030-01-0001

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Crankcase cover
2 Retaining bow 6 Resistance thermo- 10 Sealing ring

meter
3 Hex nut 7 Dowel pin 11 Bolt
4 Stud bolt 8 Cable
5 Crankcase cover 9 Cylinder crankcase
Figure 1: Crankcase cover with splash-oil temperature monitoring (illustration shows V-type engine)
48/60CR;48/60B, M010.020.030-01-0001 5 (8)

2 Retaining bow 9 Cylinder crankcase

3 Hex nut 12 Disc spring
4 Stud bolt 13 Sealing ring
5 Crankcase cover L Reference dimension
7 Dowel pin
Figure 2: Crankcase cover with splash-oil temperature monitoring
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Crankcase cover
6 (8) 48/60CR;48/60B, M010.020.030-01-0001

5 Crankcase cover B Position of the joint on sealing ring (13)

Figure 3: Crankcase cover – Position of the joint on sealing ring (illustration left: in-line engine / illustration
right: V-engine)
2 Retaining bow 12 Disc spring

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3 Hex nut 20 Washer

4 Stud bolt 21 Sleeve
Crankcase cover
Figure 4: Crankcase cover
48/60CR;48/60B, M010.020.030-01-0001 7 (8)

Figure 5: Fitting of the cup springs – illustration I - fitting CORRECT / illustration II - fitting WRONG
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Crankcase cover
8 (8) 48/60CR;48/60B, M010.020.030-01-0001

51353798283
1 (1)

Camshaft casing
Summary
Permit accessibility for work on the camshaft.
Remove camshaft covering.
fitting components.
Tools/aids required
1 Fitting and removal device 077.005 Option
1 Suspension gear 140.006 Standard
1 Sealing compound (Silicone Rhodorsil) - Inventory
Technical data
Covering Weight 238 kg
Work sequence 1 - Removal of camshaft covering

Preliminary remark Dismantling of the camshaft casing is not required for any maintenance work.
Initial situation Shut-off cocks closed, all relevant pipes drained. All piping and screwed fit-
tings obstructing the dismantling removed.
Rocker arm casing and parts of gallery removed. The cap of the camshaft
casing has been removed.

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Camshaft casing

L48/60CR, M010.020.050-01-0004 1 (6)

When dismantling, start on the free engine end!

When dismantling the camshaft coverings, start on the free engine
end.
Work steps 1. Suspend the suspension gear (140.006) by means of hook (12) and
shackle (002.453) to the installation and removal device (077.005), and
suspend the suspension gear from the lifting tackle.
2. Lift the installation and removal device (077.005), insert it over the stud
bolts (4) and fix it onto the camshaft casing (2) with hex nuts (13). See
Fig. 2.
3. Tighten the hex bolts (13) to the prescribed torque (60 Nm).
4. Tension the suspension gear slightly.
5. Unscrew the hex bolts (6, 7 and 8) and hex nuts (5).
Take care with washers and sleeves!

Take care with any washers and sleeves which may be present.
6. Remove the hex bolts (3).
Do not damage engine components

When removing, make sure that no engine parts lying around are dam-
aged.
7. Remove the camshaft casing (2) from the engine carefully and place it on
a suitable base. See Fig. 3.
8. Remove the installation and removal device (077.005) from the camshaft
casing (2).
9. Remove the remaining camshaft casings in the same way. See Work
Steps 1 to 8.
10.Clean the camshaft casings.
11.Check the sealing cord (14) for damage, remove the sealing cord if ne-
cessary and clean the grooves for the sealing cords.
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Work sequence 2 - Fitting camshaft covering

Camshaft casing
Initial situation Contact faces on camshaft casings and cylinder crankshaft cleaned.
When fitting start on the coupling side

When fitting the camshaft coverings start on the coupling side.
2 (6) L48/60CR, M010.020.050-01-0004

Installation is essentially carried out in reverse order to removal. In doing this,

observe the following Steps:
Work steps
Notes for sealing

Insert sealing cord (14) in groove without securing compound Silicone
Rhodorsil CAF50.
Apply securing compound Silicone Rhodorsil CAF50 bead-shaped.
Apply securing compound Silicone Rhodorsil CAF50 on covering joints
on both sides of the sealing cord, pass round screw holes and fill
pockets at the groove runouts.
Apply securing compound Silicone Rhodorsil CAF50 on sealing face on
cylinder crankcase within the screw connection rows. Apply securing
compound Silicone Rhodorsil CAF50 on contact surfaces only.
After fitting remove the excessive securing compound Silicone
Rhodorsil CAF50 in a wet condition. Do not scrape it out of the joint!
1. Apply securing compound Silicone Rhodorsil CAF50 on the contact faces

of the camshaft casing (2) and the cylinder crankcase as described in the
notes for sealing.
2. Fit the camshaft casing (2), loosely screw in/on the hex bolts (6, 7 and 8)
and hex nuts (5).
Do not forget washers and sleeves

Do not forget any washers and sleeves that may be required.
9007217426544011
3. Align the camshaft casing.

First tighten the hex nuts (5), then tighten the hex bolts (3).
4. Fit the remaining camshaft casings in the same way.
5. Fit all engine parts that were removed, connect the piping, open the shut-
off cocks, and bleed the pipes.
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Camshaft casing
L48/60CR, M010.020.050-01-0004 3 (6)

1 Cylinder crankcase 5 Hex nut 9 Lock washer

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2 Camshaft casing 6 Hex bolt 10 Sleeve

3 Hex bolt 7 Hex bolt 11 Camshaft casing
4 Stud bolt 8 Hex bolt
Camshaft casing
Figure 1: Camshaft casing fitted
4 (6) L48/60CR, M010.020.050-01-0004

1 Cylinder crankcase 4 Stud bolt 13 Hex nut

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2 Camshaft casing 12 Hooks

Figure 2: Camshaft casing with attached mounting device
Camshaft casing
L48/60CR, M010.020.050-01-0004 5 (6)

1 Cylinder crankcase 11 Camshaft casing 14 Sealing cord

2 Camshaft casing 12 Hooks
Figure 3: Removing/installing the camshaft casing
9007217426544011
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Camshaft casing
6 (6) L48/60CR, M010.020.050-01-0004

51353802507
1 (1)

Safety valve for crankcase

Summary
Execute work on time according to the maintenance schedule, ensure / re-
store operating reliability again.
Examine safety valves on crankcase covers at regular intervals for their easy
movement.
The work / work steps extend to:
Inspection of parts/ components,
Detaching and attaching parts/ components.
Safety requirements
l Engine stopped
Tools/aids required
1 Mounting device 073.002 Option
1 Shackle A0.6 002.452 Option
1 Rope - Inventory

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Technical data
Crankcase cover with safety valve Weight 74 kg
Safety valve Weight 35 kg
Reference dimension (L) Dimension 17,6 mm
General, M010.020.100-01-0011 1 (14)

Preliminary remark
The purpose of checking the ease of movement of all safety valves mounted
on the crankcase is to ensure that increases in pressure or pressure waves,
e.g. following an explosion, can be safely reduced.

Nm Nm Nm Nm
3 20 O
O Lube oil, clean
Work Sequence 1 - Checking the safety valves

Preliminary remark The following Work Steps describe the procedure for checking the safety
valves on an engine with clockwise rotation. For engines with anticlockwise
rotation, removal and fitting of the resistance thermometer (points 1 and 17) is
not required.
Explosion hazard
When opening the crankcase cover, hot components, oil mist gener-
ated in the crankcase and inflowing oxygen may form an explosive
mixture.
• Carry out any work on the engine only after a period of 20 minutes after
engine stop
Engine operation after an explosion in the crankcase

After an explosion in the crankcase, the functionality of relief valves is
no longer guaranteed. In case of further engine operation, this may
lead to severe personal injuries and damage to property.

• After an explosion in the crankcase, the relief valves must be renewed.
2018-12-12 - de
Work steps 1. Remove resistance thermometer (6). Put it safely to the side. See Fig. 1.
2. Unscrew and remove two hex bolts (17). See Fig. 3.
3. Place the mounting device (073.002) on the crankcase cover (5). Fix with
two hexagon head bolts (22). See Fig. 4.
4. Attach the rope (23) with shackle (002.452) to the mounting device. Sus-
pend it on the lifting tackle. Tension the rope slightly.
2 (14) General, M010.020.100-01-0011


5. Release hex nuts (3). Twist retaining bow (2). See Fig. 5.
6. Carefully remove the crankcase cover (5). See Figs. 6 and 7.
7. Check that safety valve (1) is in good condition and check it for ease of
movement; if necessary, detach it and replace with a new safety valve
(see Work Sequence 2).
8. Check valve plate (15), compression spring (16) and O-ring (14) for dam-
age, detach safety valve (1) if necessary, and replace it with a new safety
valve (see Work Sequence 2). See Fig. 11.
9. Check safety valve (1) according to the manufacturer's instructions and
replace if necessary. See Volume 010.005 Engine - Operating Manual,
chapter Engine attachments.
10.Check the sealing ring (13) for damage, replace it if necessary.
Fitting a new sealing ring

Before fitting a new sealing ring (13), clean the groove in the crankcase
cover (5). When fitting the sealing ring into the groove observe position
of joint (B) (joint behind plate). See Fig. 8.
11.Lubricate the thread of stud bolts (4) and contact area of hex nuts (3) with
clean lube oil.
12.Carefully place the crankcase cover (5 ) onto the dowel pins (7). Fit to cyl-
inder crankcase (9).
13.Turn back the retaining bows (2).
Studs fracture
2018-12-12 - de
In the event of incorrectly installed (= tightened with too high torque)

cup springs or hexagon nuts a fracture of the studs may occur. This
can lead to minor or moderate injuries.
• Hexagon nut must be tightened to the prescribed torque.
• Observe the correct position when installing new cup springs.
14.Tighten hexagon nuts (3) to the prescribed torque. See table “Values for
bolt tightening”.
General, M010.020.100-01-0011 3 (14)

Undercutting of control dimension

If the control dimension is undercut, repeat the tightening operation,
replace cup springs (12) if necessary.
15.Determine the reference dimension (L) for each retaining bow (2). See Fig.
2.
16.Detach the tool.
17.Insert two hexagon head bolts (17) plus new lock washers (18) through
the safety valve (1). Screw into crankcase cover (5). Tighten with max.
torque 44 Nm.
18.Install the resistance thermometer (6). See Fig. 1.
19.Check the remaining safety valves (1) in the same manner.
Work Sequence 2 - Detaching and attaching the safety valve

Initial situation Crankcase cover with safety valve removed and placed on a clean base.
Work steps 1. Remove mounting device (073.002).
2. Unscrew and remove hexagon bolts (17) and safety valve (1) from the
crankcase cover (5).
3. Remove seal (19).
4. Mount a new seal (19).
5. Check the new safety valve (1) for ease of movement.
6. Attach the new safety valve (1) to the crankcase cover (5), insert the
hexagon bolts (17) plus new lock washers (18) through the safety valve,
screw them into the crankcase cover and tighten them with max. torque
44 Nm
7. Fit mounting device (073.002) to crankcase cover (5) and fix with two
hexagon head bolts (22).
2018-12-12 - de
4 (14) General, M010.020.100-01-0011


2018-12-12 - de
1 Safety valve 5 Crankcase cover 9 Cylinder crankcase

2 Retaining bow 6 Resistance thermo- 10 Sealing ring
meter
3 Hex nut 7 Dowel pin 11 Bolt
4 Stud bolt 8 Cable
Figure 1: Crankcase cover with attached safety valve and splash-oil temperature monitoring
General, M010.020.100-01-0011 5 (14)

1 Safety valve 7 Dowel pin

2 Retaining bow 9 Cylinder crankcase
3 Hex nut 12 Cup spring
4 Stud bolt 13 Sealing ring
5 Crankcase cover L Control length
Figure 2: Crankcase cover with attached safety valve and splash-oil temperat-
ure monitoring
2018-12-12 - de
6 (14) General, M010.020.100-01-0011

1 Safety valve 5 Crankcase cover 9 Cylinder crankcase

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2 Retaining bow 6 Resistance thermo- 17 Hex bolt

meter
3 Hex nut 7 Dowel pin 18 Lock washer
4 Stud bolt 8 Cable
Figure 3: Crankcase cover with attached safety valve – Removal/Fitting
General, M010.020.100-01-0011 7 (14)

1 Safety valve 5 Crankcase cover 22 Hex bolt

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8 (14) General, M010.020.100-01-0011

2 Retaining bow 4 Stud bolt 9 Cylinder crankcase

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3 Hex nut 7 Dowel pin 23 Rope

General, M010.020.100-01-0011 9 (14)

1 Safety valve 4 Stud bolt 23 Rope

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2 Retaining bow 5 Crankcase cover

3 Hex nut 7 Dowel pin
10 (14) General, M010.020.100-01-0011

1 Safety valve 4 Stud bolt 9 Cylinder crankcase

2018-12-12 - de
2 Retaining bow 5 Crankcase cover 13 Sealing rings

3 Hex nut 7 Dowel pin 23 Rope
General, M010.020.100-01-0011 11 (14)

5 Crankcase cover B Position of the joint on

sealing ring (13)
Figure 8: Crankcase cover – Position of the sealing ring joint
2 Retaining bow 12 Cup spring

3 Hex nut 20 Washer

4 Stud bolt 21 Sleeve
2018-12-12 - de
Figure 9: Crankcase cover
12 (14) General, M010.020.100-01-0011

Figure 10: Fitting of the cup springs – illustration I - fitting CORRECT / illustration II - fitting WRONG
9007217274914315
2018-12-12 - de
General, M010.020.100-01-0011 13 (14)

5 Crankcase cover
14 O-ring
15 Valve plate
16 Compression spring
17 Hex bolt
18 Lock washer
19 Seal
Figure 11: Crankcase cover with attached safety valve
9007217274914315
2018-12-12 - de
14 (14) General, M010.020.100-01-0011


010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas
010.030 Drive train
51353806475
1 (1)

010.030 Drive train
51353810699
1 (1)

Counterweight bolts
inspecting
Summary
Balance weight screws must be checked at regular intervals using hydraulic
tensioners.
Safety requirements
l Engine stopped
l Access shaft secured so it cannot turn
Tools/aids required


Item Hydraulic tightening procedure Note
Oil pressure Set the dial Expansion Resetting
2020-12-14 - de
gauge to ‘0’ min. max. when loosen-

Counterweight bolts
for oil pres- ing

sure
bar bar mm mm °/l
1 800 50 0.5 0.7
2 210°/7l Hydraulic tensioner

(009.631)
L48/60CR, M010.030.010-01-0009 1 (5)

Work Sequence - Checking the counterweight bolts

pressure hoses.
Initial situation Crankcase has been opened, the running gear has been turned in such a way
that the balance weight bolts are easily accessible (balance weight is pointing
towards the crankcase opening). See Fig. 1.
Work steps 1. Clean the threads of the balance weight bolts (1).
3. Screw the hydraulic tensioners (009.631) onto the balance weight
4. Turn the hydraulic tensioners back by the turn-back angle. See table ‘Val-
ues for bolt tightening’.
structions 015.000.002-01.
sioners.
18014416670757771
2020-12-14 - de
a maximum of 5% above the tensioning pressure. See table ‘Values for

Counterweight bolts
bolt tightening’ and Work Instructions 015.000.001-01.

table ‘Values for bolt tightening’.
9. Tighten both nuts (2) by hand through the cut-out in the thrust pieces us-
2 (5) L48/60CR, M010.030.010-01-0009

1 Balance weight bolt 3 Balance weight

2 Nut 4 Crankshaft
Figure 1: Balance weight
2020-12-14 - de
Counterweight bolts
L48/60CR, M010.030.010-01-0009 3 (5)


Figure 2: Balance weight bolts with installed hydraulic tensioners
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Counterweight bolts
4 (5) L48/60CR, M010.030.010-01-0009


2 Nut
Figure 3: Balance weight bolt with fitted hydraulic tensioner
18014416670757771
2020-12-14 - de
Counterweight bolts
L48/60CR, M010.030.010-01-0009 5 (5)

18014416670757771
2020-12-14 - de
Counterweight bolts
L48/60CR, M010.030.010-01-0009
Counterweight
Summary
Ensure correct execution of work, enable emergency operation.
Dismantling a balance weight is not customary maintenance work. This is ne-
cessary only in special cases, e.g. emergency operation of the engine with
dismantled running gear.
removing components,
installing components.
Safety requirements
l Engine stopped
Tools/aids required
1 Bolt extractor 014.015 Standard
1 Extension piece 25x400 001.916 Standard
1 Open-jaw wrench and ring spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory
2019-05-13 - de

Counterweight

Work and safety instructions when turning the running gear 010.000.004-05
Checking counterweight bolts 010.030.010-01
L51/60DF;L48/60CR, M010.030.010-02-0016 1 (9)

Technical data
Counterweight Weight 317 kg

Tightening 1st stage 2nd stage 3rd + 4th Lubricant/
Nm Nm Nm Nm
1 Hand-tight M
M Lubricating paste ≤ 200 °C (e.g. Molykote-Paste G-N, Optimol-Paste White-T)
Work sequence 1 - Removing the balance weight
Removal and installation of the counterweight

We strongly recommend having the removal and installation of a coun-
terweight carried out by MAN Energy Solutions personnel or at an MAN
Energy Solutions support centre.
Initial situation
Risk to life while working in the crankcase!

During all work in the crankcase, there is a risk to life as a result of the
engine being started and rotating/turning of the running gear.
• Fix an instruction plate to operating devices
• Observe working and safety instructions
2019-05-13 - de

Counterweight
Crankcase has been opened, the running gear has been turned in such a way
that the counterweight bolts are easily accessible (counterweight is pointing
Work steps 1. Insert the foot board (011.007 for a normal oil sump or 111.003 for a V oil
sump) in the oil sump (8 and 9).
2. Release the counterweight bolts (1) for the relevant counterweight (3).
2 (9) L51/60DF;L48/60CR, M010.030.010-02-0016

3. Unscrew one nut (2) by half a revolution but do not remove.

5. Screw the bolt extractor (014.015) onto the counterweight bolt (1).
Observe the projection

Observe the projection (A) between the bolt extractor and the counter-
weight bolt. See Fig. 2.

8. Loosen the counterweight bolt (1) but do not remove.
9. Tighten the nut (2) hand-tight again until it makes contact with the
Tommy bar (000.262), remove the bolt extractor.
10.Loosen the second counterweight bolt (1) in the same manner. See
Steps 3 to 9.
Danger to life during the turning process

Remaining in the crankcase during the turning process poses a danger
to life.
• do not work in the crankcase during turning operation
• cover any opened crankcase windows
• prior to the start of the turning operation, watch out for acoustic and
optical signals
11.Turn the running gear over carefully until the counterweight (3) points
downwards. See Fig. 3.
12.Screw the lifting eye bolts (000.143) into the side of the counterweight (3),
fasten the ropes (5) with a shackle (002.453) to the lifting eye bolts and
suspend on a lifting tackle. Tension the ropes.
13.Unscrew both nuts (2).
14.Unscrew the counterweight bolts (1).
2019-05-13 - de

Counterweight

15.Lower the counterweight (3) evenly until clamping sleeve (7) and bolt (6)
become free.
L51/60DF;L48/60CR, M010.030.010-02-0016 3 (9)

Observe the position of the clamping sleeve and the bolt

Ensure that the clamping sleeve and the pin stick in the counterweight
and do not remain in the crankshaft web.
16.Pull the counterweight (3) carefully out of the crankcase by alternatively

slackening and tightening the ropes (5). See Fig. 5.
17.Place the counterweight (3) on a supporting surface and remove the tool.
18.Clean the individual parts.
Work sequence 2 - Fitting the balance weight

Initial situation All individual parts are cleaned, the foot board is inserted into the oil sump.
Work steps 1. Clean the joint face on the crankshaft web.
2. Screw the lifting eye bolts (000.143) into the side of counterweight (3) and
fasten the ropes (5) with the shackle (002.453) to the lifting eye bolts.
3. Guide a rope (5) through the crankcase. Suspend the rope from the lifting
tackle.

Position of clamping sleeve

Ensure that the clamping sleeve (7) is in the correct position. See Fig.
3.
4. Move the counterweight (3) carefully into the crankcase by alternately

slackening and tightening the ropes (5). See Fig. 5.
2019-05-13 - de
5. Lift the counterweight (3) evenly until the counterweight makes contact
with the crankshaft web. Ensure that the clamping sleeve (7) and bolt (6)
align with the holes.
6. Apply MoS2 lubricant to the threads of counterweight bolts (1) and screw
Counterweight
them in by hand until they make contact.

7. Screw on the nuts (2) hand-tight until they make contact with the coun-
terweight bolts (1).
8. Remove the tool.
4 (9) L51/60DF;L48/60CR, M010.030.010-02-0016


to life.
optical signals
9. Turn the running gear over carefully until the counterweight bolts (1) are
easily accessible (counterweight (3) points to crankcase opening). See
Fig. 1.
10.Screw backwards one nut (2) by half a revolution; do not unscrew it.
11.Check that the hex nuts (10) on the bolt extractor (014.015) are released.
12.Screw the bolt extractor (014.015) onto the counterweight bolt (1).
Observe the projection

Observe the projection (A) between the bolt extractor and the counter-
weight bolt. See Fig. 2.
27021624176275979
13.Tighten the hex nuts (10).

14.Screw the counterweight bolt (1) by hand into the crankshaft until contact
is made. See table “Values for bolt tightening”.
15.Tighten the nut (2) with the tommy bar (000.262) hand-tight until contact
is made; remove the bolt extractor.
16.Install the second counterweight bolt (1) in the same manner. See points
10 to 15.
17.Tension the counterweight bolts (1). See Work Instructions
010.030.010-01
18.Remove the foot board from the oil sump (8 or 9).
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Counterweight
L51/60DF;L48/60CR, M010.030.010-02-0016 5 (9)

1 Counterweight bolt 3 Counterweight

2 Nut 4 Crankshaft
Figure 1: Counterweight attached
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Counterweight
6 (9) L51/60DF;L48/60CR, M010.030.010-02-0016

1 Counterweight bolt 10 Hex nut M10

2 Nut A Protrusion (Bolt extractor - counterweight
bolt)
3 Counterweight
Figure 2: Installing the bolt extractor to the counterweight bolt
2019-05-13 - de
Counterweight
L51/60DF;L48/60CR, M010.030.010-02-0016 7 (9)

1 Counterweight bolt 4 Crankshaft 7 Clamping sleeve

2 Nut 5 Rope
3 Counterweight 6 Bolts
Figure 3: Removing/installing the counterweight bolt
2019-05-13 - de
Counterweight
8 (9) L51/60DF;L48/60CR, M010.030.010-02-0016

Figure 4: Removing/installing the counterweight

2019-05-13 - de
Counterweight
Figure 5: Removing/installing the counterweight

27021624176275979
L51/60DF;L48/60CR, M010.030.010-02-0016 9 (9)

27021624176275979
2019-05-13 - de
Counterweight
L51/60DF;L48/60CR, M010.030.010-02-0016
Coupling bolts
inspection
Summary
Coupling bolts must be checked at regular intervals using hydraulic tension-
ers.
Safety requirements
l Engine stopped
Tools/aids required

Removing and fitting casing on coupling side 010.020.010-01
2021-01-26 - de

Coupling bolts
Technical data
48/60CR, M010.030.010-03-0009 1 (6)

Work sequence - Controlling the coupling bolts

pressure hoses.
Initial situation Coupling and centring ring are removed. See Volume 020 Connecting ele-
ments – 020.010 Coupling arrangement. Coupling bolts are accessible and
flywheel fastened to the crankshaft by means of four hexagon socket bolts.
See Fig. 1.
Work steps 1. Remove oil pipe (3) and casing (5). See Work Instructions
010.020.010-01.
2. Clean the threads of coupling bolts (7 and 14).
3. Insert thrust pieces (055.241) over two opposing nuts (6). See Figs. 2 and
3.
4. Screw the hydraulic tensioners (009.632) onto both coupling bolts (7 or
14). In doing so, ensure that the thrust pieces are centrally aligned by the
hydraulic tensioners.
5. Turn the hydraulic tensioners back by the turn-back angle. See Volume
000 of the plant information documentation - 000.100 System docu-
ments - Arrangement drawing of flywheel
structions 015.000.002-01.
sioners.
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Coupling bolts

a maximum of 5% above the tensioning pressure. See Volume 000 of the
plant information documentation - 000.100 System documents - Ar-
rangement drawing of flywheel and Work Instructions 015.000.001-01.
Volume 000 of the plant information documentation - 000.100 System
documents - Arrangement drawing of flywheel
2 (6) 48/60CR, M010.030.010-03-0009

12.Disconnect the high-pressure hoses from the hydraulic tensioners.
14.Place the thrust pieces over the nuts (6) of the next opposing pair of
bolts.
15.Screw the hydraulic tensioners onto both coupling bolts (7 and 14). In
draulic tensioners.
16.Turn the hydraulic tensioners back by the turn-back angle. See Volume
17.Connect high-pressure hoses to the hydraulic tensioners and secure. See
sioners.
Volume 000 of the plant information documentation - 000.100 System
documents - Arrangement drawing of flywheel
21.Tighten both nuts (6) through the cut-out in the thrust pieces using a
23.Repeat the process (work steps 12 to 22) in the same way until all coup-
ling bolts (7 and 14) have been checked.
26.Fit the casing (5) and oil pipe (3). See Work Instructions 010.020.010-01.
2021-01-26 - de
27.Coat the threads and the contact surfaces of the bolts (11) with lubricat-
ing oil.
28.Screw in the bolts (11) until hand-tight and tighten to the specified
torque. See Volume 000 Plant information – 000.100 System documents
Coupling bolts
– Flywheel arrangement drawing and coupling installation.

29.Attach the coupling (13). See Volume 020 Connecting elements –
020.010 Coupling arrangement.
48/60CR, M010.030.010-03-0009 3 (6)

1 Hexagon socket bolt 6 Nut **11 Screw

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2 Covering 7 Coupling bolt (fitting 12 Washer

bolt)
3 Oil pipe 8 Nut *13 Coupling
4 Crankshaft *9 Flywheel 14 Coupling bolt
Coupling bolts
5 Covering 10 Centring ring A Bolt projection

Figure 1: Connection between crankshaft, flywheel, centring ring and coupling
4 (6) 48/60CR, M010.030.010-03-0009

4 Crankshaft *9 Flywheel
7 Coupling bolt (fitting bolt) 14 Coupling bolt
8 Nut
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Figure 2: Coupling bolts with attached hydraulic tensioners

Coupling bolts
48/60CR, M010.030.010-03-0009 5 (6)

4 Crankshaft 7 Coupling bolt (fitting bolt)

6 Nut 14 Coupling bolt
Figure 3: Coupling bolt with attached hydraulic tensioner
* Shape and size of the coupling and of the flywheel may differ from the rep-
resentation in the illustrations.
** Shape, size and type of the threaded connection between coupling and fly-
wheel may differ from the representation in the illustrations. The illustration
shows the type with hex bolts and washers.
27021615758050955
2021-01-26 - de
Coupling bolts
6 (6) 48/60CR, M010.030.010-03-0009

Coupling bolts
Summary
For servicing work, coupling screws must be released and tensioned again
using hydraulic tensioners.
Safety requirements
l Engine stopped
Tools/aids required

Removing and fitting casing on coupling side 010.020.010-01
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Coupling bolts
Technical data
48/60CR, M010.030.010-04-0005 1 (7)

Work Sequence 1 – Releasing the coupling bolts

Initial situation Coupling and centring ring are removed. See Volume 020 Connecting ele-
ments – 020.010 Coupling arrangement. Coupling bolts are accessible and
flywheel fastened to the crankshaft by means of four hexagon socket bolts.
See Fig. 1.
Work steps 1. Remove oil pipe (3) and casing (5). See Work Instructions
010.020.010-01.
2. Clean the threads of coupling bolts (7 and 14).
3.
5. Turn the hydraulic tensioners back by the turn-back angle. See Volume
structions 015.000.002-01.
sioners.
angle through the cut-out in the thrust pieces. See Volume 000 of the
rangement drawing of flywheel
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Coupling bolts
bolts.
draulic tensioners.
2 (7) 48/60CR, M010.030.010-04-0005

15.Turn the hydraulic tensioners back by the turn-back angle. See Volume
sioners.
19.Using a tommy bar, turn both nuts (6) back by the turning-back angle
through the cut-out in the thrust pieces. See Volume 000 of the plant in-
formation documentation - 000.100 System documents - Arrangement
drawing of flywheel
ling bolts (7 and 14) have been released.
Work Sequence 2 – Tensioning of the coupling bolts

Initial situation Flywheel fastened to the crankshaft with four hexagon socket bolts, coupling
bolts cleaned and inserted in bores. See Fig. 1.
Nuts are hand tightened until the stop. Threads of the coupling bolts have
been cleaned.
Work steps 1. Check the bolt projection (A) of the coupling bolts (7 and 14). See Tech-
nical Data.
2021-01-26 - de
3.
Coupling bolts
structions 015.000.002-01.
sioners.
48/60CR, M010.030.010-04-0005 3 (7)

5. Put the high-pressure pump into operation, and tighten the coupling
bolts (7 and 14) to the prescribed tensioning pressure. See Volume 000
of the plant information documentation - 000.100 System documents -
Arrangement drawing of flywheel and Work Instructions 015.000.003-01.
6. Tighten both nuts (6) by hand through the cut-out in the thrust pieces us-
8. Disconnect the high-pressure hoses from the hydraulic tensioners.
9. Remove the hydraulic tensioners and thrust pieces.
bolts.
draulic tensioners.
sioners.
13.Put the high-pressure pump into operation, and tighten the coupling
bolts (7 and 14) to the prescribed tensioning pressure. See Volume 000
of the plant information documentation - 000.100 System documents -
Arrangement drawing of flywheel and Work Instructions 015.000.003-01.
ling bolts (7 and 14) have been tensioned.
19.Fit the casing (5) and oil pipe (3). See Work Instructions 010.020.010-01.
20.Coat the threads and the contact surfaces of the bolts (11) with lubricat-
ing oil.
21.Screw in the bolts (11) until hand-tight and tighten to the specified
torque. See Volume 000 Plant information – 000.100 System documents
– flywheel arrangement drawing and coupling installation.
22.Attach the coupling (13). See Volume 020 Connecting elements –
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020.010 Coupling arrangement.

Coupling bolts
4 (7) 48/60CR, M010.030.010-04-0005

1 Hexagon socket bolt 6 Nut **11 Screw

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2 Covering 7 Coupling bolt (fitting 12 Washer

bolt)
3 Oil pipe 8 Nut *13 Coupling
4 Crankshaft *9 Flywheel 14 Coupling bolt
Coupling bolts
5 Covering 10 Centring ring A Bolt projection

Figure 1: Connection between crankshaft, flywheel, centring ring and coupling
48/60CR, M010.030.010-04-0005 5 (7)

4 Crankshaft *9 Flywheel
7 Coupling bolt (fitting bolt) 14 Coupling bolt
8 Nut
2021-01-26 - de
Figure 2: Coupling bolts with attached hydraulic tensioners

Coupling bolts
6 (7) 48/60CR, M010.030.010-04-0005

4 Crankshaft 7 Coupling bolt (fitting bolt)

6 Nut 14 Coupling bolt
Figure 3: Coupling bolt with attached hydraulic tensioner
* Shape and size of the coupling and of the flywheel may differ from the rep-
resentation in the illustrations.
** Shape, size and type of the threaded connection between coupling and fly-
wheel may differ from the representation in the illustrations. The illustration
shows the type with hex bolts and washers.
27021615758055307
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Coupling bolts
48/60CR, M010.030.010-04-0005 7 (7)

27021615758055307
2021-01-26 - de
Coupling bolts
48/60CR, M010.030.010-04-0005
Crankshaft oil bore

closing
Summary
If the engine has to continue to run in an emergency despite a removed run-
ning gear (piston with connecting rod), the oil bores of the respective crank
pin are to be closed.
proper assembly
and if necessary
disassembly.
Safety requirements
l Engine stopped
Tools/aids required
1 Locking device 020.045 Standard
1 Threaded rod 020.045-1 Standard
2 Sealing plug 020.045-2 Standard

Disconnecting and connecting the cabling on high pressure 010.110.054-14
pump and Common-Rail accumulator unit
2016-10-11 - de
Preliminary remarks
Crankshaft oil bore
It may be necessary in an emergency to continue running the engine despite a

removed running gear (piston and connecting rod). In order to sustain the oil
circuit, and ensure the lubrication of other engine parts, the oil bore in the
crank pin must be closed.
48/60CR, M010.030.010-05-0006 1 (4)

Observe additional notes

It is only in an emergency that the engine should continue to run when
the running gear is removed and only if the performance and speed is
reduced. See comprehensive illustration in 010.005 Engine Operating
Manual 010.000.026-02.
Work sequence 1 - Closing the oil drain hole

Initial situation Piston with connecting rod, connecting rod bearing and push rods dis-
mantled.
Work steps 1. Insert new O-rings (5) lubricated with clean lubricating oil in the O-ring
grooves of the sealing plug (020.45-2). In doing so, make sure that O-
rings are tensioned along their entire circumference and are not twisted.
2. Fit he first sealing plug (020.045-2) on the threaded rod (020.045-1). See
Fig. 1.
3. Insert the threaded rod (020.045-1) with the sealing plug (020.045-2) into
the oil bore (2) on the crank pin (1).
Brace the threaded rod

When tightening or loosening the castle nut (3), brace the threaded rod
with an open-jaw spanner on the hex nut.
4. Fit a second sealing plug on the threaded rod, screw on the castle nut (3)
and tighten.
5. Secure the castle nut (3) with the cotter pin (4). See Fig. 1.
Note for V engine

Close the second oil bore in the crank pin in the same way. See Steps
1 to 5.
6. Install the complete cylinder head, do not insert the push rods. Shut
down the exhaust and inlet rocker arms (fix them at the outside of the
2016-10-11 - de
cam range), and close the lubricating bores.

Crankshaft oil bore
7. Disconnect the cabling of the corresponding valve group on the next ter-
minal box. See Work Instructions 010.110.054-14.
8. Close the oil pipe to the rocker arm lubrication.
Work sequence 2 - Removal of locking device on oil drain hole

Initial situation Crankcase cover opened.
Work steps Removal of the locking device is carried out in reverse order to installation, ob-
serving the following Steps:
2 (4) 48/60CR, M010.030.010-05-0006

Brace the threaded rod

When tightening or loosening the castle nut (3), brace the threaded rod
with an open-jaw spanner on the hex nut.
1. Remove the cotter pin (4) and unscrew the crown nuts (3). See Fig. 1.
2. Push the threaded rod (020.045-1) back into the oil bore (2), remove the
plug (020.045-2) from the threaded rod and remove the threaded rod
from the oil bore.
3. Remove the second sealing plug from the threaded rod.
Note for V engine

Remove the second locking device of the crank pins in the same way.
See Steps 1 to 3.
17994534027
2016-10-11 - de
Crankshaft oil bore
48/60CR, M010.030.010-05-0006 3 (4)

1 Crankshaft/crank pin 4 Cotter pin

2 Oil bore 5 O-ring
3 Castle nut M10
Figure 1: Crankshaft – Closing the oil bore (the illustration shows the in-line
engine L48/60)
17994534027
2016-10-11 - de
Crankshaft oil bore
4 (4) 48/60CR, M010.030.010-05-0006

Crankshaft gearwheel bolts

inspection
Summary
Crankshaft bearing bolts must be checked at regular intervals using hydraulic
tensioners.
Safety requirements
l Engine stopped
Tools/aids required
2 Tension bolt 020.063 Standard
1 Sliding calliper - Inventory

2021-01-27 - de

48/60CR, M010.030.010-06-0004 1 (7)

Work sequence – Inspection of crankshaft gearwheel bolts

pressure hoses.
Initial situation Casing cover on control drive removed. Running gear turned so as to allow
hydraulic tensioners to be screwed on to crankshaft gear wheel bolts.
Work steps Standard oil pan V oil pan
L 48/60 CR 011.007 011.003
V 48/60 CR 011.009 011.010
27021615758218507
1. Insert the foot board (tool number given above) in the oil pan.
2. Clean the threads of crankshaft gearwheel bolts (8).
3. Screw in the tension screws (020.063) until they are in contact with the
crankshaft gearwheel bolts (8) at bolt positions 1 and 2. See Figs. 2 and
4.
4. Fit the thrust pieces (020.062) over the tension screws and the nuts (6).
5. Screw the hydraulic tensioners (009.631) onto the tension screws.
structions 010.000.003-05.
structions 015.000.002-01.
2021-01-27 - de
sioners.
010.000.003-05 and 015.000.001-01.
2 (7) 48/60CR, M010.030.010-06-0004

14.Remove the hydraulic tensioners, thrust pieces and tension screws.
15.Screw in the tension screws until they abut on the crankshaft gearwheel
bolts (8) at bolt positions 3 and 4. See Figs. 3 and 4.
16.Place the thrust pieces over the tension screws and nuts (6).
17.Screw the hydraulic tensioners onto the tension screws.
structions 010.000.003-05.
sioners.
010.000.003-05 and 015.000.001-01.
26.Remove the hydraulic tensioners, thrust pieces and tension screws.
27.Remove the foot board from the oil pan.
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48/60CR, M010.030.010-06-0004 3 (7)

1-4 Bolt position/ 6 Nut 8 Crankshaft gearwheel

tightening sequence bolt
5 Crankshaft gear wheel 7 Crankshaft
Figure 1: Crankshaft gearwheel *

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4 (7) 48/60CR, M010.030.010-06-0004

1-4 Bolt position/ 5 Crankshaft gear wheel 8 Crankshaft gearwheel

Figure 2: Crankshaft gearwheel bolts with attached hydraulic tensioners – the illustration shows the ar-
rangement for bolt positions 1-2 *
2021-01-27 - de
48/60CR, M010.030.010-06-0004 5 (7)


2021-01-27 - de
6 (7) 48/60CR, M010.030.010-06-0004

5 Crankshaft gear wheel 8 Crankshaft gearwheel bolt

6 Nut
Figure 4: Crankshaft gearwheel bolt with attached hydraulic tensioner
* Illustration in the figures shows V engine 48/60.

27021615758218507

2021-01-27 - de
48/60CR, M010.030.010-06-0004 7 (7)

27021615758218507
2021-01-27 - de
48/60CR, M010.030.010-06-0004

Summary
For maintenance work, crankshaft gearwheel bolts must be released and ten-
sioned using hydraulic tensioners.
Safety requirements
l Engine stopped
Tools/aids required
2 Tension bolt 020.063 Standard

2021-01-13 - de

48/60CR, M010.030.010-07-0004 1 (9)

Warning message

pressure hoses.
Preliminary remark
We recommend having the control drive overhaul carried out at a service
branch or by MAN Energy Solutions personnel.
Work sequence 1 – Release crankshaft gearwheel bolts

Initial situation Casing cover on control drive removed. Running gear turned so as to allow
hydraulic tensioners to be screwed on to crankshaft gear wheel bolts.
Work steps Normal oil pan V oil pan
L 48/60 CR 011.007 011.003
V 48/60 CR 011.009 011.010
1. Insert the foot board (tool number given above) in the oil pan.
2. Clean the threads of crankshaft gearwheel bolts (8).
3. Screw the tension bolts (020.063) in until they abut on the crankshaft
gearwheel bolts (8) at bolt positions 1 and 2. See Figures 2 and 4.
4. Fit the thrust pieces (020.062) over the tension bolts and the nuts (6).
5. Screw the hydraulic tensioners (009.631) onto the tension bolts.
2021-01-13 - de
structions 010.000.003-05.
structions 015.000.002-01.
sioners.
2 (9) 48/60CR, M010.030.010-07-0004

010.000.003-05 and 015.000.001-01.
10.Using a tommy bar (000.263), turn both nuts (6) back by the turning-back
010.000.003-05.
13.Remove the hydraulic tensioners, thrust pieces and tension bolts.
14.Screw the tension bolts in until they abut on the crankshaft gearwheel
bolts (8) at bolt positions 3 and 4. See Figures 3 and 4.
15.Place the thrust pieces over the tension bolts and nuts (6).
16.Screw the hydraulic tensioners onto the tension bolts.
structions 010.000.003-05.
sioners.
010.000.003-05 and 015.000.001-01.
21.Using a tommy bar, turn both nuts (6) back by the turning-back angle
through the cut-out in the thrust pieces. See Work Instructions
010.000.003-05.

2021-01-13 - de
Work sequence 2 – Tensioning crankshaft gearwheel bolts

Initial situation Foot board inserted in oil pan. Nuts screwed on and tightened by hand.
Crankshaft gearwheel bolt threads cleaned.
Work steps 1. Measure the length of crankshaft gearwheel bolts (8) and note it down.
48/60CR, M010.030.010-07-0004 3 (9)

2. Screw the tension bolts (020.063) in until they abut on the crankshaft
gearwheel bolts (8) at bolt positions 1 and 2. See Figures 2 and 4.
4. Screw the hydraulic tensioners (009.631) onto the tension bolts.
tions 015.000.002-01.
sioners.
6. Start the high-pressure pump and tighten the crankshaft gearwheel bolts
(8) to the specified pre-tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.003-01.
7. Tighten both nuts (6) through the cut-out in the thrust pieces using the
9. Disconnect the high-pressure hoses from the hydraulic tensioners.
sioners.
15.Start up the high-pressure pump, and tighten the crankshaft gearwheel
bolts (8) to the prescribed tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.003-01.
16.Tighten both nuts (6) through the opening in the thrust pieces using a
2021-01-13 - de

sioners.
24.Start up the high-pressure pump, and tighten the crankshaft gearwheel
bolts (8) to the prescribed tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.003-01.
25.Tighten both nuts (6) through the opening in the thrust pieces using a
4 (9) 48/60CR, M010.030.010-07-0004


29.Measure the length of crankshaft gearwheel bolts (8) and note it down.
30.Determine the difference (screw elongation Δl) of the individual crankshaft
gearwheel bolts (8) based on the measurements from work steps 1 and
29.
31.Compare the bolt elongation Δl of the individual crankshaft gearwheel
bolts (8) with the setpoint. The measurement of the bolt elongation Δl
serves only as a check. See Work Instructions 010.000.003-05.

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48/60CR, M010.030.010-07-0004 5 (9)

1-4 Bolt position/ 6 Nut 8 Crankshaft gearwheel

5 Crankshaft gear wheel 7 Crankshaft
Figure 1: Crankshaft gearwheel *

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6 (9) 48/60CR, M010.030.010-07-0004


2021-01-13 - de
48/60CR, M010.030.010-07-0004 7 (9)


2021-01-13 - de
8 (9) 48/60CR, M010.030.010-07-0004

5 Crankshaft gear wheel 8 Crankshaft gearwheel bolt

6 Nut
Figure 4: Crankshaft gearwheel bolt with attached hydraulic tensioner
* Illustration in the figures shows V engine 48/60.

18014416503481867

2021-01-13 - de
48/60CR, M010.030.010-07-0004 9 (9)

18014416503481867
2021-01-13 - de
48/60CR, M010.030.010-07-0004
Crankshaft flange position in relation to the driven flange

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

Preliminary remarks
Crankshaft flange position in relation to the driven flange

The flange of the crankshaft, i.e. ultimately the engine, must show certain axial
offsets in the cold state, with respect to the driven flange so that influencing
factors are compensated for under operating conditions. Such factors are:
▪ thermal expansion of the foundations,
▪ thermal expansion of the engine, generator or the gear,
▪ thermal expansion of the rubber elements in the case of resilient mount-
ing,
▪ the settling behaviour of the resilient mounting and
▪ shaft disalignment under pressure.
2016-12-15 - de
The position of both flanges is to be measured on the original equipment and

checked subsequently at regular intervals in accordance with the mainten-
ance schedule.
Deviations from flywheel alignment diagram

If required, a special manual can be prepared for certain propulsion
systems, in which the necessary alignment measurements are given.
These can vary from those in the flywheel alignment diagram.
General, M010.030.010-11-0001 1 (4)

1 Driven shaft flange C Reference mounting di- G Shaft axis

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

Initial situation The crank web deflection is in accordance with the specifications. See Work
Prerequisites/measuring In order to ascertain the exact alignment during assembly, it is necessary to
procedure make a measuring clamp with two dial gauges to be fastened to the flywheel.
One dial gauge records the radial axle misalignment (A) for the vertical and ho-
rizontal deviations, and the other gauge measures the plane parallelism or the
flange divergence (B). The measuring bracket can be used for subsequent
checks, as required in resiliently mounted engines in particular.
The axial distance (E) is measured using a micrometer from the flange of the
crankshaft to the flange of the driven shaft, the reference dimension is meas-
ured (C) from the flywheel to the flange of the driven shaft. The distance
between the engine and the driven flange and the fitting dimension (C) of the
flexible coupling is adjusted / checked with the pretension possibly required.
2016-12-15 - de
Emergency lubrication
The engine bearings must, if required, be provided with emergency

lubrication during rotation of the crankshaft for alignment.
The measured values are to be noted and recorded on a printed form (see the
suggestion on the following page). During this process, the original measured
values are to be compared with the calculated setpoint values, or with empir-
2 (4) General, M010.030.010-11-0001

ical values. If necessary, the alignment must be corrected again. Later com-
parison of the values allows conclusions to be drawn concerning time se-
quencing, the scope and possible causes for changes.
2016-12-15 - de
General, M010.030.010-11-0001 3 (4)

2016-12-15 - de
18014400491883147
4 (4) General, M010.030.010-11-0001

Crankshaft web clearance

measuring (mechanical)
Summary
Check alignment, detect problems (having an influence) on components/sys-
tems, ensure/restore operational safety.
The web deflection indicates the alignment of the crankshaft bearing and the
bearing/alignment of the driven shaft. Web deflection must be checked in reg-
ular intervals.
The work includes:
checking the alignment,
recording measured values and
evaluation of results.
Safety requirements
l Engine stopped
Personnel and time required

1 Assistant Personnel 0,15
Tools/aids required
1 Guide tube 021.032 Standard
1 Web deflection measurement unit (mechanical) 008.171 Option
1 Thickness gauges 0.05-0.4 000.454 Standard
1 Felt-tip pen/marker pen - Inventory
Preliminary remark
2019-12-02 - de
Crank web deflection is the difference in the measured values between two
crank web positions offset by 180º. Crank web deflection indicates the align-
ment of the main bearings and the bearing of the driven shaft. If the measured
values (Table 2 and 3) exceed the maximum values (Table 4) allowed, the
cause should be eliminated and the crankshaft realigned. Possible causes
are:
▪ Unequal wear on crankshaft bearing,
▪ Changes of the position of the driven shaft or
▪ Changes in the fixing of the engine on the foundations or of the founda-
tion.
General, M010.030.010-12-0001 1 (9)

The results of the crank web deflection measurement are correlated with the
check of the alignment of the crankshaft flange to the driven shaft.
Work sequence 1 - Measuring the crank web deflection

The dial gauge is to be read at the RBDC and LBDC positions if the connect-
ing rod is retrofitted. If the connecting rod is removed then it is to be read in
the BDC position.
The position of the crank pin is decisive for the designation, not that of the
web-deflection measuring device.
For a clear designation of the sides and the direction of rotation the crankshaft
is to be viewed from the coupling flange (coupling side).
In the subsequent work steps, the measurement is carried out with fitted con-
necting rods (normal situation).
Work Steps 1. Remove the cover from the crankcase openings.
2. Turn the crankshaft of cylinder 1 into the starting position, which is either
LBDC or RBDC depending on the engine’s normal direction of rotation.
Starting position
The starting position for the measurement of each crank is a position
which is as close as possible to the right or left of the BDC and thereby
allows for the web-deflection measuring device to be inserted.
3. Use thickness gauges (000.454) to check whether the crankshaft is rest-

ing on the bottom bearing shells.
Incorrect values for hollow crankshafts

A hollow crankshaft gives incorrect values for crank web deflection.
4. Select suitable extension rods and mount on the dial gauge.

5. Use the web-deflection measuring device in measuring points (2).
Measuring points for measurement

The measuring points for measurement with fitted driving mechanisms
2019-12-02 - de
are located in the counterweights! Exception: in engine L 58/64, the

measuring points are in the crank webs!
Measurement when engine is warm

For measurements taken when the engine is warm, the web-deflection
measuring device must be stored in the crankcase for approx. 15
minutes for temperature equalisation.
2 (9) General, M010.030.010-12-0001

6. Set the dial gauge approximately in the centre of the measuring range to
“0” as an initial value.
7. Turn the crankshaft carefully in the normal direction of rotation into the in-
tended measurement positions (for counter-clockwise engine from RBDC
to RTDC - TDC - LTDC - LBDC / for clockwise engine from LBDC to
LTDC - TDC - RTDC - RBDC). For the specified positions, read the size
and direction of the measuring gauge’s maximum reading compared to
the initial value which has been set and record in a table (similar to Table
1). Positive values (+) if the measurement distance is larger, negative val-
ues (-) if the measurement distance is smaller than the initial value
“0” (Figures 2, 3, 4 / Table 1).
Turning the crankshaft

When turning the crankshaft it should be ensured that the sensor is not
damaged by the connecting-rod bearing bolt.
For the V-engine, when turning it should also be ensured that the
sensor is not damaged by the articulated connecting rod.
8. Measure the remaining cranks in the same manner.

9. After measuring all cranks, dismantle the web-deflection measuring
device, clean it and store it in a wooden box.
Work sequence 2 - Recording measured values

The measuring protocol must contain the following information:
▪ Measured value and direction of the deviation (Figure 3 / Table 1),
▪ Assembly condition (e.g. piston/connecting rods installed/not installed),
▪ Type of coupling (rigid, elastic),
▪ Engine mounting (rigid, elastic, semi-elastic),
▪ Other relevant marginal conditions (e.g. vessel in dock / afloat),
▪ Oil and coolant temperatures if the measurement is taken with the engine
at operating temperature and
▪ Main direction of rotation of the engine.
Work sequence 3 - Evaluation/Assessment

Crank position Crank number

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1 2 3 4 5 6 ...
Crank at RBDC1) 0 0 0 0 0 0 ...
Crank at RTDC -2 +1 0 +2 +1 -1 ...
Crank at TDC -5 +3 +5 +6 +1 -3 ...
Crank at LTDC +1 +2 +4 +3 -3 -2 ...

1)
Crank at LBDC +2 0 +2 0 -1 -1 ...
Table 1: Recording of measured values (example for anticlockwise rotation) -
measured values in 1/100 mm
General, M010.030.010-12-0001 3 (9)

45035998262505099
1)
Measurement without connecting rod installed = BDC
45035998262505099
Crank web deflection Crank number
1 2 3 4 5 6 ...
vertical av -6 +3 +4 +6 +1.5 -2.5 ... av = TDC - 1/2 (LBDC+RBDC)
horizontal ah -3 -1 -4 -1 +4 +1 ... ah = RTDC - LTDC

Table 2: Evaluation of measured values (example) - crank web deflections in 1/100 mm
45035998262505099
Calculation of av or ah
The calculation of av or ah is always carried out using the above-men-
tioned formula (independently of the engine rotation direction).
For comparison with the maximum permissible crank web deflection values,
the measured values of Table 1 must be evaluated as stated in Table 2. Here,
the crank web deflection is determined (av and ah) according to the relative
vertical and horizontal position of the measurement positions to each other
(see Figure 2).
To obtain a value corresponding to the BDC position, the mean value of
LBDC and RBDC is calculated.
Example:
vertical av crank No. 6: av = (-3) - 0.5 ((-1) + 0) = -2.5

horizontal ah crank No. 6: ah = (-1) - (-2) = +1
45035998262505099
Crank web deflection (av and ah), with the corresponding algebraic sign, must
not exceed the maximum permissible value (see Table 4).
Crank number
1 to 2 2 to 3 3 to 4 4 to 5 5 to 6 6 to ... ...
Difference 8 2 1 5 4 ... ...

Table 3: Evaluation of TDC measured values of adjacent cylinders (example) - absolute differential values in
1/100 mm
45035998262505099
The absolute difference between the TDC values of adjacent cranks (calcu-
lated in Table 3) must not exceed the limit values of the permissible crank web
deflection from Table 4.
2019-12-02 - de
Example:
TDC measured value between crank 5 and +1 - (-3) = 4

6:
TDC measured value between crank 2 and +3 - (+5) = -2, absolute difference = 2
3:
45035998262505099
4 (9) General, M010.030.010-12-0001

Reference values of the Limit values of the per- Limit values of the per- Measuring point dis-
permissible crank web missible crank web de- missible crank web de- tance from centre of
deflection for the flection for the meas- flection for the meas- crank pin (mm)
measurement after fit- urement during align- urement of the engine
ting the crankshaft in ment of the cold en- at operating temperat-
the engine installation gine on the test bench, ure on the test bench,
upon commissioning at upon commissioning at
the customer’s the customer’s
premises or on board premises or on board
and after maintenance and after maintenance
work work
V28/33D +6 +9 +13 320

-9 -13 -17
L32/40 +8 +11 +15 460

L32/40CD -10 -15 -20
V32/40 +8 +12 +16 460

V32/40CD -11 -17 -22
L32/44 +12 +19 +25 540

L32/44K -17 -25 -33
L32/44CR
L35/44DF
V32/44 +10 +14 +19 550

V32/44CR -13 -20 -26
V32/44CRTS +11 +16 +21 550

-14 -22 -29
V35/44G +10 +15 +20 550

-14 -20 -27
V35/44GTS +11 +17 +22 550

-15 -22 -30
L40/54 +7 +11 +15 505

-10 -15 -20
V45/60CR +18 +27 +36 890

-24 -36 -48
L48/60 +10 +15 +21 580

L51/60 -14 -21 -28
V48/60 +12 +18 +24 580

V51/60 -16 -24 -32
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L58/64 +8 +13 +17 560

-11 -17 -23
Table 4: Values for permissible crank web deflection in 1/100 mm
45035998262505099
General, M010.030.010-12-0001 5 (9)

1 Crank web
2 Measuring point (centre punch)
3 Crank pin
A Measuring point distance
Figure 1: Measuring the crank web deflection
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1 Crank web 5 Balance weight LTDC Left Top Dead Centre

2 Measurement point LR Direction of engine ro- RTDC Right Top Dead Centre
tation anticlockwise
3 Crank pin RR Direction of engine ro- LBDC Left Bottom Dead
tation clockwise Centre
4 Connecting rod TDC Top Dead Centre RBDC Right Bottom Dead
Centre
Figure 2: Crank web deflection measurement (with connecting rod) - seen from the coupling side - figure
shows in-line engine 48/60 B
6 (9) General, M010.030.010-12-0001

1 Crank web
3 Crank pin
Figure 3: Direction of deviation - measurement point distance relative to the
initial value “0” at BDC or LBDC or RBDC (plus = increase / minus = de-
crease)
TDC Top Dead Centre

LTDC Left Top Dead Centre
RTDC Right Top Dead Centre
BDC Bottom Dead Centre
LBDC Left Bottom Dead Centre
RBDC Right Bottom Dead Centre
Figure 4: Designation of crank positions - seen from the coupling side

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General, M010.030.010-12-0001 7 (9)

2019-12-02 - de
Figure 5: Measurement report for crankshaft web deflection
8 (9) General, M010.030.010-12-0001

45035998262505099

2019-12-02 - de
General, M010.030.010-12-0001 9 (9)

45035998262505099
2019-12-02 - de
General, M010.030.010-12-0001
Counterweight bolts
Summary
Balance weight bolts must be detensioned using hydraulic tensioners in order
to be able to remove the counterweight for emergency operation.
Safety requirements
l Engine stopped
Tools/aids required

2020-12-14 - de

Counterweight bolts
Item Hydraulic tightening procedure Note

Oil pressure Set the dial Expansion Resetting
gauge to ‘0’ min. max. when loosen-
for oil pres- ing
sure
bar bar mm mm °/l
1 800 50 0.5 0.7
2 210°/7l Hydraulic tensioner

(009.631)
L48/60CR, M010.030.010-13-0003 1 (7)

Warning message

pressure hoses.
Work Sequence 1 - Releasing the counterweight bolts

Initial situation Crankcase has been opened, the running gear has been turned in such a way
that the balance weight bolts are easily accessible (balance weight is pointing
Work steps 1. Clean the threads of the balance weight bolts (1).
4. Turn the hydraulic tensioners back by the turn-back angle. See table ‘Val-
ues for bolt tightening’.
structions 015.000.002-01.
sioners.
2020-12-14 - de
Counterweight bolts

a maximum of 5% above the tensioning pressure. See table ‘Values for
bolt tightening’ and Work Instructions 015.000.001-01.
angle through the cut-out in the thrust pieces. See table ‘Values for bolt
tightening’.
2 (7) L48/60CR, M010.030.010-13-0003

Work Sequence 2 -Tensioning of counterweight bolts

Initial situation The running gear has been turned in such a way that the balance weight bolts
are easily accessible (balance weight is pointing towards the crankcase open-
ing). See Fig. 1.
Nuts screwed on and tightened by hand. Balance weight bolt threads are
cleaned.
the balance weight (3) and the crankshaft (4) is closed on both sides
(measures less than 0.05 mm).
structions 015.000.002-01.
5. Unscrew set screws (5) until the locating bore in the hydraulic tensioners
is exposed. See Figure 4.
6. Insert the dial gauges (009.444) into the locating bores. Make sure that
the measuring pin of the dial gauges is resting against the piston of the
hydraulic tensioners. Fasten the dial gauges with set screws (5).
sioners.
7. Start the high-pressure pump and tension the balance weight bolts (1) to
the specified pre-tensioning pressure. See table ‘Values for bolt tighten-
ing’ and Work Instructions 015.000.003-01.
8. Set the dial gauges to zero.
sioners.
9. Tighten the counterweight bolts (1) to the specified tensioning pressure.
2020-12-14 - de
See table ‘Values for bolt tightening’ and Work Instructions

Counterweight bolts
015.000.003-01.
sioners.
12.Tension the balance weight bolts (1) with the specified pre-tensioning
pressure. See table ‘Values for bolt tightening’ and Work Instructions
015.000.003-01.
L48/60CR, M010.030.010-13-0003 3 (7)

13.Read off the bolt elongation Δl on the dial gauges, note down the values
and compare them with the setpoint value. The measurement of the bolt
elongation Δl serves only as a check. See table ‘Values for bolt tighten-
ing’
In case of larger deviations from the setpoint, repeat the tensioning pro-
cess, checking the hydraulic tensioners, bolt connections and pressure
indicator where necessary.
16.Remove the dial gauges, screw in the set screws (5).
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Counterweight bolts

2 Nut 4 Crankshaft
Figure 1: Balance weight
4 (7) L48/60CR, M010.030.010-13-0003


Figure 2: Balance weight bolts with installed hydraulic tensioners
2020-12-14 - de
Counterweight bolts
L48/60CR, M010.030.010-13-0003 5 (7)


2 Nut
Figure 3: Balance weight bolt with fitted hydraulic tensioner
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Counterweight bolts
5 Set screw I-II Work steps

Figure 4: Hydraulic tensioners with dial gauge attached
6 (7) L48/60CR, M010.030.010-13-0003

9007220497469835
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Counterweight bolts
L48/60CR, M010.030.010-13-0003 7 (7)

9007220497469835
2020-12-14 - de
Counterweight bolts
L48/60CR, M010.030.010-13-0003
51353814923
1 (1)

Check the lower crankshaft bearing shell (main bearing)
Summary
Carry out the work in good time according to the maintenance schedule, en-
sure the operational safety of the bearings.
Bearing shells must be checked at regular intervals. Usually, only the loaded
bearing shell is checked. From the wear condition and appearance of the
bearing shell running surface, conclusions can be drawn regarding the load
conditions, the lube oil maintenance etc.
lowering the bearing cover,
checking the bearing shell,
lifting the bearing cover.
Safety requirements
l Engine stopped

1 Pilot rod 034.006 Standard
2 Guide pipe 021.293 Standard
1 Retaining device 021.595 Standard
1 Hydraulic hand pump with hose 009.826 Standard
1 Telescopic cylinder 009.137 Standard
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Assess bimetal bearings (without a third layer) 010.000.003-03
Releasing and tensioning the crankshaft bearing bolts and 010.010.030-09
cross tie rods (main bearing)
L48/60CR, M010.030.020-01-0017 1 (11)

Safety instruction

• Fit the sign on the operating device
• Observe the Work Instructions and safety regulations.
Work Sequence 1 - Lowering the bearing cap

Initial situation Crankcase covers are removed. Running gear is turned so that the crankshaft
bearing cover is easily accessible.
Observe the manufacturer's Operating Manual

The relevant manufacturer's Operating Manual must be observed be-
fore putting the hydraulic hand pump and the telescopic cylinder into
operation.
Work steps 1. Insert foot board (011.003) into oil sump (8).
2. Unscrew the hex bolts (40) and remove the clips (41).
3. Dismantle the temperature sensor (30) from the crankshaft bearing cover
(7), and place it safely outside the crankcase.
4. Release the crankshaft bearing bolts (6) and the cross tie rods (3) of the
relevant main bearing. See Work Instructions 010.010.030-09.
2018-05-11 - de
5. Unscrew the nuts (2) and remove the rings (11), including O-rings (12).
6. Remove both cross tie rods (3).
7. Release the cross tie rod on the adjacent crankshaft bearings and release
the nuts. See Work Instructions 010.010.030-09.
8. Fit the retracted telescopic cylinder (009.137) in the crankcase and slide it
underneath the crankshaft bearing cover (7). See Fig. 2.
2 (11) L48/60CR, M010.030.020-01-0017

Allowing alignment of the telescopic cylinder

Tighten hex bolts by hand only to the extent that the telescope cylinder
remains movable and can self-align for further work.
9. Align the telescopic cylinder towards the crankshaft central axis, and at-
tach it to the oil sump (8) together with two hex bolts (22).
10.Place the retaining device (021.595) on the cylinder crankcase foot and
mount it on the cylinder crankcase side wall.
11.Slide hydraulic hand pump (009.826) in the guide on the retaining device,
and secure it in position.
Oil level in hydraulic hand pump

The hydraulic hand pump must always have sufficient clean slushing
oil in it. Otherwise, there is the danger that air could enter the hydraulic
system, which would necessitate complete bleeding of the entire hy-
draulic system of the raising and lowering device.
12.Check the oil level in the hydraulic hand pump with the oil dipstick (16).
13.Connect the hydraulic hoses (13) to the telescopic cylinder. See Fig. 3.

14.Position the lever (19) on the hydraulic hand pump in the upwards posi-
tion. See Fig. 3/Z.
15.Fit the pilot rod (034.006) onto the lever (18). Actuate the hydraulic hand
pump by moving the lever up and down, thereby lifting the telescopic cyl-
inder.
16.Raise the telescopic cylinder until it contacts the crankshaft bearing cover
(7). Move the lever (19) into the centre position (rest position). See Figure
3/X.
17.Attach the telescopic cylinder to the crankshaft bearing cover (7).
18.Unscrew and remove the nuts (5) from the crankshaft bearing bolts (6).
19.Screw the guide tubes (021.293) into the crankshaft bearing bolts (6) and
tighten by hand. See Fig. 4.
20.Insert the tommy bars (021.586) into the holes in guide tubes.
21.Put the lever (19) into the downwards position. See Figure 3/Y.
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Crankshaft bearing 1 (inner bearing) - bearing ring between

crankshaft gear wheel and cylinder crankcase
Secure the bearing ring between crankshaft gear wheel and cylinder
crankcase with suitable means against falling and rotating, during turn-
ing, before lowering the crankshaft bearing cap.
L48/60CR, M010.030.020-01-0017 3 (11)

Lowering the crankshaft bearing cover

Do not increase the pressure to over 100 bar when lowering the crank-
shaft bearing cover.
A sharp increase in pressure during lowering indicates that the crank-
shaft bearing cover is tilted. Stop the lowering process. Only continue
the lowering process of the crankshaft bearing cover once the tilt has
been corrected.
22.Actuate the hydraulic hand pump by moving the lever (18) up and down,
thereby lowering the telescopic cylinder.
23.Lower the crankshaft bearing cover (7) down to the tommy bars. See Fig.
5.
Work Sequence 2 - Checking the bearing shell

Work steps
Do not remove the bearing shell for inspection

Do not remove the bearing shell for inspection purposes to avoid dis-
turbing the fit as far as possible.
1. Clean the running surfaces of the bearing shell carefully, without dam-
aging them.
Checking the bearing shell

The bearing shell must not be reworked.
Change damaged or very heavily dirt-scored bearing shell.
The crank web should be inspected and repolished if necessary (pol-
ishing cloth with grain size < 15 µm).
2. Check or assess the condition of the running surface. See Work Instruc-
tions 010.000.003-03.
Replacing the bearing shell

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If a bearing shell is to be replaced, this must be done in pairs.

New bearing shells are delivered ready to install and must not be re-
worked or otherwise machined in any way. The bearing points are
numbered, the corresponding numbers should be transferred to new
shells.
Work Sequence 3 - Lifting the bearing cap

Initial situation Bearing shell is checked and replaced if necessary.
4 (11) L48/60CR, M010.030.020-01-0017

Work steps 1. Thoroughly lubricate the running surface of the bearing shell (24).
2. Move the lever (19) on the hydraulic hand pump (009.826) upwards. See
Fig. 3/Z.
Lifting the crankshaft bearing cap

Do not increase pressure to over 100 bar when lifting the main bearing
cap.
A sharp increase in pressure when lifting indicates that the main bear-
ing cap is tilted. Stop lifting process. Only continue the lifting process
of the crankshaft bearing cover once the tilt has been corrected.
3. Fit the pilot rod (034.006) onto the lever (18). Actuate the hydraulic hand
inder (009.137).
4. Raise the crankshaft bearing cover (7) until it comes into contact with the
cylinder crankcase (4). Move the lever (19) into the centre (rest) position.
See Figure 3/X.
5. Remove the Tommy bars (021.586), and unscrew and dismantle the
guide tubes (021.293).
6. Screw the nuts (5) up to the contact surface onto the crankshaft bearing
bolts (6) at the crankshaft bearing cover (7) and tighten them hand-tight.

7. Remove hex bolts (23).
8. Move the lever (19) into the downwards position. See Figure 3/Y.
9. Actuate the hydraulic hand pump by moving the lever (18) up and down,
thereby lowering the telescopic cylinder until fully retracted.
10.Uncouple the hydraulic hoses (13) from the telescopic cylinder, and re-
move the entire lifting and lowering device.
Crankshaft bearing 1 (inner bearing) - bearing ring between

crankshaft gear wheel and cylinder crankcase
Remove securing device for the bearing ring located between the
crankshaft gear and the cylinder crankcase.
11.Clean the male threads of the cross tie rods (3), apply MoS2 lubricant,
and screw them hand-tight into the crankshaft bearing cover (7) up to the
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contact surface.
12.Place new O-rings (12) and rings (11) over the cross tie rods (3) and
screw on the nuts (2) until hand-tight up to the stop.
13.Tighten the crankshaft bearing bolts (6) and cross tie rods (3). See Work
14.Tighten the nuts of the cross tie rods of the adjacent crankshaft bearing
until hand-tight. Tension the cross tie rods of the adjacent crankshaft
bearings. See Work Instructions 010.010.030-09.
L48/60CR, M010.030.020-01-0017 5 (11)

15.Check the crankshaft bearing clearance using the thickness gauges

(000.454) by inserting the thickness gauge to a depth of about 10 mm
from the coupling side and free engine end.
16.Measure the crank web deflection and record in the operating log. See
17.Install the temperature sensors (30) in the crankshaft bearing cover (7).
18.Clean the hex bolts (40) and the bores in the crankshaft bearing cover (7)
and the cylinder crankcase (4).
19.Apply Loctite 243 threadlocker to the thread of the hex bolts (40) and the
bores in the crankshaft bearing cover (7) and cylinder crankcase (4),
place the clamps (41) onto the cylinder crankcase, then screw in and
tighten the hex bolts.
20.Remove the foot board (011.003) from the oil sump (8).
Engine run-in
After installation, the engine must be run-in. See 010.005 Engine - Op-
erating Manual 010.000.024-05.
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6 (11) L48/60CR, M010.030.020-01-0017


1 Counterweight 7 Main bearing cap 30 Temperature sensor
2 Nut 8 Oil sump 40 Hexagon head bolt
3 Cross tie rod 9 Crankshaft 41 Clip
4 Cylinder crankcase 10 Conrod CS Control side
5 Nut 11 Ring
6 Main bearing bolt 12 O-ring seal
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Figure 1: Main bearing *
L48/60CR, M010.030.020-01-0017 7 (11)

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4 Cylinder crankcase 15 Hex nut 20 Hex bolt M10x30

7 Crankshaft bearing 16 Oil dipstick 21 Hex nut M10
cover
8 Oil sump 17 Pressure gauge 22 Hex bolt M12x30
13 Hydraulic hose 18 Lever 23 Hex bolt M20x45
14 Stud bolt 19 Lever ST Control side
Figure 2: Crankshaft bearing and attached lifting and lowering device *
8 (11) L48/60CR, M010.030.020-01-0017


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13 Hydraulic hose 17 Pressure gauge A Connection for hy-

draulic hose
16 Oil dipstick 18 Lever B Connection for hy-
draulic hose
Figure 3: Hydraulic hand pump and telescopic cylinder (illustration "X": Lever (19) in centre position - tele-
scopic cylinder in rest position/illustration "Y": Lever (19) down - lowering telescopic cylinder/illustration "Z":
Lever (19) up - lifting telescopic cylinder)
L48/60CR, M010.030.020-01-0017 9 (11)

6 Crankshaft bearing bolt 7 Crankshaft bearing ST Control side

cover
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10 (11) L48/60CR, M010.030.020-01-0017


4 Cylinder crankcase 18 Lever 25 Fixing piece
7 Crankshaft bearing 19 Lever ST Control side
cover
17 Pressure gauge 24 Bearing shell, bottom
* Illustration in the figures shows the engine L48/60

27021624801624331
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L48/60CR, M010.030.020-01-0017 11 (11)

27021624801624331
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L48/60CR, M010.030.020-01-0017
Upper crankshaft bearing shell (main bearing)

Summary
The upper crankshaft bearing shells must be removed if damage or severe
contamination was discovered during the check of the lower crankshaft bear-
ing shell.
The work sequences include:
Removal of the bearing shell
Check of the bearing shell
Installation of the bearing shell
Safety requirements
l Engine stopped
l Operating media system isolated / depressurised
1 Centring template 021.164 Standard
1 Turning block 021.163 Standard

1 Eye bolt M6 000.023 Standard

Check lower crankshaft bearing shell (main bearing) 010.030.020-01
Work sequence 1 – removing the bearing shell

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Initial situation Crankshaft bearing cover is lowered, lower bearing shell is removed. See
Work Instructions 010.030.020-01. See Fig. 1.
Work steps NOTICE The turning stone must be completely in contact with the crank-
shaft.
1. Insert the turning block (021.162) into the oil bore in the crankshaft (9),
noting that the crankshaft may have to be turned slightly. See Figure 2.
2. Carefully turn out the upper crankshaft bearing shell (27) without dam-
aging it.
3. Pull out the turning block with eye bolt (000.023).
L48/60CR, M010.030.020-02-0013 1 (6)

Damage to the crankshaft caused by contaminated bearing

shells
Using contaminated bearing shells may cause damage to the crank-
shaft.
• Mechanical machining of bearing shells is fundamentally prohibited.
• Always replace damaged bearing shells in pairs.
• After replacement of the bearing shells, check the bearing journal and
polish it with a suitable abrasive material (grain less than 15 µm) if ne-
cessary.
• Transfer the identification of the bearing shells to the new shells where
necessary.
Work steps 1. Clean the running surfaces of the bearing shell carefully, making sure not
to damage them.
2. Check or assess the condition of the running surface. See work instruc-
tions 010.000.003-03.
Work sequence 3 – installing the bearing shell

Work steps 1. Position the centring template (021.164) on the crankcase (4). Insert the
centring bolt of the centring template into the bore for bearing cover
fastening (centring template is held magnetically). See Figure 3.

2. Generously apply grease to the running surface of the upper crankshaft
bearing shell (27) (with the back of the bearing shell remaining dry).
3. Position the upper crankshaft bearing shell (27) on the centring template,
and push it in as far as possible by hand. In doing so, pay attention to the
position of the lug for the bearing shell positioning device (C).
NOTICE To avoid warping of the bearing shell when screwing in, the turning
stone must be as close as possible to the parting joint of the crankshaft bear-
ing.
4. Turn the crankshaft (9) until the turning block (021.163) can be inserted
into the crankshaft’s oil bore through a bore in the upper crankshaft bear-
2020-12-14 - de
ing shell (27).

5. Screw in the upper crankshaft bearing shell (27) in multiple stages (ac-
cording to bore spacing). To do this, pull out the turning block after the
first turn, turn the crankshaft (9) back by one bore distance and insert the
turning block again. Repeat the process up to the last bore.
6. Pull out the turning block and turn back the crankshaft (9) until the oil
bore is free.
7. Insert the turning block (021.162) directly into the oil bore of the crank-
shaft (9) and fully screw in the upper crankshaft bearing shell (27). When
doing this, make sure the end positions of the bearing shell joint faces are
even.
2 (6) L48/60CR, M010.030.020-02-0013

8. Remove the centring template and pull out the turning block with the eye
bolt (000.023).

4 Crankcase 18 Lever 25 Fixing piece
7 Crankshaft bearing 19 Lever PC Control side
cover
17 Pressure indicator 24 Lower crankshaft bear-
ing shell
Figure 1: Crankshaft bearing and installed lifting and lowering device *
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L48/60CR, M010.030.020-02-0013 3 (6)

4 Crankcase 28 O-ring
9 Crankshaft PC Control side
27 Upper crankshaft bearing I-II Work steps
shell
Figure 2: Removal of the upper crankshaft bearing shell*
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4 (6) L48/60CR, M010.030.020-02-0013


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4 Crankcase 28 O-ring I-III Work steps

9 Crankshaft C Lug for fastening the
bearing shell
27 Upper crankshaft bear- PC Control side
ing shell
Figure 3: Installing the upper crankshaft bearing shell*
L48/60CR, M010.030.020-02-0013 5 (6)

* Illustration in the figures shows engine L48/60

18014425666911627
2020-12-14 - de
6 (6) L48/60CR, M010.030.020-02-0013

Lower crankshaft bearing shell (external bearing)

inspecting
Summary
Bearing shells must be checked at regular intervals. Usually, only the loaded
bearing shell is checked. From the wear condition and appearance of the
bearing shell running surface, conclusions can be drawn regarding the load
conditions, the lube oil maintenance etc.
lowering the bearing cover,
checking the bearing shell,
lifting the bearing cover.
Safety requirements
l Engine stopped

1 Retaining device 021.595 Standard
1 Hydraulic hand pump with hose 009.826 Standard
1 Telescopic cylinder 009.137 Standard
2018-04-26 - de


cross tie rods (main bearing)
L48/60CR, M010.030.020-03-0013 1 (10)


cross tie rods (external bearing)
Safety instruction

• Fit the sign on the operating device
• Observe the Work Instructions and safety regulations.
Work Sequence 1 - Lowering the bearing cover

Hot surfaces
High surface temperatures developing during engine operation may
cause burns upon contact.
• Avoid direct contact with hot surfaces
• When working with certain surface temperatures, it is advisable to take
special care and to wear heat-resistant personal protective equipment
Initial situation Casing cover on control drive and crankcase cover of the adjacent cylinders
removed.
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Observe manufacturer's operating instructions

The relevant manufacturer's operating instructions must be observed
before putting the hydraulic hand pump and the telescopic cylinder
into operation.
Work steps 1. Insert foot board (011.003) into oil sump (7).
2. Unscrew the hex bolts (41) and remove the clips (42).
3. Dismantle the temperature sensor (35) from the crankshaft bearing cover
(8), and place it safely outside the crankcase.
2 (10) L48/60CR, M010.030.020-03-0013

4. Release crankshaft bearing bolts (6) and cross tie rods (3). See Work In-
structions 010.010.030-10.
5. Unscrew the nuts (2) and remove the rings (11), including O-rings (12).
6. Remove both cross tie rods (3).
7. Release the cross tie rod of the adjacent crankshaft bearing and release
the nuts. See Work Instructions 010.010.030-09.
8. Fit the retracted telescopic cylinder (009.137) in the engine and slide it
underneath the crankshaft bearing cover (8). See Fig. 2.
Allowing alignment of the telescopic cylinder

Tighten hex bolts by hand only to the extent that the telescope cylinder
remains movable and can self-align for further work.
9. Align the telescopic cylinder towards the crankshaft central axis, and at-
tach it to the oil sump (7) with two hex bolts (17).
10.Place the retaining device (021.595) on the cylinder crankcase foot and
mount it on the cylinder crankcase side wall.
11.Slide hydraulic hand pump (009.826) in the guide on the retaining device,
and secure it in position.
Oil level in hydraulic hand pump

The hydraulic hand pump must always have sufficient clean slushing
oil in it. Otherwise, there is the danger that air could enter the hydraulic

system, which would necessitate complete bleeding of the entire hy-
draulic system of the raising and lowering device.
12.Check the oil level in the hydraulic hand pump with the oil dipstick (15).
13.Connect the hydraulic hoses (18) to the telescopic cylinder. See Fig. 3.
14.Position the lever (23) on the hydraulic hand pump in the upwards posi-
tion. See Fig. 3/Z.
15.Fit the pilot rod (034.006) onto the lever (21). Actuate the hydraulic hand
inder.
16.Raise the telescopic cylinder up to contact with the crankshaft bearing
2018-04-26 - de
cover (8). Move the lever (23) into the centre position (rest position). See
Figure 3/X.
17.Attach the telescopic cylinder to the crankshaft bearing cover (8).
18.Unscrew and remove the nuts (5) from the crankshaft bearing bolts (6).
Securing the locating bearing ring

If the locating bearing ring is not locked before lowering the main bear-
ing cap, there is the danger that the locating bearing ring may also be
rotated together with the crankshaft, and may fall down.
L48/60CR, M010.030.020-03-0013 3 (10)

19.Secure the bearing ring (1) with suitable means against falling and rotat-
ing when turning.
20.Put the lever (23) into the downwards position. See Figure 3/Y.
Lowering the crankshaft bearing cap

The pressure must not exceed 100 bar during the lowering of the
crankshaft bearing cap.
A large pressure increase during lowering indicates tilting of the crank-
shaft bearing cap. Stop lowering process. Only continue the lowering
process of the crankshaft bearing cap once the tilt has been corrected.
21.Actuate the hydraulic hand pump by moving the lever (21) up and down,
thereby lowering the telescopic cylinder until it is fully retracted. See Fig.
4.

Work steps
Do not remove the bearing shell for inspection

Do not remove the bearing shell for inspection purposes to avoid dis-
turbing the fit as far as possible.
1. Clean the running surfaces of the bearing shell carefully, without dam-
aging them.
Checking the bearing shell

The bearing shell must not be reworked.
Change damaged or very heavily dirt-scored bearing shell.
The crank web should be inspected and repolished if necessary (pol-
ishing cloth with grain size < 15 µm).
2. Check or assess the condition of the running surface. See Work Instruc-
tions 010.000.003-03.
2018-04-26 - de

If a bearing shell is to be replaced, this must be done in pairs.
worked or otherwise machined in any way. The bearing points are
numbered, the corresponding numbers should be transferred to new
shells.
4 (10) L48/60CR, M010.030.020-03-0013

Work Sequence 3 - Lifting the bearing cap

Initial situation Bearing shell is checked and replaced if necessary. Running surface of the
bearing shell oiled.
Work steps 1. Move the lever (23) on the hydraulic hand pump (009.826) upwards. See
Fig. 3/Z.
Lifting the crankshaft bearing cap

The pressure must not exceed 100 bar when raising the crankshaft
bearing cap.
A large pressure increase during raising indicates tilting of the crank-
shaft bearing cap. Stop lifting process. Only continue the lifting pro-
cess of the crankshaft bearing cap once the tilt has been corrected.
2. Fit the pilot rod (034.006) onto the lever (21). Actuate the hydraulic hand
inder (009.137).
3. Raise the crankshaft bearing cover (8) until it comes into contact with the
cylinder crankcase (4). Move lever (23) into centre position (rest position).
See Figure 3/X.
4. Screw the nuts (5) up to the contact surface onto the crankshaft bearing
bolts (6) at the crankshaft bearing cover (8) and tighten them hand-tight.
5. Remove hex bolts (16).

6. Put the lever (23) into the downwards position. See Figure 3/Y.
7. Actuate the hydraulic hand pump by moving the lever (21) up and down,
thereby lowering the telescopic cylinder until it is fully retracted.
8. Uncouple the hydraulic hoses (18) from the telescopic cylinder, and re-
move the entire lifting and lowering device.
9. Remove the securing device for the locating bearing ring (1).
10.Clean the male threads of cross tie rods (3), apply MoS2 lubricant and
screw into main bearing cap (8) hand-tight to the contact surface.
11.Place new O-rings (12) and rings (11) over the cross tie rods (3) and
screw on the nuts (2) until hand-tight up to the stop.
12.Tighten the crankshaft bearing bolts (6) and cross tie rods (3). See Work
2018-04-26 - de
13.Tighten the nuts of the cross tie rods of the adjacent crankshaft bearing
hand-tight. Tension the cross tie rods of the adjacent crankshaft bearing.
14.Check the crankshaft bearing clearance with the thickness gauges
(000.454) by inserting the thickness gauge about 10 mm deep from the
coupling side and from the free engine end.
15.Measure the crank web deflection and record in the operating log. See
16.Install the temperature sensors (35) in the crankshaft bearing cover (8).
17.Clean the hex bolts (41) and the bores in the crankshaft bearing cover (8)
and the cylinder crankcase (4).
L48/60CR, M010.030.020-03-0013 5 (10)

18.Apply Loctite 243 securing compound to the thread of the hex bolts (41)
and the bores in the crankshaft bearing cover (8) and the cylinder crank-
case (4), place clips (42) onto the cylinder crankcase, and screw in and
tighten the hex bolts.
19.Remove the foot board (011.003) from the oil sump (7).
Engine run-in
After installation, the engine must be run-in. See 010.005 Engine - Op-
erating Manual 010.000.024-05.
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6 (10) L48/60CR, M010.030.020-03-0013


2018-04-26 - de
1 Locating bearing ring 7 Oil sump 35 Temperature sensor

2 Nut 8 Main bearing cap 41 Hexagon head bolt
3 Cross tie rod 9 Crankshaft gearwheel 42 Clip
4 Cylinder crankcase 10 Crankshaft CS Control side
5 Nut 11 Ring
6 Main bearing bolt 12 O-ring seal
Figure 1: Main bearing (external bearing) *
L48/60CR, M010.030.020-03-0013 7 (10)

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4Cylinder crankcase 14 Hex nut 20 Hex nut M10

5Nut 15 Oil dipstick 21 Lever
6Crankshaft bearing bolt 16 Hex bolt M20x45 22 Pressure gauge
7Oil sump 17 Hex bolt M12x30 23 Lever
8Crankshaft bearing 18 Hydraulic hose CS Coupling side
cover
13 Stud bolt 19 Hex bolt M10x30 ST Control side
Figure 2: Crankshaft bearing cover (outer bearing) and attached lifting and lowering device *
8 (10) L48/60CR, M010.030.020-03-0013


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15 Oil dipstick 22 Pressure gauge B Connection for hy-

draulic hose
18 Hydraulic hose 23 Lever
21 Lever A Connection for hy-
draulic hose
Figure 3: Hydraulic hand pump and telescopic cylinder (Illustration “X”: lever (23) in centre position – tele-
scopic cylinder in rest position / Illustration “Y”: lever (23) down – lowering telescopic cylinder / Illustration
“Z”: lever (23) up – lifting telescopic cylinder)
L48/60CR, M010.030.020-03-0013 9 (10)

8 Main bearing cap 23 Lever 25 Fixing piece

21 Lever 24 Bearing shell, bottom CS Control side
Figure 4: Main bearing (external bearing) and attached lifting and lowering device *
* Illustration in the figures shows the engine L48/60

9007225680295051
2018-04-26 - de
10 (10) L48/60CR, M010.030.020-03-0013

Upper crankshaft bearing shell (external bearing)

Summary
The upper crankshaft bearing shells must be removed if damage or severe
contamination was discovered during the check of the lower crankshaft bear-
ing shell.
Removal of the bearing shell
Check of the bearing shell
Installation of the bearing shell
Safety requirements
l Engine stopped
l Operating media system isolated / depressurised
1 Centring template 021.164 Standard

1 Eye bolt M6 000.023 Standard

Check lower crankshaft bearing shell (external bearing) 010.030.020-03
Work sequence 1 – removing the bearing shell

2020-12-14 - de
Initial situation Crankshaft bearing cover is lowered, lower bearing shell is removed. See
Work Instructions 010.030.020-03. See Fig. 1.
Work steps NOTICE The turning stone must be completely in contact with the crank-
shaft.
1. Insert the turning block (021.162) into the oil bore in the crankshaft (10),
noting that the crankshaft may have to be turned slightly. See Figure 2.
2. Carefully turn out the upper crankshaft bearing shell (26) without dam-
aging it.
3. Pull out the turning block with eye bolt (000.023).
L48/60CR, M010.030.020-04-0011 1 (5)

Damage to the crankshaft caused by contaminated bearing

shells
Using contaminated bearing shells may cause damage to the crank-
shaft.
• Mechanical machining of bearing shells is fundamentally prohibited.
• Always replace damaged bearing shells in pairs.
• After replacement of the bearing shells, check the bearing journal and
polish it with a suitable abrasive material (grain less than 15 µm) if ne-
cessary.
• Transfer the identification of the bearing shells to the new shells where
necessary.
Work steps 1. Clean the running surfaces of the bearing shell carefully, making sure not
to damage them.
2. Check or assess the condition of the running surface. See work instruc-
tions 010.000.003-03.
Work sequence 3 – installing the bearing shell

Work steps 1. Position the centring template (021.164) on the crankcase (4). Insert the
centring bolt of the centring template into the bore for bearing cover
fastening (centring template is held magnetically). See Figure 3.
2. Generously apply grease to the running surface of the upper crankshaft
bearing shell (26) (with the back of the bearing shell remaining dry).
3. Position the upper crankshaft bearing shell (26) on the centring template,
and push it in as far as possible by hand. In doing so, pay attention to the
position of the lug for the bearing shell positioning device (C).
NOTICE To avoid warping of the bearing shell when screwing in, the turning
stone must be as close as possible to the parting joint of the crankshaft bear-
ing.
4. Turn the crankshaft (10) until the turning block (021.163) can be inserted
into the crankshaft’s oil bore through a bore in the upper crankshaft bear-
2020-12-14 - de
ing shell (26).

5. Screw in the upper crankshaft bearing shell (26) in multiple stages (ac-
cording to bore spacing). To do this, pull out the turning block after the
first turn, turn the crankshaft (10) back by one bore distance and insert
the turning block again. Repeat the process up to the last bore.
6. Pull out the turning block and turn back the crankshaft (10) until the oil
bore is free.
7. Insert the turning block (021.162) directly into the oil bore of the crank-
shaft (10) and fully screw in the upper crankshaft bearing shell (26). When
doing this, make sure the end positions of the bearing shell joint faces are
even.
2 (5) L48/60CR, M010.030.020-04-0011

8. Remove the centring template and pull out the turning block with the eye
bolt (000.023).

8 Crankshaft bearing 23 Lever 25 Fixing piece
cover
21 Lever 24 Lower crankshaft bear- PC Control side
ing shell
Figure 1: Crankshaft bearing (external bearing) and installed lifting and lowering device *
2020-12-14 - de
L48/60CR, M010.030.020-04-0011 3 (5)

4 Crankcase 27 O-ring
10 Crankshaft PC Control side
26 Upper crankshaft bearing I-II Work steps
shell
Figure 2: Removal of the upper crankshaft bearing shell*
2020-12-14 - de
4 (5) L48/60CR, M010.030.020-04-0011


2020-12-14 - de
4 Crankcase 27 O-ring I-III Work steps

10 Crankshaft C Lug for fastening the
bearing shell
26 Upper crankshaft bear- PC Control side
ing shell
Figure 3: Installing the upper crankshaft bearing shell*
* Illustration in the figures shows engine L48/60

18014425627368459
L48/60CR, M010.030.020-04-0011 5 (5)

18014425627368459
2020-12-14 - de
L48/60CR, M010.030.020-04-0011
Axial clearance
inspecting
Summary
Carry out the work in good time and according to the maintenance schedule,
measure components.
The axial clearance must be checked at regular intervals.
The work/work step includes:
Checking components/parts.
Safety requirements
l Engine stopped
2 Hydraulic cylinder 009.075 Standard
1 Magnetic post - Inventory

Check locating bearing rings 010.030.020-07
Work Sequence - Measuring the axial clearance of the crankshaft

2018-01-11 - de
High operating pressures during work with high pressure tools/

hydraulic tensioners
High operating pressures are used during work with the high pressure
pump, hydraulic tensioners and high pressure hoses. Lack of informa-
Axial clearance
tion and non-observance of information may cause serious injury to

persons and serious damage to property.
• Observe the working and safety instructions when using high pressure
tools/hydraulic tensioners
L51/60G;L48/60CR;L48/60B, M010.030.020-06-0003 1 (3)

Check that pistons of the hydraulic cylinders are fully retracted

Before fitting the hydraulic cylinders, check that the pistons are fully
retracted (stroke = zero), and reset the pistons if necessary.
Initial situation Covers in the area of the control drive and crankcase covers on two cylinders
removed.
Work steps 1. Connect the high-pressure hoses (009.306) to the hydraulic cylinder
(009.075) and the high-pressure pump (009.342) and secure. See Work
Fitting the hydraulic cylinders

The hydraulic cylinders must be fitted to different cylinders.
2. Fit hydraulic cylinders between cylinder crankcase wall and counter-

weight so that the crankshaft can be displaced axially in one direction.
Maximum permissible working pressure

The maximum permissible working pressure of 500 bar must not be ex-
ceeded.
3. Set the high-pressure pump in operation and slide the crankshaft with
carefully controlled pressure until it makes contact. See Work Instructions
015.000.003-01.
4. Fit the dial gauge to the magnetic holder.
5. Fasten the magnetic holder at a suitable point and place the dial gauge
on the coupling flange or in another accessible location.
6. Reset the dial gauge to "zero".
7. Relieve the pressure.
Fitting the hydraulic cylinders

The hydraulic cylinders must be fitted to different cylinders.
2018-01-11 - de
8. Reposition the hydraulic cylinder.

Axial clearance

ceeded.
2 (3) L51/60G;L48/60CR;L48/60B, M010.030.020-06-0003

9. Set the high-pressure pump in operation and slide the crankshaft in the
opposite direction with carefully controlled pressure until it makes con-
tact. See Work Instructions 015.000.003-01.
10.Read off the displacement on the dial gauge.
Permitted axial clearance

If the permitted clearance is exceeded, the crankshaft locating bearing
rings must be removed, checked and replaced if necessary. See Work
9007206134126347
11.Note down the axial clearance and compare it with the permissible clear-
ance. Record the axial clearance in the operation notes. For maximum
permissible clearance, see Volume 010.005 Engine – Operating Manual,
sheet 010.000.035.-04.
12.Relieve the pressure.
13.Remove the hydraulic cylinders.
14.Disconnect the high-pressure hoses from the hydraulic cylinders and
high-pressure pump.
9007206134126347
15.Remove the magnetic holder and the dial gauge.
2018-01-11 - de
Axial clearance
L51/60G;L48/60CR;L48/60B, M010.030.020-06-0003 3 (3)

9007206134126347
2018-01-11 - de
Axial clearance
L51/60G;L48/60CR;L48/60B, M010.030.020-06-0003
Locating bearing rings

inspecting
Summary
evaluate contact pattern/state of wear.
Check locating bearing rings at regular intervals.
The work/work step includes:
Checking components/parts.
Safety requirements
l Engine stopped
1 Feeler gauge 0.05-1 000.451 Option
2 Wooden wedge - Inventory
1 Plastic hammer - Inventory

checking axial clearance 010.030.020-06
Technical data
Reference dimension (A) Dimension 0,5 mm
2018-01-11 - de
Work Sequence - Checking the locating bearing rings

Initial situation Covers in the area of the control drive removed.
Work steps 1. Place the foot board (011.003 for a V oil sump or 011.007 for a normal oil
sump) in oil sump.
2. Fix the crankshaft (4) in position with two wooden wedges axially so that
locating bearing rings (2) are free.
3. Detach one strip (7 or 9) each per locating bearing ring (2).
4. Unscrew both locating bearing rings (2) in the direction of rotation, do not
rotate the crankshaft (4) in the process.
L51/60DF;L48/60CR;L48/60B, M010.030.020-07-0002 1 (3)

5. Clean the locating bearing ring (2) carefully, without damaging it.
6. Check the condition of the locating bearing rings (2) and replace them
with new ones if necessary.
7. Oil the locating bearing rings (2) lightly.
8. Screw in the locating bearing rings (2) and place them on the crankshaft
(4).
9. Attach the strips (7 or 9), observing reference dimension (A) on both
sides.
10.Screw in the hex bolts (8).
11.Remove both wooden wedges.
12.Measure the axial clearance and record it in the operation notes. See
13.Remove the foot board (011.003 or 011.007) from the oil sump.
2018-01-11 - de
2 (3) L51/60DF;L48/60CR;L48/60B, M010.030.020-07-0002

1 Cylinder crankcase 5 Crankshaft bearing 9 Rail

(bearing support) cover
2 Locating bearing ring 6 Dowel pin 10 Crankshaft bearing cap
(external bearing)
3 Crankshaft gearwheel 7 Rail A Reference dimension
4 Crankshaft 8 Hexagon head bolt
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Figure 1: Crankshaft bearing (main thrust bearing)

27162882187
L51/60DF;L48/60CR;L48/60B, M010.030.020-07-0002 3 (3)

27162882187
2018-01-11 - de
L51/60DF;L48/60CR;L48/60B, M010.030.020-07-0002
51353819147
1 (1)

Bolts of the crankshaft vibration damper

inspection
Summary
Check important bolted connections, ensure precise execution of work.
The studs for the crankshaft vibration damper must be checked at regular in-
tervals using hydraulic tensioners.
The work/working steps include:
Determining and assessing release pressure.
Safety requirements
l Engine stopped
Tools/aids required

Removal and installation of crankshaft vibration damper 010.030.030-03
2016-10-14 - de
Technical data
Work Sequence - Checking the stud bolts

Initial situation Crankcase cover and free engine end covering removed.
48/60CR, M010.030.030-01-0013 1 (7)

Check one pair of bolts at a time

Check one pair of bolts (two opposing stud bolts) at a time.
Prerequisite for correct check

A prerequisite for the correct check of a bolted connection is a pres-
Work steps 1. Clean the threads of the stud bolts (5).

2. Fit thrust pieces (055.241) over two opposing nuts (2).
3. Screw hydraulic tensioners (009.632) on both stud bolts (5), ensuring that
the thrust pieces are centred with hydraulic tensioners. See Fig. 2 and 3.
4. Turn the hydraulic tensioners back by the turning-back angle. See Work
Instructions 010.000.003-05
5. Connect high-pressure hoses (009.306) to hydraulic tensioners and high-
pressure pump (009.342).

served.
6. Start high-pressure pump and close the gap caused by turning back.
7. Pump up the hydraulic tensioners until the nuts (2) can be loosened.

2016-10-14 - de

What to do in case of pressure deviations?

If the pressure is below 7%, release and remove all studs (5), remove
gear wheel (1) and check all studs (4). See steps 1 to 12. See Work In-
structions 010.030.030-03.
18002325515
2 (7) 48/60CR, M010.030.030-01-0013

9. Adjust high-pressure pump to the specified tensioning pressure. See
10.Tighten both nuts (2) hand-tight through the cut-out in the thrust piece
with the tommy bar (000.264).
11.Relieve the pressure; uncouple the high-pressure hoses from the hy-
draulic tensioners.
12.Detach the tool.
13.Place the hydraulic tensioners onto the next pair of bolts, and repeat the
process until all stud bolts (5) have been checked. See Steps 2 to 12.
14.Uncouple the high-pressure hoses from the high-pressure pump when
the inspection is completed.

1 Gear wheel 4 Stud bolt 7 Crankshaft
2 Nut 5 Stud bolt A Bolt protrusion
3 Nut 6 Crankshaft vibration
damper
Figure 1: Crankshaft vibration damper and gear wheel
2016-10-14 - de
48/60CR, M010.030.030-01-0013 3 (7)

1 Gear wheel 5 Stud bolt

Figure 2: Crankshaft vibration damper and gearwheel – stud bolts with attached tensioners
2016-10-14 - de
4 (7) 48/60CR, M010.030.030-01-0013


2 Nut
Figure 3: Stud bolt with attached tensioner

2016-10-14 - de
48/60CR, M010.030.030-01-0013 5 (7)

4 Stud bolt 6 Crankshaft vibration damper

Figure 4: Crankshaft vibration damper – stud bolts with attached tensioners
2016-10-14 - de
6 (7) 48/60CR, M010.030.030-01-0013


damper
4 Stud bolt

18002325515
2016-10-14 - de
48/60CR, M010.030.030-01-0013 7 (7)

18002325515
2016-10-14 - de
48/60CR, M010.030.030-01-0013

Summary
Loosen and tighten important bolted connections using the correct values as
specified, ensure precise execution of work.
The studs for the crankshaft vibration damper must be released and ten-
sioned at regular intervals using hydraulic tensioners.
The work / working steps include:
determining and evaluating the loosening pressure and
tightening the connection as per specified pressure.
Safety requirements
l Engine stopped
Tools/aids required

Removal and installation of crankshaft vibration damper 010.030.030-03
2016-10-14 - de
Technical data
Work Sequence 1 – Releasing the stud bolts

Initial situation Crankcase cover and free engine end covering removed.
48/60CR, M010.030.030-02-0013 1 (9)

Always release one pair of bolts at a time.

Always release one pair of bolts (two opposing stud bolts) at a time.
Prerequisite for correct releasing

A prerequisite for correct releasing of a bolted connection is a pres-
Work steps 1. Clean the threads of stud bolts (4 and 5).

2. Fit thrust pieces (055.241) over two opposing nuts (2).

served.
6. Start high-pressure pump and close the gap caused by turning back.
7. Pump up the hydraulic tensioners until the nuts (2) can be loosened.

2016-10-14 - de

9. Using the tommy bar (000.264), turn both nuts (2) back through the cut-
out in the thrust piece. For turn-back angle see Work Instructions
010.000.003-05.
draulic tensioners.
2 (9) 48/60CR, M010.030.030-02-0013

11.Detach the tool.

process until all stud bolts (5) have been released. See steps 2 to 11.
13.Remove stud bolts (5) and detach gearwheel (1). See Work Instructions
010.030.030-03.
14.Fit the thrust pieces (055.241) over nuts (2).
15.Screw hydraulic tensioners (009.632) on both stud bolts (4), ensuring that
16.Turn the hydraulic tensioners back by the turning-back angle. See Work
17.Connect the high-pressure hoses (009.306) to the hydraulic tensioners.

served.
18.Start high-pressure pump and close the gap caused by turning back.
19.Pump up the hydraulic tensioners until the nuts (2) can be loosened.


20.Record the release pressure and compare it with the tensioning pressure.
21.Using the tommy bar (000.264), turn both nuts (2) back through the cut-
out in the thrust piece. For turn-back angle see Work Instructions
010.000.003-05.
22.Release the pressure and uncouple the high-pressure hoses from the hy-
draulic tensioners and the high-pressure pump.
2016-10-14 - de
23.Detach the tool.
Work Sequence 2 – Tightening the stud bolts

Initial situation Threads of stud bolts are cleaned, stud bolts (4) are mounted, nuts are
screwed in hand-tight to the stop.
Always tension one pair of bolts at a time.

Always tension pairs of bolts (two opposing stud bolts) together.
48/60CR, M010.030.030-02-0013 3 (9)

Prerequisite for correct tightening

A prerequisite for correct tightening of a bolted connection is a pres-
Work steps 1. Check the bolt protrusion (A) of stud bolts (4). See Fig. 1.
2. Fit the thrust pieces (055.241) over nuts (2).

served.
5. Start high-pressure pump and tighten the stud bolts (4) to the prescribed
015.000.003-01.
6. Tighten both nuts (2) hand-tight through the cut-out in the thrust piece

7. Relieve the pressure; uncouple the high-pressure hoses from the hy-
draulic tensioners.
8. Detach the tool.
9. Attach gear wheel (1) and insert stud bolts (5). See Work Instructions
010.030.030-03.
10.Check the bolt projection (A) of stud bolts (5). See Fig. 1.
11.Fit thrust pieces (055.241) over two opposing nuts (2).
2016-10-14 - de
12.Screw hydraulic tensioners (009.632) on both stud bolts (5), ensuring that
13.Connect the high-pressure hoses (009.306) to the hydraulic tensioners.
4 (9) 48/60CR, M010.030.030-02-0013


served.
18002329867
14.Start high-pressure pump and tighten the stud bolts (5) to the prescribed
015.000.003-01.
15.Tighten both nuts (2) hand-tight through the cut-out in the thrust piece
draulic tensioners.
17.Detach the tool.
process until all stud bolts (5) have been tensioned. See Steps 11 to 17.
19.Once all stud bolts (5) are tensioned, uncouple the high-pressure hoses
from the high-pressure pump.

2016-10-14 - de
1 Gear wheel 4 Stud bolt 7 Crankshaft

2 Nut 5 Stud bolt A Bolt protrusion
damper
Figure 1: Crankshaft vibration damper and gear wheel
48/60CR, M010.030.030-02-0013 5 (9)


Figure 2: Crankshaft vibration damper and gearwheel – stud bolts with attached tensioners
2016-10-14 - de
6 (9) 48/60CR, M010.030.030-02-0013


2 Nut

2016-10-14 - de
48/60CR, M010.030.030-02-0013 7 (9)

4 Stud bolt 6 Crankshaft vibration damper

Figure 4: Crankshaft vibration damper – stud bolts with attached tensioners
2016-10-14 - de
8 (9) 48/60CR, M010.030.030-02-0013


damper
4 Stud bolt

18002329867
2016-10-14 - de
48/60CR, M010.030.030-02-0013 9 (9)

18002329867
2016-10-14 - de
48/60CR, M010.030.030-02-0013
Crankshaft vibration damper

Summary
Carry out the work in due time according to the maintenance schedule, en-
sure correct execution of the work, ensure /restore operational safety.
The crankshaft vibration damper is to be checked and replaced at specified
intervals according to the maintenance schedule.
Safety requirements
l Engine stopped
l Fuel systems isolated / depressurized
Tools/aids required
2 Attachment eye 027.034 Option
1 Pipe 027.111 Option
1 Suspension plate 027.112 Option
1 Slide piece 027.113 Option
1 Bracket 027.107 Option
1 Slide piece 027.110 Option
1 Ratchet hoist 002.552 Standard
3 Threaded rod 027.114-1 Option
6 Sleeve 027.114-3 Option

2018-05-11 - de
1 Hydraulic cylinder 009.165 Option

1 Adapter 20x12.5 001.923 Standard
L48/60CR;L48/60B, M010.030.030-03-0006 1 (26)


2 Wooden support - Inventory
1 Marker pen - Inventory
2 Shackle - Inventory
2 Rope - Inventory

Loosening and tightening bolts of crankshaft vibration 010.030.030-02
damper
Technical data
Torsional vibration damper 2240 - kg
Weight
3760
Cover Weight 46 kg
Stud bolt with nut Weight 18,5 kg
Gear Weight 315 kg
Preliminary remark
Each torsional vibration damper is a special component specifically designed
for an individual piece of equipment. Improper installation can lead to damage
of the equipment or to the torsional vibration damper.
Work sequence 1 - removing the torsional vibration damper

2018-05-11 - de
Starting position All pipes obstructing the dismantling of the torsional vibration damper are re-
moved, attached pumps (lubricating oil and/or cooling water pump) are de-
tached, crankcase cover and casing on free engine end are detached.
2 (26) L48/60CR;L48/60B, M010.030.030-03-0006


Work in drive chamber

Danger to life due to work in the drive chamber during the turning op-
eration.
• do not work in the drive chamber during the turning operation
• cover any opened drive chamber windows
• prior to start with the turning operation; take into account acoustic and
optical signals
Work steps 1. Turn the crankshaft (13) so that the marking “OT 1/TDC 1” on the tor-
sional vibration damper (10) is at the top.
Detaching the cover 2. Screw the lifting eye bolt (000.141) into the cover (4) and tighten it. See
Fig. 2/I.
3. Fasten the rope (15) with the shackle (002.452) to the lifting eye bolt and
attach it to the lifting tackle.
4. Unscrew the hexagon socket bolts (3) and detach the cover (4). Place the
cover on a suitable support. See Fig. 2/II.
5. Detach the tool from the cover.
6. Turn the crankshaft (13) by approx. 45° so that the threaded hole on the
front end of the gear wheel (2) is at the top. See Fig. 4.
Removal of the stud bolts 7. Release the stud bolts (9). See Work Instructions 010.030.030-02.
(9) 8. Turn back the nut (6) by several turns, unscrew the nut (7) and remove
the stud bolt (9) with the nut and place on a support. See Fig. 3.
9. Remove the remaining stud bolts (9) in the same manner. See Step 8.
Dismantling the gear wheel 10.Screw the lifting eye bolt (000.156) into the gear wheel (2) and tighten it.
See Fig. 4/I.
2018-05-11 - de
11.Fasten the rope (15) with the shackle (002.454) to the lifting eye bolt and
attach it to the lifting tackle. Tension the rope (15).
Applying markings correctly

The marking must lie in one axis with the marking "OT 1/TDC 1" on the
torsion vibration damper.
12.Mark the position of the gear wheel (2) in relation to the torsional vibration
damper (10).
L48/60CR;L48/60B, M010.030.030-03-0006 3 (26)

13.Unscrew and remove the hexagon socket bolts (1).

14.Detach the gear wheel (2) and set it down on a suitable support. See Fig.
4/II.
15.Detach the tool.
Removal of the stud bolts 16.Rotate the crankshaft (13) until the marking "OT 1 / TDC 1" on the tor-
(8) sional vibration damper (10) is at the top again.
17.Release the stud bolts (8). See Work Instructions 010.030.030-02.
18.Turn back the nut (6) by several turns, unscrew the nut (7) and remove
the stud bolt (8) with the nut and place on a support. See Fig. 5.
19.Remove the second stud bolt (8) in the same manner. See Step 18.
Installation of pipe, bracket, 20.Fasten the attachment plate (027.112) to the crankshaft (13), ensuring
slide piece correct installation position and centring. See Fig. 6.
Damage of pipe
To prevent pipe tilting, the pipe must be supported on the free end us-
ing suitable means.
21.Fasten the bracket (027.107) on the foundation at the height of the lower
edge of the cylinder crankcase (C) and at a distance (E) of 1750.5 mm to
the end of the cylinder crank casing (D). See Fig. 6.
22.Insert the pipe (027.111) into the attachment plate using the pin (18) and
place it on the bracket. See Fig. 7.
23.Screw the hex bolt (21) into the pin (18) and fasten the pipe to the
bracket. See Fig. 7.
24.Lubricate the sliding surface of the slide piece (027.113) and push it
between the pipe and torsional vibration damper (10). See Fig. 8.
25.Screw in the hex bolts (22) up to the system but do not tighten them.
26.Screw in the hex bolt (21) until the slide piece abuts the torsional vibration
damper (10).
27.Tighten the hex bolts (22).
28.Hook in the ratchet hoist (002.552) to the slide piece and pipe. See Fig.
9.
29.Oil the pipe.

30.Unscrew and remove the hexagon socket bolts (14).
31.Pull the torsional vibration damper (10) out carefully by actuating the
2018-05-11 - de
ratchet hoist. See Fig. 10.

Attaching the torsional vi-
bration damper

Read the manufacturer's operating manual carefully before using the
attachment eye (027.034).
4 (26) L48/60CR;L48/60B, M010.030.030-03-0006

32.Screw the load hooks (027.034) into the torsional vibration damper (10)
and tighten them hand-tight with a spanner. See Fig. 11.
33.Fasten the ropes (15) with the shackle (23) to the bearing block and at-
tach them to the lifting tackle.
34.Unhook the ratchet hoist from the slide piece and the pipe.
Removing the torsional vi- 35.Slightly lift up the torsional vibration damper (10). See Fig. 12/I.
bration damper 36.Unscrew the hex bolt (21), unscrew and remove the hex nuts (19), re-
move the hex bolts (20) and detach the pipe. See Fig. 12/II.
37.Move the torsional vibration damper (10) away and set it down on a suit-
able support.
38.Detach the tool from the torsional vibration damper (10).
39.Clean the stud bolts (8 and 9) and nuts (6 and 7) and inspect them for
damage.
40.Clean the gear wheel (2).
Work Sequence 2 - Transporting the torsional vibration damper

The torsional vibration damper may only be transported in a horizontal posi-

tion. Only use the designated slings for this purpose. The torsional vibration
damper should be supported from at least two lashing points both during re-
moval/installation and during transportation. See also plant documentation
010.010 … 010.190 engine components – 010.030 crankshaft vibration
damper.
Work Sequence 3 – Installing the torsional vibration damper

Initial situation Piston of cylinder 1 is at TDC. The attachment plate (027.112) is attached to
2018-05-11 - de
the crankshaft, the bracket (027.107) is fastened to the foundation.

L48/60CR;L48/60B, M010.030.030-03-0006 5 (26)

Work in drive chamber

Danger to life due to work in the drive chamber during the turning op-
eration.
• do not work in the drive chamber during the turning operation
• cover any opened drive chamber windows
• prior to start with the turning operation; take into account acoustic and
optical signals
Work steps 1. Clean the flange on the crankshaft (13).

Preparatory steps 2. Blow out the supply bore in the crankshaft (13) with compressed air.
3. Clean all anti corrosion agent from the torsional vibration damper (10).
4. Blow out the oil bores in the torsional vibration damper (10) with com-
pressed air.
Attaching the tool to the tor-
sional vibration damper
Ensure correct installation position

The slide piece must lie in vertical axis with the marking "OT 1 / TDC 1"
on the torsion vibration damper.
5. Secure the slide piece (027.110) on the torsional vibration damper (10); in
doing so, ensure that the slide piece abuts on the torsional vibration
damper.

Read the manufacturer's operating manual carefully before using the
attachment eye (027.034).
6. Screw the load hooks (027.034) into the torsional vibration damper (10)
and tighten them hand-tight with a spanner. See fig. 13/I and fig. 14/l.
7. Fasten the ropes (15) with the shackle (23) to the bearing block and at-
tach them to the lifting tackle.
8. Lift up the torsional vibration damper (10) and move it in between the cyl-
2018-05-11 - de
inder crankcase (11) and the bracket (027.107).

Attaching the pipe and the 9. Insert the pipe (027.111) through the torsional vibration damper (10) and
bracket place it on the pin (18) on the attachment plate and on the bracket. See
Fig. 14/I.
10.Screw the hex bolt (21) into the pin (18) and fasten the pipe to the
bracket. See Fig. 14/I.
6 (26) L48/60CR;L48/60B, M010.030.030-03-0006

Damage of pipe
To prevent pipe tilting, the pipe must be supported on the free end us-
ing suitable means.
11.Lightly oil the pipe.

12.Lower the torsional vibration damper (10) onto the pipe. See Fig. 14/I.
13.Detach the ropes (15), shackles and load hooks.
14.Insert the pipe (027.109) through the pipe (027.111). See Fig. 14/I.
15.Oil the sliding surface of the slide piece (027.110), place it on the pipe
(027.111) and insert it into pipe (027.109). See Fig. 14/I.
16.Insert the pin (26) into the pipe (027.109). See Fig. 14/I.
17.Insert the hydraulic cylinder (009.165) into the slide piece. See Fig. 14/I.
Pushing the torsional vibra- 18.Connect the high pressure hose (009.306) to the hydraulic cylinder and
tion damper forwards onto high-pressure pump (009.342). Connect the oil pressure gauge (0 - 400
the pipe bar) to the high-pressure pump.
Recognising tilting
A sudden pressure increase during the displacement indicates tilting.
• Observe the oil pressure gauge during the displacement.
19.Start up the high-pressure pump and slide the torsional vibration damper
(10) in the direction of the crankshaft (13). See Fig. 14/II.
21.Reset the hydraulic cylinder piston by hand. The relief valve on the high-
pressure pump must be open to do this. See Work Instructions
015.000.003-01.
22.Remove the bolts (26), displace the pipe including the slide piece and in-
sert the bolts in the next hole.
23.Start up the high-pressure pump and slide the torsional vibration damper
(10) again in the direction of crankshaft (13).
24.Repeat the process until the torsional vibration damper (10) abuts the
crankshaft (13). See Steps 19 to 23 / see Figures 14, 15 and 16.
2018-05-11 - de
Use of pipe (027.108)

To bring the torsional vibration damper to the end position, the pipe
(027.108) must be attached as an extension to the pipe (027.109). See
Figs. 15 and 16.

26.Check that the marking “OT 1/TDC 1” on the torsional vibration damper
(10) is at the top. See Fig. 17.
L48/60CR;L48/60B, M010.030.030-03-0006 7 (26)

Attaching the torsional vi- 27.Insert the threaded rods (027.114-1) through the holes, place the sleeves
bration damper (027.114-3) on both sides and screw on the hex nuts (27 and 28). See
Fig. 17.
28.Adjust the bolt projection (G = 55mm) on the threaded rods and tighten
the hex nuts (28). See Fig. 17.
29.By evenly tightening the hex nuts (28) in an alternating sequence, attach
the vibration damper (10) until it makes contact with the crankshaft (13).
See Fig. 18.
30.Coat the threads and contact surfaces of the hexagon socket bolts (14)
with Loctite 243 securing compound, screw them in and tighten them.
See Fig. 1.
31.Detach the tool completely.
Attaching the stud bolts (8) 32.Insert the stud bolt (8) and screw on the nuts (6 and 7). See Fig. 5.
33.Set the bolt projection (A = 153 mm) on the stud bolt (8) and tighten the
nut (6) hand-tight using a tommy bar (000.264). See Figs. 1 and 5.
34.Insert the second stud bolt (8) in the same manner. See Steps 32 and 33.
35.Tension the stud bolts (8). See Work Instructions 010.030.030-02.
Attaching the gear wheel 36.Turn the crankshaft (13) by approx. 45°. See Fig. 4.
Use the correct hole for the lifting eye bolt 000.156
Install the lifting eye bolt in the correct threaded bore. The markings
that were made (see Work Sequence 1 / Step 12) must be in the same
position during the refitting process.
37.Screw the lifting eye bolt (000.156) into the gear wheel (2) and tighten it.
38.Fasten the rope with the shackle (002.454) on the lifting eye bolt and sus-
39.Lift up the gear wheel (2) and move it in front of the torsional vibration
damper (10). See Fig. 4/II.
40.Attach the gearwheel (2) to the torsional vibration damper (10). Ensure
that the gearwheel/torsional vibration damper position is correct. See Fig.
4/I.
See Fig. 4.
42.Detach the tool.
2018-05-11 - de
Attaching the stud bolts (9) 43.Insert the stud bolt (9) and screw on the nuts (6 and 7). See Fig. 3.
44.Set the bolt projection (A = 153 mm) on the stud bolt (9) and tighten the
nut (6) hand-tight using a tommy bar (000.264). See Figs. 1 and 3.
45.Insert the remaining stud bolts (9) in the same manner. See Steps 43 and
44.
46.Tension the stud bolts (9). See Work Instructions 010.030.030-02.
Installing the cover 47.Turn the crankshaft (13) so that the marking “OT 1/TDC 1” on the tor-
sional vibration damper (10) is at the top.
48.Screw the lifting eye bolt (000.141) into the cover (4).
8 (26) L48/60CR;L48/60B, M010.030.030-03-0006

49.Fasten the rope with the shackle (002.452) on the lifting eye bolt and sus-
50.Attach the cover (4). See Fig. 2.
52.Detach the tool.
53.Clean the pipe and the slide pieces. Reset the hydraulic cylinder pistons.
Commissioning Before commissioning the engine, the torsional vibration damper must be lub-
ricated with lubricating oil by means of a priming pump, until lubricating oil
flows from the return holes (B) in the side disc (12). See Fig. 1.
1 Hexagon socket bolt 7 Nut 13 Crankshaft

2 Gear wheel 8 Stud bolt 14 Hexagon socket bolt
3 Hexagon socket bolt 9 Stud bolt A Bolt projection
2018-05-11 - de
4 Cover *10 Torsional vibration B Return bore

damper
5 Oil sump 11 Cylinder crankcase
6 Nut 12 Side disc
Figure 1: Torsional vibration damper and gear wheel
L48/60CR;L48/60B, M010.030.030-03-0006 9 (26)

3 Hexagon socket bolt *10 Torsional vibration I-II Work steps

damper
4 Cover 15 Rope
Figure 2: Removing/installing the cover
2018-05-11 - de
10 (26) L48/60CR;L48/60B, M010.030.030-03-0006

2 Gear wheel 9 Stud bolt A Bolt projection

6 Nut *10 Torsional vibration I-II Work steps
damper
7 Nut 13 Crankshaft
Figure 3: Detaching/attaching the stud bolts

2018-05-11 - de
L48/60CR;L48/60B, M010.030.030-03-0006 11 (26)

2018-05-11 - de
1 Hexagon socket bolt 8 Stud bolt 15 Rope

2 Gear wheel *10 Torsional vibration I-II Work steps
damper
Figure 4: Removing/installing the gearwheel
12 (26) L48/60CR;L48/60B, M010.030.030-03-0006

6 Nut 8 Stud bolt A Bolt projection

7 Nut *10 Torsional vibration I-II Work steps
damper
Figure 5: Detaching/attaching the stud bolts

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L48/60CR;L48/60B, M010.030.030-03-0006 13 (26)

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*10 Torsional vibration 16 Hex bolt M24x55 C Cylinder crankcase

damper lower edge
13 Crankshaft 17 Hex bolt M16 D Cylinder crankcase end
edge
E Distance (cylinder
crankcase - end edge -
bracket)
Figure 6: Removing the torsional vibration damper
14 (26) L48/60CR;L48/60B, M010.030.030-03-0006

*10 Torsional vibration 19 Hex nut M16 21 Hex bolt

damper
18 Pins 20 Hex bolt M16x40

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L48/60CR;L48/60B, M010.030.030-03-0006 15 (26)

2018-05-11 - de
*10 Torsional vibration 21 Hex bolt 22 Hex bolt M16x75

damper
16 (26) L48/60CR;L48/60B, M010.030.030-03-0006

*10 Torsional vibration damper 14 Hexagon socket bolt


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L48/60CR;L48/60B, M010.030.030-03-0006 17 (26)


2018-05-11 - de
18 (26) L48/60CR;L48/60B, M010.030.030-03-0006

*10 Torsional vibration 15 Rope 23 Shackle

damper

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L48/60CR;L48/60B, M010.030.030-03-0006 19 (26)

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*10 Torsional vibration 20 Hex bolt M16x40 I-II Work steps

damper
19 Hex nut M16 21 Hex bolt
20 (26) L48/60CR;L48/60B, M010.030.030-03-0006

*10 Torsional vibration 24 Suspension link I Removal/installation

damper
15 Rope 25 Lifting tackle II Transportation
23 Shackle F Angle, 60° max.
Figure 13: Suspending the torsional vibration damper during removal/installation/transport of the torsional
vibration damper

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L48/60CR;L48/60B, M010.030.030-03-0006 21 (26)

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*10 Torsional vibration 20 Hex bolt M16x40 26 Bolts

damper
15 Rope 21 Hex bolt I-II Work steps
19 Hex nut M16 23 Shackle
Figure 14: Installation of the torsional vibration damper
22 (26) L48/60CR;L48/60B, M010.030.030-03-0006


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*10 Torsional vibration 26 Bolts I-II Work steps

damper
L48/60CR;L48/60B, M010.030.030-03-0006 23 (26)

*10 Torsional vibration 13 Crankshaft 26 Bolts

damper
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24 (26) L48/60CR;L48/60B, M010.030.030-03-0006


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*10 Torsional vibration 27 Hex nut M30 G Bolt projection

damper
13 Crankshaft 28 Hex nut M30
L48/60CR;L48/60B, M010.030.030-03-0006 25 (26)

*10 Torsional vibration 13 Crankshaft 27 Hex nut M30

damper
28 Hex nut M30
* The shape and size of the torsional vibration damper may differ from the one shown in the illustrations.
36028803914193931
2018-05-11 - de
26 (26) L48/60CR;L48/60B, M010.030.030-03-0006


inspecting
Summary
Carry out all work on time in accordance with the maintenance schedule, en-
sure that all work is carried out properly, and make sure that operational
safety is established (or re-established if necessary).
The torsional vibration damper on the crankshaft/camshaft (if equipped)
should be inspected at the intervals specified in the maintenance schedule.
The work/ work steps include:
Disassembling components,
Assembling components,
Checking components.
Tools/aids required
1 Thickness gauges 0.05-1 000.451 Inventory
1 Data sheet (Geislinger & Co.) - Special
1 Measuring wedge (Geislinger & Co.) - Special
1 Sliding calliper Form A - Inventory
1 Ratchet tool - Inventory
1 Torque wrench - Inventory
1 Socket spanner (set) - Inventory
2 lifting eye bolt (high-strength design) - Inventory
2 Shackle - Inventory
2 Rope - Inventory
1 Hammer - Inventory
1 Rubber mallet - Inventory
1 Centre-punch - Inventory
1 Brass wedge - Inventory

2017-03-25 - de

1 Silicone grease - Inventory
Preliminary remark
Each torsional vibration damper is a special component that is tuned to the in-
dividual system. Improper disassembly or assembly can cause severe dam-
age to the system and/or the torsional vibration damper.
General, M010.030.030-04-0001 1 (12)

Ensure that you observe the manufacturer's instructions when you work on
the torsional vibration damper.
Choose eyebolts, shackles and lifting gear as required by the currently used
torsional vibration damper.
Work sequence 1 - Disassembling and checking torsional vibration damper
Disassembling and assembling the torsional vibration damper

It is strongly recommended to have the torsional vibration damper dis-
assembled and assembled by manufacturer personnel or a manufac-
turer service point.
Initial situation Torsional vibration damper dismantled and placed on flange (5) with a
wooden support. Crankshaft flange side of inner star (9) is pointing down-
wards.
Work steps 1. Mark position of the flange (5) and the side plate (7) on the spring pack (1)
of the torsional vibration damper. Mark with a centre-punch.
2. Unscrew hexagon head bolts (750) with cup springs (810). See Fig. 2/I.
3. Screw lifting eye bolts into side plate (7). See Fig. 2/II.
4. Secure the rope with a shackle at eyebolts and hang it on the lifting gear.
See Fig. 2/II.

5. Lift side plate (7) from spring pack (1), turn and place on wooden sup-
port. See Fig. 2/II.

6. Remove the slings.
2017-03-25 - de
7. Remove O-ring seals (850 and 851) from side plate (7) and spring pack
(1). See Fig. 2/III.
Replacement of the entire torsional vibration damper

Replace the torsional vibration damper when the limits indicated on
the data sheet are exceeded.
8. Check sealing face of the side plate (7). Refer to data sheet for permiss-
ible wear limit.
2 (12) General, M010.030.030-04-0001

9. Check the permissible wear limit with measuring wedge or vernier gauge.
See Work Sequence 2 - Measuring the wear limit.
10.Screw lifting eye bolts into inner star (9). See Fig. 3/V.
11.Secure the rope with a shackle at eyebolts and hang it on the lifting gear.
See Fig. 3/V.

12.Carefully lift inner star (9) from spring pack (1) and place on wooden sup-
port. Do not tilt inner ring or damage adjacent components in the pro-
cess. See Fig. 3/V.
13.Remove the slings.

14.Check sealing surfaces of the inner star (9). Refer to data sheet for per-
missible wear limit.
15.Screw lifting eye bolts into spring pack (1). See fig. 3/VI.
See fig. 3/VI.


2017-03-25 - de

17.Lift spring pack (1) and place on wooden support. See fig. 3/VI.
General, M010.030.030-04-0001 3 (12)


19.Check sealing surfaces of the flange (5). Refer to data sheet for permiss-
ible wear limit.
20.Remove O-ring seals (850 and 851) from flange (5) and spring pack (1).
See Fig. 3/VII.
21.Clean all the components.
Work sequence 2 - Measuring the wear limit
Number of measuring points

Check approximately every fourth spring pack.
Measuring wedge 1. Place measuring wedge between spring-leaf tips at the base of groove.

Replace the torsional vibration damper when the measuring wedge
can be inserted up to the parallel end (maximum mark) between the
spring-leaf ends.
2. Press measuring wedge down (manually or using a rubber mallet) until

both sides of the spring-leaf tips are in contact with the groove flanks.
See data sheet and fig. 2/IV.
Sliding calliper 3. Place brass wedge between the spring-leaf tips approx. 10 mm above
the base of groove.
4. Press brass wedge down (manually or using a rubber mallet) until both
sides of the spring-leaf tips are in contact with the groove flanks.

2017-03-25 - de

5. Measure dimension between the spring-leaf tips and enter results into
measurement log.
4 (12) General, M010.030.030-04-0001

Work sequence 3 - Assembling the torsionial vibration damper
Disassembling and assembling the torsional vibration damper

It is strongly recommended to have the torsional vibration damper dis-
assembled and assembled by manufacturer personnel or a manufac-
turer service point.
Initial situation All parts cleaned and lightly oiled with clean lubricating oil.
Work steps 1. Insert a new O-ring (850) wetted with clean lubricating oil into the sealing
ring groove of the flange (5). Make sure that it is evenly tensioned along
the entire circumference and is not twisted.
2. Screw lifting eye bolts into spring pack (1).
3. Secure the rope with a shackle at eyebolts and hang it on the lifting gear.

4. Lift spring pack (1) over flange (5). In doing so, pay attention to the mark-
ing.
5. Insert a new O-ring (851) wetted with clean lubricating oil into the lower
sealing ring groove of the spring pack (1). Make sure that it is evenly ten-
sioned along the entire circumference and is not twisted. Apply silicone
grease to the O-ring seal at several points to prevent it falling out during
the assembly.
6. Screw two hexagon head bolts (750) into the guide. See Fig. 4.
7. Lower spring pack (1) over flange (5).

8. Use a dial gauge with magnet holder or vernier gauge to align spring
pack (1) with flange (5). Take the maximum permissible radial run-out into
2017-03-25 - de
account (see drawing).

9. Remove the slings.
10.Use two hexagon head bolts (750) and old cup springs (810) as spacer
washers to screw down spring pack (1) on flange (5). See Fig. 4.
11.Unscrew the guide bolts from Work Step 6.
12.Screw lifting eye bolts into inner star (9).
13.Attach rope with shackle to lifting eye bolt and suspend from lifting tackle.
General, M010.030.030-04-0001 5 (12)


14.Carefully insert inner star (9) into spring pack (1). Do not tilt inner ring or
damage adjacent components in the process.
15.Align inner star (9) with spring pack (1). Provide even clearance between
inner ring and spring pack in the process.
17.Unscrew fixing screws from spring pack.
18.Insert a new O-ring seal (851) wetted with clean lubricating oil in the seal-
ing ring groove of spring pack (1). Make sure that it is evenly tensioned
along the entire circumference and is not twisted.
19.Screw lifting eye bolts into side plate (7).

21.Lift side plate (7) over spring pack (1). In doing so, pay attention to the
marking.
22.Insert a new O-ring seal (850) wetted with clean lubricating oil in the lower
sealing ring groove of side plate (7). Make sure that it is evenly tensioned
along the entire circumference and is not twisted. Apply silicone grease
to the O-ring seal at several points to prevent it falling out during the as-
2017-03-25 - de
sembly.
23.Carefully lower side plate (7) over spring pack (1).
24.Use a dial gauge with magnet holder or vernier gauge to align side plate
(7) with spring pack (1). Take the maximum permissible radial run-out into
account (see drawing).
26.Place new cup springs (810) coated with Loctite on both sides over the
holes in the side plate (7).
6 (12) General, M010.030.030-04-0001

Cup springs must have flat contact

If the cup springs do not have flat contact, the tightening torque of the
hexagon head bolts is distorted.
Correct tightening of the hexagon head bolts

First of all, tighten four hexagon head bolts in a diagonally opposed se-
quence. Tighten the remaining bolts in a circle. In the case of torsional
vibration dampers with two bolt hole circles, the inner one must be
tightened first and then the outer one.
27.Apply MoS2 lubricant to threads and contact faces of hexagon head bolts
(750). Screw in hexagon bolts, tighten them with the contact torque (see
table) until the cup springs are completely pressed down. Subsequently
tighten up with the prescribed torsion angle (see data sheet).
Nominal width of cup spring Contact torque

M8 8 Nm
M 10 13 Nm
M 12 21 Nm
M 14 30 Nm
M 16 40 Nm
M 18 50 Nm
M 20 70 Nm
M 22 100 Nm
M 24 – with 2.5 mm cup-spring width 105 Nm
M 24 – with 3.6 mm cup-spring width 125 Nm
M 27 – with 3 mm cup-spring width 177 Nm
M 27 – with 4 mm cup-spring width 160 Nm

M 30 205 Nm
M 33 345 Nm
2017-03-25 - de
M 36 350 Nm
Table 1: Contact torque for cup springs*
27021601869215499
* The values are only valid in compliance with the specified installation specific-
ations for bolts: "Thread oiled with Molykote and both sides of the cup
springs coated with Loctite."
See Geislinger drawing.
27021601869215499
General, M010.030.030-04-0001 7 (12)

1 Spring pack 15 Bearing bush 851 O-ring

2017-03-25 - de
5 Flange 750 Hex bolt

7 Side plate 810 Cup spring I Torsional vibration
damper without bear-
ing bush
9 Inner star 850 O-ring II Torsional vibration
damper with bearing
bush
Figure 1: Torsional vibration damper*
8 (12) General, M010.030.030-04-0001


2017-03-25 - de
1 Spring pack 750 Hex bolt 1001 Measuring wedge

5 Flange 810 Cup spring
7 Side plate 850 O-ring I - IV Work steps
9 Inner star 851 O-ring
Figure 2: Disassembling and assembling the torsional vibration damper*
General, M010.030.030-04-0001 9 (12)

2017-03-25 - de
1 Spring pack 9 Inner star 851 O-ring

5 Flange 850 O-ring V - VII Work steps
10 (12) General, M010.030.030-04-0001

1 Spring pack 750 Hex bolt

5 Flange 810 Cup spring
* Shape and size of the torsional vibration damper may differ from the illustration in the figures
27021601869215499

2017-03-25 - de
General, M010.030.030-04-0001 11 (12)

2017-03-25 - de
Figure 5: Sample of a data sheet

27021601869215499
12 (12) General, M010.030.030-04-0001


010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas 010.040 Connecting rod and piston
51353827595
1 (1)


51353831819
1 (1)

Connecting rod shank bolts

inspecting
Summary
Connecting rod shank screws are to be checked at regular intervals using hy-
draulic tensioners.
Safety requirements
l Engine stopped
1 Hand rail 011.013 Standard


2021-01-27 - de
Dismantling and assembling hydraulic tensioning tools 015.000.030-02
L51/60DF;L48/60CR, M010.040.010-01-0020 1 (7)

Work sequence – checking the connecting rod shank bolts

pressure hoses.
Initial situation Crankcase covers have been removed, the respective cylinder’s crank pin is
at bottom dead centre. See Fig. 1.
Work steps 1. Attach the handle (011.013) to the crankcase (9). See Figure 2.
2. Insert the foot board (011.012 for a normal oil pan or 011.011 for a V oil
pan) into the oil sump (13).
3. Clean the threads of the connecting rod shank bolts (11).
4. Check the tensioning nut (030.539) on the piston of the hydraulic ten-
sioner (009.664) for secure fit using an open-ended spanner (000.569). If
the tensioning nut is loose, retighten it with torque. See Work Instructions
015.000.030-02.
5. Place the thrust piece (030.538) over the nut (10) onto the connecting
rod shank bolt (11) at bolt position 1 and screw on the hydraulic ten-
sioner. See Figures 2/Y and 4.
6. Repeat the process (work steps 4 and 5) in the same way for the con-
necting rod shank bolts (11) at bolt positions 4, 5 and 8. See Fig. 2/Y.
structions 010.000.003-05.

tions 015.000.002-01.
2021-01-27 - de

sioners.
10.Pump up the hydraulic tensioners until the nuts (10) can be undone.
pressure. The release pressure must not be more than a maximum of 7%
below or a maximum of 5% above the tensioning pressure. See Work In-
structions 010.000.003-05 and 015.000.001-01.
2 (7) L51/60DF;L48/60CR, M010.040.010-01-0020

12.Manually tighten the nuts (10) through the opening in the thrust pieces
using a tommy bar (009.068) until hand-tight.
16.Place the thrust piece over the nut (10) onto the connecting rod shank
bolt (11) at bolt position 2 and screw on the hydraulic tensioner. See Figs.
3/X and 4.
17.Repeat work step 16 in the same way for the connecting rod shank bolts
(11) at bolt positions 3, 6 and 7. See Figure 3/X.
structions 010.000.003-05.
sioners.
structions 010.000.003-05 and 015.000.001-01.
27.Remove the foot board from the oil pan (13).
28.Detach the handle.
2021-01-27 - de
L51/60DF;L48/60CR, M010.040.010-01-0020 3 (7)

1-8 Bolt position/tightening 10 Nut 12 Connecting rod

2021-01-27 - de
sequence
9 Crankcase 11 Connecting rod shank 13 Oil pan
bolt
Figure 1: Connecting rod *
4 (7) L51/60DF;L48/60CR, M010.040.010-01-0020


2021-01-27 - de
1-8 Bolt position/tightening 12 Connecting rod 15 Hex bolt

sequence
9 Crankcase 13 Oil pan
Figure 2: Connecting rod shank bolts with attached hydraulic tensioners* – The illustration shows the ar-
rangement for bolt positions 1-4-5-8
L51/60DF;L48/60CR, M010.040.010-01-0020 5 (7)

2021-01-27 - de
1-8 Bolt position/tightening 12 Connecting rod 15 Hex bolt

sequence
rangement for bolt positions 2-3-6-7
6 (7) L51/60DF;L48/60CR, M010.040.010-01-0020

10 Nut
11 Connecting rod shank bolt
12 Connecting rod
Figure 4: Connecting rod shank bolt with attached hydraulic tensioner
* Illustration in the figures shows in-line engine 51/60DF.

27021624810701707

2021-01-27 - de
L51/60DF;L48/60CR, M010.040.010-01-0020 7 (7)

27021624810701707
2021-01-27 - de
L51/60DF;L48/60CR, M010.040.010-01-0020
Connecting rod bearing bolts

inspecting
Summary
Connecting rod bearing screws are to be checked at regular intervals using
Safety requirements
l Engine stopped
2 Angle piece 009.667 Standard


2021-01-26 - de
L48/60CR, M010.040.010-02-0009 1 (5)

Work Sequence - Checking the big-end bearing bolts

pressure hoses.
Initial situation Crankcase covers are removed. Respective cylinder’s crank pin at BDC. See
Fig. 1.
Work steps 1. Place the foot board (011.003 for a V oil sump or 011.007 for a normal oil
sump) into the oil sump (5). See Fig. 2.
2. Clean the threads of the big-end bearing bolts (1).
4. Screw the hydraulic tensioners (009.632) onto the big-end bearing bolts
(1). In doing so, ensure that the thrust pieces are centrally aligned by the
5. Connect the angled pieces (009.667) to the hydraulic tensioning devices
and secure it against being disconnected inadvertently (screw on the cor-
rugated threaded ring until the stop once the angled piece has engaged).
structions 010.000.003-05.
7. Connect high-pressure hoses (009.306) to the angle pieces and high-
pressure pump (009.342) and secure. See Work Instructions
015.000.002-01.

sioners.
2021-01-26 - de

010.000.003-05 and 015.000.001-01.
11.Tighten both nuts (2) through the cut-out in the thrust pieces using the
Tommy bar (000.264).
2 (5) L48/60CR, M010.040.010-02-0009


13.Disconnect the high-pressure hoses from the angle pieces and the high-
pressure pump.
14.Remove the angle pieces from the hydraulic tensioners.
16.Remove the foot board from the oil sump (5).

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1 Big-end bearing screw 3 Connecting rod 5 Oil pan

2 Nut 4 Crankcase
L48/60CR, M010.040.010-02-0009 3 (5)

3 Connecting rod 4 Crankcase 5 Oil pan

Figure 2: Big-end bearing bolts with installed hydraulic tensioners*
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4 (5) L48/60CR, M010.040.010-02-0009

1 Big-end bearing screw 3 Connecting rod

2 Nut
Figure 3: Removing/installing the hydraulic tensioners on the big-end bearing

bolt
2021-01-26 - de

27021601143037963
L48/60CR, M010.040.010-02-0009 5 (5)

27021601143037963
2021-01-26 - de
L48/60CR, M010.040.010-02-0009

Summary
For maintenance work, connecting rod shank screws must be released and
tensioned using hydraulic tensioners.
Safety requirements
l Engine stopped
1 Measuring device 030.573 Standard
1 Measuring rod 030.573-1 Standard
1 Vernier gauge Form E - Inventory

2020-12-08 - de

Dismantling and assembling hydraulic tensioning tools 015.000.030-02
Technical data
Max. screw length 282,6 mm
L51/60DF;L48/60CR, M010.040.010-03-0021 1 (11)

Warning message

pressure hoses.
Work Sequence 1 – Releasing the connecting rod shank bolts

Initial situation Crankcase covers have been removed, the respective cylinder’s crank pin is
at bottom dead centre. See Fig. 1.
Work steps 1. Attach the handle (011.013) to the crankcase (9).
2. Place the foot board (011.011 for a V oil sump or 011.012 for a normal oil
sump) into the oil sump (13).
3. Clean the threads of the connecting rod shank bolts (11).
015.000.030-02.
rod shank bolt (11) at screw position 1 and screw on the hydraulic ten-
sioner. See Figures 2/Y and 4.
necting rod shank bolts (11) at screw positions 4, 5 and 8. See Fig. 2/Y.
structions 010.000.003-05.
2020-12-08 - de

tions 015.000.002-01.
sioners.
2 (11) L51/60DF;L48/60CR, M010.040.010-03-0021

structions 010.000.003-05 and 015.000.001-01.
11.Using a tommy bar (009.068), turn the nuts (10) back by the turning-back
010.000.003-05.
bolt (11) at screw position 2 and screw on the hydraulic tensioner. See
Figs. 3/X and 4.
(11) at screw positions 3, 6 and 7. See Figure 3/X.
structions 010.000.003-05.
sioners.
structions 010.000.003-05 and 015.000.001-01.
21.Using a tommy bar, turn the nuts (10) back by the turning-back angle
through the cut-out in the thrust pieces. See Work Instructions
010.000.003-05.

2020-12-08 - de
L51/60DF;L48/60CR, M010.040.010-03-0021 3 (11)

Work Sequence 2 – Tightening the connecting rod shank bolts
Property damage due to the use of overextended screws

Improper conditions may lead to the permanent elongation of screws
as soon as the screw's yield strength is exceeded. Using screws with
excessive elongation can result in property damage.
• Tighten the screws with the specified tensioning pressure.
• Repeat the tensioning process in case of noticeable deviations, if ne-
cessary check the measuring devices or pressure indicator.
• Replace the screws as soon as the screw length exceeds the max.
screw length in the non-tensioned condition (see “Technical data”).
Initial situation Connecting rod small end is fitted on connecting rod shank, connecting rod
shank bolts screwed in by hand up to contact in connecting rod shank, nuts
screwed in and tightened by hand, connecting rod shank bolt threads
cleaned. The crank pin is at BDC.
The handle is attached to the crankcase, the foot board is inserted in the oil
sump.
Work steps 1. Using a feeler gauge (000.451), check that the gap in the separation joint
between the connecting rod shank and connecting rod small end is
closed around the entire circumference (less than 0.05 mm).
NOTICE Property damage due to the use of overextended screws.
2. Measure and note down the bolt length of connecting rod shank bolts
(11) using a vernier calliper.
3. Clamp the measuring rod (030.573-1) into the measuring device
(030.573) and set the scale of the dial gauge (14) to “zero”. Remove the
measuring rod. See Fig. 5/I.
4. Mount the measuring device between the centring devices of the con-
necting rod shank bolt (11) at screw position 1. Read off the dial gauge
(14) and note down the value. See Figs. 1/Z and 5/II.
2020-12-08 - de
5. Remove the measuring device.

necting rod shank bolts (11) at screw positions 2 to 8.
015.000.030-02.
rod shank bolt (11) at screw position 2 and screw on the hydraulic ten-
sioner. See Figs. 3/X and 4.
4 (11) L51/60DF;L48/60CR, M010.040.010-03-0021

necting rod shank bolts (11) at screw positions 3, 6 and 7. See Figure 3/
X.
tions 015.000.002-01.
sioners.
11.Start up the high-pressure pump and tension the connecting rod shank
bolts (11) with the specified tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.003-01.
bolt (11) at screw position 1 and screw on the hydraulic tensioner. See
Figures 2/Y and 4.
(11) at screw positions 4, 5 and 8. See Fig. 2/Y.
sioners.
19.Start up the high-pressure pump and tension the connecting rod shank
bolts (11) with the specified tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.003-01.
24.Clamp the measuring rod into the measuring device and set the scale of
the dial gauge (14) to “zero”. Remove the measuring rod. See Fig. 5/I.
25.Mount the measuring device between the centring devices of the con-
2020-12-08 - de
necting rod shank bolt (11) at screw position 1. Read off the dial gauge
(14) and note down the value. See Figs. 1/Z and 5/II.
26.Remove the measuring device.
27.Repeat the process (work steps 25 and 26) in the same way for the con-
necting rod shank bolts (11) at screw positions 2 to 8.
28.Determine the difference (screw elongation Δl) of the individual connect-
ing rod shank bolts (11) based on the measurements from work steps 4
or 6 and 25 or 27.
L51/60DF;L48/60CR, M010.040.010-03-0021 5 (11)

29.Compare the screw elongation Δl of the individual connecting rod shank

bolts (11) with the setpoint value. The measurement of the screw elonga-
tion Δl serves only as a check. See Work Instructions 010.000.003-05.
30.For storage, keep the measuring device and the measuring rod in the
wooden box.
31.Remove the foot board (011.011 or 011.012) from the oil sump (13).
32.Detach the handle (011.013). Screw the hex bolt (15) into the handle (loss
prevention).
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6 (11) L51/60DF;L48/60CR, M010.040.010-03-0021

1 to 8 Screw position/tight- 10 Nut 12 Connecting rod

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ening sequence
9 Crankcase 11 Connecting rod shank 13 Oil pan
bolt
L51/60DF;L48/60CR, M010.040.010-03-0021 7 (11)

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1-8 Screw position/tighten- 12 Connecting rod 15 Hex screw

ing sequence
rangement for screw positions 1-4-5-8
8 (11) L51/60DF;L48/60CR, M010.040.010-03-0021


2020-12-08 - de
1-8 Screw position/tighten- 12 Connecting rod 15 Hex screw

ing sequence
rangement for screw positions 2-3-6-7
L51/60DF;L48/60CR, M010.040.010-03-0021 9 (11)

10 Nut
12 Connecting rod
Figure 4: Connecting rod shank bolt with attached hydraulic tensioner
2020-12-08 - de
11 Connecting rod shank 14 Dial gauge

bolt
12 Connecting rod I-II Work steps
Figure 5: Measuring the bolt elongation – Left illustration: Setting the dial
gauge to “zero” / Right illustration: Measuring the connecting rod shank bolt
10 (11) L51/60DF;L48/60CR, M010.040.010-03-0021


18014425580017931

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L51/60DF;L48/60CR, M010.040.010-03-0021 11 (11)

18014425580017931
2020-12-08 - de
L51/60DF;L48/60CR, M010.040.010-03-0021

Summary
Tension and release important threaded connections with the correct values,
ensure correct execution of work.
Big-end bearing bolts should be inspected at regular intervals by means of hy-
draulic tensioners.
tensioning the connecting rod bolts
releasing the connecting rod bolts.
Safety requirements
l Engine stopped
1 Sliding calliper 009.060 Standard
1 Thickness gauges 0.05-1 000.451 Option


2019-01-25 - de

Preliminary remarks
Checking for correct pretension of the hydraulically tensioned connecting rod
bearing bolts also forms part of the work specified in the maintenance sched-
ule. The release pressure is to be noted and compared with the tension pres-
L48/60CR, M010.040.010-04-0009 1 (9)

sure. Work Instructions describe the untightening or tightening the connecting

rod bearing bolts. This work is required in conjunction with other work e.g.
when checking the connecting rod bearing shells.
Do not turn the running gear!

When hydraulic tensioners are installed, the running gear may not be
turned.
Work Sequence 1 - Releasing the connecting rod bearing bolts

Starting position Crankcase is opened, crank pin of the concerned cylinder is at BDC.
Prerequisite for correct releasing

A prerequisite for correct releasing of a bolted connection is a pres-
Work steps 1. Insert the foot board (011.007 for a normal oil sump or 011.003 for a V oil
2. Clean the threads of the connecting rod bearing bolts (1).
3. Place the thrust pieces (055.241) over the nuts (2).
4. Screw the hydraulic tensioners (009.632) onto the connecting rod bear-
ing bolts (1), ensuring that the thrust pieces are centred by the hydraulic
tensioners. See Figs. 2 and 3.
and the high-pressure pump (009.342).

2019-01-25 - de

served.
7. Start up the high-pressure pump and close the gap caused by turning
back. See Work Instructions 015.000.003-01.
2 (9) L48/60CR, M010.040.010-04-0009


9. Make a note of the release pressure and compare it to the tensioning

pressure.
10.Turn both nuts (2) back through the opening in the thrust pieces using
the tommy bar (000.264). For turning-back angle, see Work Instructions
010.000.003-05.
draulic tensioners and high-pressure pump.
12.Detach the tool.
Work Sequence 2 - Tightening the connecting rod bearing bolts

Initial situation Connecting rod bearing is pre-assembled, connecting rod bearing bolt
threads are cleaned. Respective cylinder’s crank pin at BDC. Foot board in-
serted in oil sump.
Prerequisite for correct tightening

A prerequisite for correct tightening of a bolted connection is a pres-
Work steps 1. Check that the parting line between the connecting rod bearing cover
and connecting rod shank is equal on both sides.
Permanent length of big-end bearing bolt

As a result of irregular circumstances, the big-end bearing bolt can be
permanently stretched. If the length of 686.90 mm (untensioned) is ex-
ceeded, the big-end bearing bolt should be replaced.

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Preparing measurement report

A separate measurement report for the tensioning of the big-end bear-
ing bolts is recommended.
2. Measure and note the length of both connecting rod bearing bolts (1) us-
ing a vernier scale (009.060). See Fig. 4.
3. Position thrust piece (055.241) over the nuts (2).
L48/60CR, M010.040.010-04-0009 3 (9)

4. Screw the hydraulic tensioners (009.632) onto the connecting rod bear-
ing bolts (1), ensuring that the thrust pieces are centred by the hydraulic
tensioners. See Figs. 2 and 3.
and the high-pressure pump (009.342).

served.
6. Start the high-pressure pump and tighten the connecting rod bearing
bolts (1) with a pre-tensioning pressure of 400 bar. See Work Instructions
015.000.003-01
7. Tighten both nuts (2) by hand through the opening in the thrust pieces,
using the tommy bar (000.264).
9. Reset the hydraulic tensioners, so that the complete tensioners are again
in full contact with the connecting rod shank.

served.
10.Start the high-pressure pump (see Work Instructions 015.000.003-01)

and tighten the connecting rod bearing bolts (1) with the specified ten-
sioning pressure (see Work Instructions 010.000.003-05).
11.Tighten both nuts (2) by hand through the opening in the thrust pieces,
2019-01-25 - de
using the tommy bar (000.264).

draulic tensioners and high-pressure pump.
13.Detach the tool.
14.Measure and note the bolt length of both connecting rod bearing bolts (1)
using a vernier scale.
4 (9) L48/60CR, M010.040.010-04-0009

Difference values are elongation values

The difference values are the elongation values of individual connect-
ing rod bearing bolts.
15.Determine the difference value of individual connecting rod bearing bolts

(1) based on the measured values, Steps 2 and 14.
Bolt elongation only intended for inspection purposes

Bolts should be tensioned to the specified tensioning pressure, not ac-
cording to the bolt elongation ∆l. The measurement of the bolt elonga-
tion ∆l is only intended for inspection purposes.
9007202633559179
16.Compare the bolt elongation Δl of the individual connecting rod bearing

bolts (1) with the target value. See Work Instructions 010.000.003-05
17.Remove the foot board from the oil sump (5).

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L48/60CR, M010.040.010-04-0009 5 (9)

1 Connecting rod bearing 3 Connecting rod 5 Oil sump

bolt
2 Nut 4 Cylinder crankcase
Figure 1: Connecting rod – Illustration of engine with normal oil sump
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6 (9) L48/60CR, M010.040.010-04-0009

3 Connecting rod 4 Cylinder crankcase 5 Oil sump

Figure 2: Connecting rod bearing bolts with attached tensioners

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L48/60CR, M010.040.010-04-0009 7 (9)

1 Connecting rod bearing bolt 3 Connecting rod

2 Nut
Figure 3: Connecting rod bearing bolt with attached tensioner
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8 (9) L48/60CR, M010.040.010-04-0009

1 Connecting rod bearing 3 Connecting rod

bolt
Figure 4: Measuring the connecting rod bearing bolt
9007202633559179

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L48/60CR, M010.040.010-04-0009 9 (9)

9007202633559179
2019-01-25 - de
L48/60CR, M010.040.010-04-0009
Lower big-end bearing shell

inspecting
Summary
ensure the operational safety of the bearings.
Bearing shells must be checked at regular intervals. From wear condition and
running profile, conclusions can be drawn regarding the load conditions, lub-
ricating oil care etc.
Safety requirements
l Engine stopped
1 Cable guide 030.810 Standard
1 Wire rope 030.756 Standard
2 Bracket 030.195 Standard

2018-02-15 - de

Evaluate galvanised bearings 010.000.003-01
Loosening and tightening the big-end bearing bolts 010.040.010-04
Check contact surface for big-end bearing shells 010.040.010-07
Rework contact surface for big-end bearing shells 010.040.010-08
Work Sequence 1 - Removal of the bottom big-end bearing shell

Initial situation Crankcase covers are removed. Respective cylinder’s crank pin at BDC.
L51/60DF, M010.040.010-05-0023 1 (11)

Work steps 1. Release the big-end bearing bolts (2) See Work Instructions
010.040.010-04.
2. Fasten two retaining devices (030.195) onto the big-end bearing cover (7)
and connecting rod shank (4) using hex bolts (9 and 10). See Fig. 2.
3. Unscrew the nuts (3).
4. Unscrew the big-end bearing bolts (2) by hand, and remove. See Fig. 3.
Turning the running gear over

Turning the running gear after fitting the rope guides is not allowed.
5. Fasten the cable guide (030.810) between counterweights (1). Screw in

both bolts (11) of the cable guide at the counterweights until they abut.
See Fig. 4.
6. Attach cable guide (030.809) with hex bolts (12) to counter weights (1).
Make sure that the cable guide can still be easily moved.
7. Hook in the ratchet hoist (002.552) at a suitable place.
8. Place the cable (030.756) over the cable guides. In doing so, pay atten-
tion to the different lengths of the cable ends. See Fig. 5.
9. Fasten the ends of the cable with shackles (002.452) to the retaining
devices.
10.Suspend cable from the ratchet hoist.
11.Tension the cable slightly.
12.Unscrew hex bolts (9). See Fig. 6.
13.Actuate the ratchet hoist to lower big-end bearing cover (7) until it
reaches oil sump (6). See Fig. 7.
14.Remove the big-end bearing shell (14).
15.Clean the running surfaces of big-end bearing shell (14) carefully, without
damaging them.
16.Check the condition of the running surface. See Work Instructions
010.000.003-01.
Inspection of connecting rod bearing shell

Reworking of the connecting rod bearing shell is forbidden.
Connecting rod bearing shells that are damaged or that have severe
2018-02-15 - de
score marks should be replaced.

If there are score marks on the connecting rod bearing shell, the crank
pins must be inspected and re-polished if necessary (polishing cloth
with grain size < 15μm).
17.Carefully clean the contact area (F) on big-end bearing cover (7) and
check for fretting. See Work Instructions 010.040.010-07. Rework any
areas affected by fretting. See Work Instructions 010.040.010-08/see
Fig. 8.
2 (11) L51/60DF, M010.040.010-05-0023

Work Sequence 2 - Installation of the lower big-end bearing shell
New connecting rod bearing shells

New connecting rod bearing shells are delivered ready to install and
must not be reworked or otherwise machined in any way.
Initial situation Respective cylinder’s crank pin at BDC. The big-end bearing shell is cleaned.
Contact area on big-end bearing cover cleaned and checked for fretting.
Work steps 1. Thoroughly lubricate the running surface of the big-end bearing shell (14)
with oil (the backside of the big-end bearing shell remains dry).
2. Insert big-end bearing shell (14) in big-end bearing cover (7), ensuring the
correct position of locating pin (15) for fixing the big-end bearing shells.
See Fig. 7.
3. Lift up big-end bearing cover (7) by operating the ratchet hoist (002.552)
until it makes contact with the connecting rod shank (4). When joining the
big-end bearing cover with the connecting rod shank, pay attention to
the locating pins (8). See Figs. 1 and 7.
4. Screw the hex bolts (9) into the connecting rod shank (4) through the re-
taining devices (030.195) and tighten. See Figs. 5 and 6.
5. Unhook the cable (030.756) from the ratchet hoist.
6. Detach the cable from the retaining devices and remove it.
7. Remove the ratchet hoist.
8. Remove the cable guides (030.809 and 030.810). See Fig. 4.
9. Clean the big-end bearing bolts (2).
10.Install big-end bearing bolts from above, through connecting rod shank
(4), screw them into big-end bearing cover (7) and tighten by hand until
the big-end bearing bolt collar comes into contact. See Fig. 3.
11.Tighten the nuts (3) hand-tight until contact is made. See Fig. 2.
12.Remove the retaining devices (030.195).
13.Tension big-end bearing bolts (2). See Work Instructions
010.040.010-04.
14.Check the bearing clearance with thickness gauge (000.454); in doing so,
insert the thickness gauge approx. 10 mm deep from the coupling side
and from the free engine end.
2018-02-15 - de
Engine run-in
After installation, the engine must be run in. See Volume 010.005 En-
gine - operating manual, Sheet 010.000.024-05.
L51/60DF, M010.040.010-05-0023 3 (11)

1 Counterweight 4 Conrod shank 7 Big-end bearing cover

2 Big-end bearing bolt 5 Cylinder crankcase 8 Locating pin
3 Nut 6 Oil sump
Figure 1: Conrod - big-end bearing*

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4 (11) L51/60DF, M010.040.010-05-0023


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2 Big-end bearing bolt 4 Conrod shank 9 Hexagon bolt M16 x 25

3 Nut 7 Big-end bearing cover 10 Hexagon bolt M16 x 25
Figure 2: Big-end bearing - attaching/detaching the retaining brackets//screwing the nuts off/on *
L51/60DF, M010.040.010-05-0023 5 (11)

2 Big-end bearing bolt 4 Conrod shank 7 Big-end bearing cover

Figure 3: Big-end bearing - removing/installing the big-end bearing bolts *
2018-02-15 - de
6 (11) L51/60DF, M010.040.010-05-0023


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4 Connecting rod shank 12 Hex bolt M16x30
7 Big-end bearing cover
Figure 4: Big-end bearing - fitting/removing the cable guides *
L51/60DF, M010.040.010-05-0023 7 (11)

13 Suspension point
Figure 5: Big-end bearing - fitting/removing the wire rope *
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8 (11) L51/60DF, M010.040.010-05-0023

4 Conrod shank 9 Hexagon bolt M16 x 25

Figure 6: Big-end bearing - removing/installing the hexagon bolts (connecting the conrod shank/retaining
brackets) *

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L51/60DF, M010.040.010-05-0023 9 (11)

6 Oil sump 8 Locating pin 15 Locating pin

7 Big-end bearing cover 14 Big-end bearing shell
Figure 7: Big-end bearing - lowering/raising the big-end bearing cover//inspecting the big-end bearing shell
*
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7 Big-end bearing cap

F Contact area
Figure 8: Big-end bearing cap - contact face for big-end bearing shell
10 (11) L51/60DF, M010.040.010-05-0023

* Illustration in the figures

The illustration in the figures shows the 51/60DF in-line engine with V
oil sump.
The illustration of the counterweight in the figures may differ in shape
from the actual counterweights installed on the engine.
27949444235

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L51/60DF, M010.040.010-05-0023 11 (11)

27949444235
2018-02-15 - de
L51/60DF, M010.040.010-05-0023
Upper connecting rod bearing shell

inspecting
Summary
ensure the operational safety of the bearings.
Bearing shells must be checked at regular intervals. From wear condition and
running profile, conclusions can be drawn regarding the load conditions, lub-
ricating oil care etc.
Safety requirements
l Engine stopped
Tools/aids required
2 Support fixture 030.503 Standard
1 Strap 030.208 Standard
2 Holder 030.192 Standard

1 Rope - Inventory

Evaluate galvanised bearings 010.000.003-01
2019-05-23 - de
checking lower big-end bearing shell 010.040.010-05
Preliminary remark
The figures in these work instructions show the engine with V oil sump. The
work instructions are also valid for engines with standard oil sump since the
procedure is the same.
L48/60CR, M010.040.010-06-0024 1 (14)

Work Sequence 1 - Removing the upper big-end bearing shell

Initial situation Connecting rod bearing cover lowered. Respective cylinder’s crank pin at
BDC.
Work steps 1. Unhook the wire rope (030.756) from the ratchet hoist (002.552).
2. Release the wire rope from the retaining devices (030.195) and remove it.
3. Remove the rope guides (030.809 and 030.810). See Fig. 2
Affixing the connecting rod bearing shell

Holders are used for fixing the connecting rod bearing shell in the con-
necting rod shank.
4. Fasten two holders (030.192) to the connecting rod shank (4). See Fig. 3
Secure the connecting rod shank

With the assembly of the tensioning strap, the connecting rod shank is
secured against slipping off the crank pin during turning.
5. Lay the tensioning strap (030.208) around the crank pin (16) and fasten it
to the connecting rod shank (4).

to life.
optical signals
6. Turn running gear until crank pin (16) is about 60° before/after TDC. See
Fig. 4
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Information on the support device 030.503 or 030.504

Depending on the installed cylinder head, the two support devices
030.503 or the two support devices 030.504 are included in the scope
of supply of the tools and must be installed.
7. Mount two support devices (030.503 or 030.504) on the cylinder liner

(20), fastening a support device each on the coupling side (CS) and on
the free engine end (FFE) in the process. See Fig. 5
2 (14) L48/60CR, M010.040.010-06-0024


to life.
optical signals
Place piston on supporting devices

Turn the running gear only until the piston rests on the supporting
devices.
8. Turn the piston (21) carefully downwards until it rests on the support fix-
tures. See Fig. 6
9. Loop the rope (22) around the connecting rod shank (4), attach it to the
lifting tackle, and fix the connecting rod shank in this position. See Fig. 7
10.Remove the tensioning strap.

to life.
optical signals
11.Turn out the crank pin (16) downwards from the connecting rod shank (4) Upper connecting rod bearing shell
until the big-end bearing shell (23) is easily accessible. See Fig. 8
12.Hold on to the big-end bearing shell (23) by hand and remove the retain-
ing devices. Remove the big-end bearing shell.
13.Clean the running surfaces of big-end bearing shell (23) carefully, without
damaging them.
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14.Check the condition of the running surface. See Work Instructions

010.000.003-02.
L48/60CR, M010.040.010-06-0024 3 (14)

Inspection of connecting rod bearing shell

Reworking of the connecting rod bearing shell is forbidden.
Connecting rod bearing shells that are damaged or that have severe
score marks should be replaced.
If there are score marks on the connecting rod bearing shell, the crank
pins must be inspected and re-polished if necessary (polishing cloth
with grain size < 15μm).
15.Carefully clean the contact surface (F) on the connecting rod shank (9)
and check for fretting. See Work Instructions 010.040.010-07. Rework
any areas affected by fretting. See Work Instructions 010.040.010-08/
Fig. 9.
Work Sequence 2 - Installing the upper big-end bearing shell
New connecting rod bearing shells

New connecting rod bearing shells are delivered ready to install and
must not be reworked or otherwise machined in any way.
Initial situation Crank pin turned out of connecting rod shank. The connecting rod bearing
shell has been cleaned. Contact area on connecting rod shank cleaned and
checked for fretting.
Work steps 1. Thoroughly oil the running surface of the connecting rod bearing shell (23)
(the back side of the big-end bearing shell remains dry).
2. Insert the big-end bearing shell (23) into the connecting rod shank (4), en-
suring correct position of locating pin (24) for fixing the big-end bearing
shells. See Fig. 8

necting rod shank.
3. Fasten two holders (030.192) to the connecting rod shank (4).

2019-05-23 - de

to life.
optical signals
4 (14) L48/60CR, M010.040.010-06-0024

4. Carefully turn the running gear until the crank pin (16) abuts the connect-
ing rod shank/big-end bearing shell (4/23). See Fig. 7

5. Lay the tensioning strap (030.208) around the crank pin (16) and fasten it
to the connecting rod shank (4). See Fig. 3 and 7.
6. Remove the rope (22).

to life.
optical signals
7. Turn running gear until crank pin (16) is about 60° before/after TDC. See
Fig. 5
8. Remove the support device (030.503 or 030.504).

to life.
optical signals
9. Turn the running gear until the crank pin (16) is at BDC. See Fig. 3
2019-05-23 - de
10.Remove the tensioning strap (030.208) and holders (030.192).

11.Fasten the rope guide (030.810) between the counterweights (1). Screw
in both bolts (11) of the rope guide at the counterweights until they abut.
See Fig. 2
L48/60CR, M010.040.010-06-0024 5 (14)

12.Attach the rope guide (030.809) with hex bolts (12) to the counterweights
(1). Make sure that the rope guide can still be easily moved.
13.Place the wire rope (030.756) over the rope guides. In doing so, pay at-
tention to the different lengths of the wire rope ends. See Fig. 1
14.Fasten the wire rope ends with shackles (002.452) to the retaining
devices (030.195).
15.Hook the wire rope onto the ratchet hoist (002.552).
16.Tension the wire rope lightly.
Engine run-in
After installation, the engine must be run in. See Volume 010.005 En-
gine - operating manual, Sheet 010.000.024-05.
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1 Counterweight 7 Big-end bearing cover

4 Connecting rod shank 13 Suspension point
6 Oil sump 16 Crankshaft/crank pin
Figure 1: Big-end bearing - lowered big-end bearing cover *
6 (14) L48/60CR, M010.040.010-06-0024


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1 Counterweight 12 Hex bolt M16x30

4 Connecting rod shank 16 Crankshaft/crank pin
11 Bolts
L48/60CR, M010.040.010-06-0024 7 (14)

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16 Crankshaft/crank pin 18 Hexagon bolt M10 x 20
Figure 3: Big-end bearing - fitting/removing the holders and the tensioning strap *
8 (14) L48/60CR, M010.040.010-06-0024

16 Crankshaft/crank pin
Figure 4: Big-end bearing - crank pin approx. 60° before/after TDC *

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L48/60CR, M010.040.010-06-0024 9 (14)

4 Connecting rod shank 20 Cylinder liner FEE Free engine end

19 Hex bolt M16 x 55 CS Coupling side
Figure 5: Connecting rod bearing - fitting/removing the support devices *
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10 (14) L48/60CR, M010.040.010-06-0024

4 Connecting rod shank 20 Cylinder liner

16 Crankshaft/crank pin 21 Piston
Figure 6: Connecting rod bearing - lowering the piston onto the support devices *

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L48/60CR, M010.040.010-06-0024 11 (14)

4 Conrod shank 16 Crankshaft/crank pin 22 Rope

Figure 7: Big-end bearing - fixing the conrod shank *
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12 (14) L48/60CR, M010.040.010-06-0024

4 Conrod shank 22 Rope 24 Locating pin

16 Crankshaft/crank pin 23 Big-end bearing shell
Figure 8: Big-end bearing - rotating back the crank pin/inspecting the big-end bearing shell *
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L48/60CR, M010.040.010-06-0024 13 (14)

4 Connecting rod shank

F Contact area
Figure 9: Connecting rod shank - Contact surface for big-end bearing shell
* Illustrations in the figures

18014427035976331
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14 (14) L48/60CR, M010.040.010-06-0024

Contact surface for connecting rod bearing shells

checking
Summary
Ensure/ restore operational safety, ensure correct execution of work.
The contact surfaces of the big-end bearing shells shall be cleaned and
checked during every inspection of the big-end bearing shells.
The work sequence includes:
cleaning and checking components.
Safety requirements
l Components secured against moving
Tools/aids required
1 safety goggles - Inventory
1 Protective gloves - Inventory
1 Fibre mat with resin-bonded abrasive - Inventory
1 Diesel oil, clean - Inventory

1 Rust inhibitor - Inventory
1 Solvent cleaner - Inventory

checking lower big-end bearing shell 010.040.010-05
Remove / install big-end bearing cap/big-end shank 010.040.010-10
Work sequence - Cleaning and checking the contact surface

Initial condition Connecting rod bearing cap lowered, connecting rod shank secured, con-
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necting rod bearing shell removed. See Work Instructions 010.040.010-05.
General, M010.040.010-07-0001 1 (5)

Risk of acid burns

Poisonous gases and fumes can develop from cleaning agents and
may lead to severe personal injuries.
manufacturer
Work Steps 1. Cover crankcase using suitable equipment, especially at the sides, to
prevent the ingress of dirt.
2. Apply anti-corrosion agent or clean diesel oil onto contact surface (FL) on
the connecting rod bearing cap (2). Clean contact surface using non-
woven fabric (3) until it is absolutely dirt-free. To facilitate cleaning, wrap
non-woven fabric around a type of support (4). See Figs. 1 to 3.
3. Check contact surface (FL) on the connecting rod bearing cap (2) com-
pletely and thoroughly for fretting (G). Fretting can easily be identified by
running one's fingernail over suspicious surfaces. If in doing so rough or
uneven surfaces are felt/detected, these are indications of fretting. Please
contact MAN PrimeServ if you are in any doubt. For examples, see Fig-
ures 4 and 5.
Fretting areas
If there is no fretting (G) on the clean contact surfaces (FL), the con-
necting rod bearing cap (2) can be mounted again without further in-
spection of the contact area (FU) on the connecting rod shank (1).
If there are fretting areas on the contact surfaces (FL) on the connect-
ing rod bearing cap (2), the contact area (FU) on the connecting rod
shank (1) must be inspected and reworked if necessary. See Points 6
to 9/see Work Instructions 010.040.010-08.
If fretting areas are found on a connecting rod, MAN Energy Solutions
recommends inspecting the connecting rod bearing cover on all other
connecting rods. Points 1 to 4 must always be followed when doing
this. If more fretting is found on a connecting rod bearing cover, points
6 to 9 must then be followed on the connecting rod shank.
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4. Clean contact surface (FL) on connecting rod bearing cap (2) with a
solvent cleaner. The contact surface must be absolutely free of dirt and
oil residues.
5. Remove the cover from the crankcase.
6. Remove connecting rod shank (1). See Work Instructions
010.040.010-10.
7. Apply anti-corrosion agent or clean diesel oil onto contact surface (FU) of
the connecting rod shank (1). Clean contact surface using non-woven
fabric (3) until it is absolutely dirt-free. To facilitate cleaning, wrap non-
woven fabric around a type of support (4).
2 (5) General, M010.040.010-07-0001

8. Check contact surface (FU) on the connecting rod shank (1) completely
and thoroughly for fretting (G).
9. Clean contact surface (FU) on connecting rod shank (1) with a solvent
cleaner. The contact surface must be absolutely free of dirt and oil
residues.
Tool name Manufacturer (example)
Non-woven fabric with resin-bonded ab- Scotch-BriteTM WR-RL, Type A medium

rasive
Anti-corrosion agent ANTICORIT 1
Solvent cleaner ARDROX 9PR88

Table 1: Required tools/manufacturers
1 Connecting rod shank Contact surface for connecting rod bearing shells
2 Connecting rod bearing cover
FL Contact area (connecting rod bearing cover)
FU Contact area (connecting rod shank)
Figure 1: Connecting rod shank and connecting-rod bearing cover (Depiction
shows 48/60 B)
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General, M010.040.010-07-0001 3 (5)

2 Connecting rod bearing 4 Support (e.g. aluminium

cover profile)
3 Non-woven fabric FL Contact area (connecting
rod bearing cover)
Figure 2: Connecting rod bearing cover - Cleaning with non-woven fabric
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Figure 3: Connecting rod bearing cover - Illustration above: before cleaning/il-

lustration below: after cleaning
4 (5) General, M010.040.010-07-0001

G Fretting
Figure 4: Big-end bearing cap - Fretting *

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G Fretting
Figure 5: Big-end bearing cap - Fretting *
* not all fretting areas are marked in the illustrations

18014405420291979
General, M010.040.010-07-0001 5 (5)

18014405420291979
2018-09-11 - de
General, M010.040.010-07-0001

reworking
Summary
Ensure / restore operational safety, ensure correct execution of work.
If fretting areas are identified during cleaning and inspection of the contact
surface for the big-end bearing shells, the contact surface must be reworked.
reworking the components.
1 Straightedge - Inventory
1 Hand grinder - Inventory
1 Grinding tool and measurement equipment, - Inventory
refer to table
1 Torch - Inventory
1 Loctite 7063 rapid cleaner - Inventory

Grinding tool and measurement equipment
Tool designation
Callipers with pin gauge, Ø1–1.5 mm ultra-thin probe
Sharpening stone 150x50x25 mm, with 100 grits at the top / 280/320 grits at the
bottom
Abrasive pencil, spherical, Ø5–7 mm, 150 grits
Abrasive pencil for polishing, Ø6x10 mm, 280 grits

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Surface examination using magnetic leakage flux method 010.000.003-09

Removing / installing connecting rod bearing cover/con- 010.040.010-10
necting rod shank
Work Sequence - Reworking contact surfaces

Initial situation The contact surfaces for the connecting rod bearing shells are cleaned and
checked. Refer to work instructions 010.040.010-07.
Connecting rod shank and connecting rod bearing cover are removed. See
General, M010.040.010-08-0004 1 (17)

Work steps
Start-up of the portable grinding machine

Read the Operator's Manual carefully before start-up of the portable
grinding machine.
Risk of injury
The rotation of the tool at high speed can result in parts that fly off the
grinder causing injuries to the eyes and turning parts could catch long
hair and loose clothing.
• Wear safety goggles
• Tie back long hair
• Do not wear loose clothing
Acid burn risk

• Wear protective clothing.

manufacturer
Test method for crack-testing

The crack-testing must be carried out by a qualified professional by
means of magnetic particle inspection. Crack-testing by means of a
penetration test is insufficient, since not all fine cracks can be detec-
ted.
1. Using a sharpening stone, remove material build-up around the fretting

areas (including the smallest ones) until a flat contact surface (F) is re-
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stored.
There is no need to rework the entire contact surface (F) using the
sharpening stone. It is not permitted to use fan grinders to remove mater-
ial build-up! See Figs. 5 to 8.
2. Clean contact surface (F) using Loctite 7063 rapid cleaner.
3. Check the contact surface (F) for cracks using only the magnetic particle
inspection method. See Work Instructions 010.000.003-09/see Figs. 9
and 10.
4. Evaluate crack indications according to zones A and B. See instructions
in "Evaluating zone A" and "Evaluating zone B" on page 3/refer to Figs. 2
and 11.
2 (17) General, M010.040.010-08-0004

5. Using an abrasive pencil, hollow out crack indications to a minimal extent

so as to preserve the original contact surface as much as possible.
Hollowing-out should usually be performed within an area of 10 x 10 mm.
Ideally, the hollow-out process should be carried out under illumination
using a UV light. See Figs 12 and 13.
6. Repeat work steps 3 to 5 in several cycles as required until no more
crack indications are present or the depth of the hollowed-out section
has reached 1.0 mm.
In case crack indications are still visible at the maximum permissible hol-
low-out depth of 1.0 mm, further use of the connecting rod is not al-
lowed. If this is the case, it is advised that an overhaul by means of re-
machining be performed by MAN PrimeServ Hamburg as soon as pos-
sible.
7. Smooth out hollowed-out area with a polishing pin and break or chamfer
edges. See Figs 14 and 15.
Evaluating zone A
Zone A (marked red, ±35° from the apex)
• generally, no crack indications/hollowed-out sections are permitted in
this area
• should crack indications be present in these areas, it is advised that an
overhaul by means of re-machining be performed by MAN PrimeServ
Hamburg as soon as possible

Evaluating zone B
Zone B (marked grey, quadrants I to IV)
In this area, the presence of hollowed-out sections is permitted, how-
ever, note that the following restrictions apply (see Fig. 3):
• Maximum permissible number of hollowed-out sections in quadrants I
and IV is 7, respectively
• Maximum permissible number of hollowed-out sections in quadrants II
and III is 10, respectively
• A maximum of 4 hollowed-out sections along the perimeter, inter-con-
nected and consecutively located; further hollowed-out sections must
be at a distance of at least 10 mm from each other
• A maximum of 2 hollowed-out sections in axial direction, inter-connec-
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ted and consecutively located; further hollowed-out sections must be

at a distance of at least 10 mm from each other
Exceedance
In case the permissible number, distribution and depth of hollowed-out
sections is exceeded, no further use of the connecting rod in its
present condition is allowed. It is advised that an overhaul by means of
re-machining be performed by MAN PrimeServ Hamburg as soon as
possible.
General, M010.040.010-08-0004 3 (17)

Fatal injury due to breakage of the connecting rod

Owing to existing cracks, components may escape from the engine as
a result of connecting rod breakage. This can cause fatal injuries.
• Replace connecting rod when crack indications persist
No crack indications
If no cracks have been reported then the connecting rod can be re-
used.
Manually reworked connecting rods

Manually reworked connecting rods must be checked for repeated
fretting, assessed and reworked as needed (work steps 1 to 7) after
every 12,000 operating hours at the latest. In case the permissible lim-
its for hollowed-out sections are exceeded in such a way that further
crack indications can’t be removed, it is advised that overhaul by
means of re-machining be performed by MAN PrimeServ Hamburg as
soon as possible.
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4 (17) General, M010.040.010-08-0004


2 Connecting rod bearing cover
F Contact area
in figure shows 48/60A)
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General, M010.040.010-08-0004 5 (17)

1 Connecting rod shank B grey zone

2 Connecting rod bearing ST Control side
cover
A red zone I-IV Quadrant
Figure 2: Connecting rod (Figure shows 48/60A)
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6 (17) General, M010.040.010-08-0004

Figure 3: Example of permissible number and spacing of hollowed-out sec-

tions

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General, M010.040.010-08-0004 7 (17)

Figure 4: Connecting rod bearing cover exhibiting severe fretting in certain

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areas*
8 (17) General, M010.040.010-08-0004


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Figure 5: Reworking fretting using a sharpening stone*
General, M010.040.010-08-0004 9 (17)

Figure 6: Smoothing of areas affected by fretting, with material build-up still

visible*
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10 (17) General, M010.040.010-08-0004

Figure 7: Complete removal of material build-up*

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General, M010.040.010-08-0004 11 (17)

Figure 8: Inspection of reworked contact surface for straightness using a

straightedge*
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12 (17) General, M010.040.010-08-0004


Figure 9: Magnetising the connecting rod bearing cover*
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Figure 10: Inspection for crack indications using a UV light*
General, M010.040.010-08-0004 13 (17)

Figure 11: Crack indications*

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14 (17) General, M010.040.010-08-0004

Figure 12: Hollowing out the crack indications under UV light*

Figure 13: Hollowing out section using an abrasive pencil*
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General, M010.040.010-08-0004 15 (17)

Figure 14: Polishing hollowed-out section*
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Figure 15: Gradually polished hollowed-out section (Top surface fully

smoothed by polishing and surrounding edges rounded off)*
16 (17) General, M010.040.010-08-0004

Figure 16: Checking for cracks with no further crack indications present*
* Illustrations show components of 32/40 engine

18014418878925451

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General, M010.040.010-08-0004 17 (17)

18014418878925451
2018-11-28 - de
General, M010.040.010-08-0004
Connecting rod shank

Summary
Ensure correct execution of work. If damaged slightly, rework the crank pin.
The connecting rod shank does not have to be removed for normal mainten-
ance work. Removal is only necessary in extraordinary circumstances.
Safety requirements
l Engine stopped
1 support 030.812 Standard
1 Wire rope 030.756 Standard
1 Suspension device 030.508 Standard
1 Carrier 030.507 Standard
1 Washer 030.507-2 Standard
1 Strap 030.208 Standard
2 Bracket 030.195 Standard
2 Holder 030.192 Standard
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1 Rope - Inventory
L51/60DF, M010.040.010-10-0018 1 (24)


Loosening and tightening the big-end bearing bolts 010.040.010-04
Technical data
Connecting rod shank with connecting rod 310 kg
Weight
bearing shell
Connecting rod bearing cover with connecting Weight 135 kg
rod bearing shell
Connecting rod bearing bolt Weight 15 kg
Work Sequence 1 - Disassembly of the connecting rod shank
Removing the conrod shank

The figures and text relate to the removal of the conrod shank on the
exhaust-gas side. Removal on the control side is also possible.
Initial situation Crankcase covers are removed. Flame ring and pistons are removed. Re-
spective cylinder’s crank pin at BDC.
Work steps 1. Release the big-end bearing bolts (2) See Work Instructions
010.040.010-04.
2. Fasten two retaining devices (030.195) onto the big-end bearing cover (7)
and connecting rod shank (4) using hex bolts (9 and 10). See Fig. 2.
3. Unscrew the nuts (3).
4. Unscrew the big-end bearing bolts (2) by hand, and remove. See Fig. 3.

5. Fasten the cable guide (030.810) between counterweights (1). Screw in

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See Fig. 4.
6. Attach cable guide (030.809) with hex bolts (12) to counter weights (1).
7. Hook in the ratchet hoist (002.552) at a suitable place.
8. Place the cable (030.756) over the cable guides. In doing so, pay atten-
9. Fasten the ends of the cable with shackles (002.452) to the retaining
devices.
2 (24) L51/60DF, M010.040.010-10-0018


12.Unscrew hex bolts (9). See Fig. 6.
13.Actuate the ratchet hoist to lower big-end bearing cover (7) until it
reaches oil sump (6). See Fig. 7.
14.Unhook the cable from the ratchet hoist.
15.Detach the cable from the retaining devices and remove it.
16.Remove the ratchet hoist.
17.Remove the cable guides (030.809 and 030.810). See Fig. 8.

necting rod shank.
18.Fasten two retaining devices (030.192) to the connecting rod shank (4).
See Fig. 9.
19.Insert support (030.507) into connecting rod shank (4) from above. Fit
disc (030.507-2) and washer (17) on the support, then screw on and
tighten hex nut (16).

20.Lay the tensioning strap (030.208) around the crank pin (14) and fasten it

to life.
optical signals
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21.Rotate the running gear until the connecting rod shank (4) is 10° from the
horizontal. See Fig. 10.
22.Guide the support (030.812) into the crankcase from the exhaust-gas
side, making sure that the rollers (22) of the support (030.507) are resting
on the bottom flange of the support. See Fig. 11.
23.Place the support (030.812) onto the crank pin (14). Fasten support to
cylinder crankcase (5) with hex bolt (19). It may be necessary to carefully
turn the running gear a little.
L51/60DF, M010.040.010-10-0018 3 (24)

24.Check that rollers (22) of the support (030.507) are resting on the bottom
flange of the support (030.812), slightly turn the running gear carefully if
necessary.
25.Fasten the support (030.812) to counterweights (1) using two hex bolts
(20).
26.Hook the guide piece (24) of the holder (030.508) into the support
(030.812). Insert the holder into the connecting rod shank (4), then screw
in and tighten the hex nuts (25). See Fig. 12.
27.Remove the securing clip (030.811) and the tensioning strap (030.208).
28.Fasten rope (23) with shackle (002.453) to the suspension device. Attach
the rope to the lifting tackle.
29.Pull connecting rod shank (4) out towards the exhaust-gas side until it
reaches the stop of the guide piece (24) at the end of the support. See
Fig. 13.
30.Slightly lift the connecting rod shank (4). Unhook the guide piece (24)
from the support (030.812).
31.Pull out the connecting rod shank (4) parallel to the support (030.812) un-
til the support (030.507) is in contact with the end of the support. See
Fig. 14.
Swivelling the conrod shank

To swivel the conrod shank for further removal, two hexagon bolts
need to be screwed into the carrier. If this is not performed, then it will
not be possible to swivel the conrod shank.
32.Screw two hex bolts (27) into the support (030.812). See Fig. 15.

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33.Pull connecting rod shank (4) upwards and unhook the support (030.507)
from the support (030.812). See Fig. 16.
34.Detach support (030.507).
35.Set connecting rod shank (4) down carefully on a wooden support, taking
holders (030.192) into account.
36.Detach or remove the tools (030.812 and 030.508).
4 (24) L51/60DF, M010.040.010-10-0018

Work Sequence 2 - Installing the connecting rod shank
Installing the conrod shank

The figures and text relate to the installation of the conrod shank on
the exhaust-gas side. Installation on the control side is also possible.
Initial situation Running gear turned so that the crank pin/counterweight lies at 10° from the
horizontal. Big-end bearing shell is inserted into connecting rod shank and se-
cured in place with two holders (030.192).
Work steps 1. Insert the support (030.812) into the crankcase from the exhaust-gas
side and fasten it to cylinder crankcase (5) using hex bolt (19). See Fig.
11.
2. Check that the support (030.812) is resting on crank pin (14), slightly turn
the running gear carefully if necessary.
3. Fasten the support (030.812) to counterweights (1) using two hex bolts
(20).
Swivelling the conrod shank

To swivel the conrod shank for further installation, two hexagon bolts
need to be screwed into the carrier. If this is not performed, then it will
not be possible to swivel the conrod shank.
4. Screw two hex bolts (27) into the support (030.812). See Fig. 15.
5. Insert suspension device (030.508) into the connecting rod shank (4),
making sure that the installation position is correct (guide piece (24) must
be on the control side of the connecting rod shank – see marking on
connecting rod shank). Screw on and tighten hex nuts (25). See Fig. 12.
6. Fasten rope (23) with shackle (002.453) to the suspension device. Attach
the rope to the lifting tackle.

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7. Lift connecting rod shank (4).

8. Insert support (030.507) into connecting rod shank (4) on the control side
(see identification on the connecting rod shank), making sure that the
mounting position is correct. Fit disc (030.507-2) and washer (17) on the
support, then screw on and tighten hex nut (16). See Fig. 9.
L51/60DF, M010.040.010-10-0018 5 (24)

9. Oil the running surface of the big-end bearing shell (30) well.
10.Move the connecting rod shank (4) over the support (030.812).
11.Lower connecting rod shank (4) and hook support (030.507) into support
(030.812). See Fig. 15.
12.Lower connecting rod shank (4) further until it is in parallel with the sup-
port (030.812). See Fig. 14.
13.Unscrew and remove two hex bolts (27). Let connecting rod shank (4)
slide slowly and carefully onto support (030.812) in the crankcase until
the guide piece (24) is at the end of the support.
14.Hang guide piece (24) into the support (030.812). See Fig. 13.
15.Let connecting rod shank (4) slide slowly on support (030.812) in the
crankcase, until the connecting rod shank /big-end bearing shell rests
against crank pin (14). See Fig. 12.

16.Lay the tensioning strap (030.208) around the crank pin (14) and fasten it
17.Fit retaining device (030.811-1) around connecting rod shank (4) and
fasten to counterweight (1) with two hex bolts (26). See Figs. 12 and 17.
18.Screw two hex bolts (28) into the retaining device until they make contact
with connecting rod shank (4).
19.Place thrust piece (030.811-2) on retaining device Turn the hex bolt (29)
until it makes contact with the counterweight (1) and the thrust piece on
the connecting rod shank (4). See Fig. 17.
20.Remove rope (23) from the suspension device.
21.Remove the suspension device (030.508) from connecting rod shank (4).
22.Carefully remove the support (030.812) from the crankcase.

to life.
2018-02-15 - de

optical signals
23.Turn the running gear until the crank pin (14) is at BDC. See Fig. 9.
24.Remove the tensioning strap (030.208) and holders (030.192).
6 (24) L51/60DF, M010.040.010-10-0018


25.Fasten the cable guide (030.810) between counterweights (1). Screw in

See Figs. 4 and 8.
26.Attach cable guide (030.809) with hex bolts (12) to counter weights (1).
27.Hook in the ratchet hoist (002.552) at a suitable place.
28.Place the cable (030.756) over the cable guides. In doing so, pay atten-
29.Fasten the cable ends with shackles (002.452) to the retaining devices
(030.195).
32.Oil the running surface of the big-end bearing shell (31) well.
33.Lift up big-end bearing cover (7) by operating the ratchet hoist until con-
tact is made with connecting rod shank (4). When joining the big-end
bearing cover with the connecting rod shank, pay attention to the locat-
ing pins (8). See Figs. 1 and 7.
34.Screw the hex bolts (9) into the connecting rod shank (4) through the re-
taining devices (030.195) and tighten. See Fig. 6.
35.Unhook the cable (030.756) from the ratchet hoist.
36.Detach the cable from the retaining devices and remove it.
37.Remove the ratchet hoist.
38.Remove the cable guides (030.809 and 030.810). See Fig. 4.
39.Clean the big-end bearing bolts (2).
40.Install big-end bearing bolts from above, through connecting rod shank
(4), screw them into big-end bearing cover (7) and tighten by hand until
the big-end bearing bolt collar comes into contact. See Fig. 3.
41.Tighten the nuts (3) hand-tight until contact is made. See Fig. 2.
42.Remove the retaining devices (030.195).
43.Tension big-end bearing bolts (2). See Work Instructions
010.040.010-04.
2018-02-15 - de
44.Check the bearing clearance with thickness gauge (000.454); in doing so,
insert the thickness gauge approx. 10 mm deep from the coupling side
and from the free engine end.
L51/60DF, M010.040.010-10-0018 7 (24)

1 Counterweight 6 Oil sump

2 Big-end bearing bolt 7 Big-end bearing cover
3 Nut 8 Locating pin
4 Connecting rod shank 30 Upper connecting rod bearing shell
5 Cylinder crankcase 31 Lower connecting rod bearing shell
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Figure 1: Connecting rod shank - big-end bearing *
8 (24) L51/60DF, M010.040.010-10-0018

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2 Big-end bearing bolt 7 Big-end bearing cover

3 Nut 9 Hex bolt M16x25
Figure 2: Big-end bearing - detaching/attaching the retaining brackets//screwing the nuts off/on *
L51/60DF, M010.040.010-10-0018 9 (24)

2 Big-end bearing bolt 4 Conrod shank 7 Big-end bearing cover

Figure 3: Big-end bearing - removing/installing the big-end bearing bolts *
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10 (24) L51/60DF, M010.040.010-10-0018

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L51/60DF, M010.040.010-10-0018 11 (24)

13 Suspension point
Figure 5: Big-end bearing - fitting the wire rope *
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12 (24) L51/60DF, M010.040.010-10-0018


Figure 6: Big-end bearing - removing/installing the hexagon bolts (connecting the conrod shank/retaining
bracket) *
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L51/60DF, M010.040.010-10-0018 13 (24)

6 Oil sump 8 Locating pin

7 Big-end bearing cover 31 Lower big-end bearing shell
Figure 7: Big-end bearing - lowering/raising the big-end bearing cover *
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14 (24) L51/60DF, M010.040.010-10-0018

1 Counterweight 12 Hex bolts M16x30

4 Connecting rod shank 14 Crankshaft
11 Bolts
Figure 8: Conrod shank - fitting/removing the cable guides *
2018-02-15 - de
L51/60DF, M010.040.010-10-0018 15 (24)

2018-02-15 - de
4 Connecting rod shank 17 Washer

14 Crankshaft 18 Hex bolt M10 x 20
15 Hex bolt M16x25 30 Upper connecting rod bearing shell
16 Hex nut M16
Figure 9: Connecting rod shank - fitting/removing the retaining devices, the carrier and the tensioning strap
*
16 (24) L51/60DF, M010.040.010-10-0018

14 Crankshaft
Figure 10: Conrod shank - crank pin turned 10° from the horizontal *
2018-02-15 - de
L51/60DF, M010.040.010-10-0018 17 (24)

2018-02-15 - de
1 Counterweight 19 Hex bolt M20x40


5 Cylinder crankcase 21 Support
14 Crankshaft 22 Roller
Figure 11: Conrod shank - installing/removing the carrier *
18 (24) L51/60DF, M010.040.010-10-0018

2018-02-15 - de
1 Counterweight 23 Rope
4 Connecting rod shank 24 Guide piece

14 Crankshaft 25 Hex nut M30
15 Hex bolt M16x25 26 Hex bolt M16x30
Figure 12: Conrod shank - fitting/removing the suspension device *
L51/60DF, M010.040.010-10-0018 19 (24)

4 Connecting rod shank 24 Guide piece

Figure 13: Connecting rod shank - removal/installation *
2018-02-15 - de
20 (24) L51/60DF, M010.040.010-10-0018


2018-02-15 - de
L51/60DF, M010.040.010-10-0018 21 (24)

2018-02-15 - de

Figure 15: Connecting rod shank - screwing the hex bolts in/out // swivelling the connecting rod shank *
22 (24) L51/60DF, M010.040.010-10-0018

1 Counterweight 14 Crankshaft
4 Connecting rod shank 30 Upper connecting rod bearing shell
5 Cylinder crankcase
2018-02-15 - de
L51/60DF, M010.040.010-10-0018 23 (24)

1 Counterweight 28 Hex bolt M12 x 45

4 Connecting rod shank 29 Hex bolt M12 x 45
26 Hex bolt M16 x 30
Figure 17: Mounting the securing clip *
* Illustration in the figures

2018-02-15 - de
The illustration in the figures shows the 51/60DF in-line engine with V
oil sump.
27972857611
24 (24) L51/60DF, M010.040.010-10-0018

Contact surface conrod small end/conrod shank

inspecting
Summary
Contact surfaces big-end bearing body/conrod shank must be cleaned and
checked after each release of this connection (e.g. during removal and install-
ation of piston).
Safety requirements
Tools/aids required


Reworking the contact surface conrod small end/conrod 010.040.010-15
shank
Work Sequence - Cleaning and checking the contact surfaces

Starting position Conrod shank secured, piston with conrod small end removed.
2014-12-17 - de
Protection during cleaning work!

Wear safety goggles and protective gloves for cleaning work!
Follow instructions issued by the manufacturing companies!
Work Steps 1. Cover crankcase using suitable equipment, especially at the sides, to
prevent the ingress of dirt.
L58/64CD, M010.040.010-14-0002 1 (3)

2. Apply slushing oil or clean diesel oil onto contact surfaces (F) on conrod
small end (1) or conrod shank (2). Clean the contact surfaces using fibre
mat (3) until it is absolutely dirt-free. To facilitate cleaning, wrap fibre mat
around a type of support.
3. Check contact surfaces (F) on conrod small end (1) or conrod shank (2)
completely and thoroughly for fretting (G). Fretting can easily be identified
by running one's finger nail over suspicious surfaces. If in doing so rough
or uneven surfaces are felt/detected, these are indications of fretting.
Fretting areas
If there is no fretting on the cleaned contact surfaces (F), conrod small
end or conrod shank may continue to be used.
If there are fretting areas, these must be reworked. See Work Instruc-
tions 010.040.010-15.
4. Clean contact surfaces (F) on conrod small end (1) or conrod shank (2)
with a solvent cleaner. Contact surfaces must be absolutely free of dirt
and oil residues.
Tool name Manufacturer (example).
Fibre mat with resin-bonded abrasive Scotch-BriteTM WR-RL, Type A medium
Anticorrosive agent ANTICORIT 1


13779268875
2014-12-17 - de
2 (3) L58/64CD, M010.040.010-14-0002

1 Conrod small end F Contact surface

2 Conrod shank
Figure 1: Conrod small end and conrod shank ready for inspection
13779268875

2014-12-17 - de
L58/64CD, M010.040.010-14-0002 3 (3)

13779268875
2014-12-17 - de
L58/64CD, M010.040.010-14-0002

reworking
Summary
surfaces conrod small end/conrod shank, the contact surfaces must be re-
worked.
Safety requirements
1 Fan grinder Ø40x10 mm - Inventory
1 Grinding cap Ø15 mm - Inventory

1 Abrasive cap holder - Inventory
1 Universal abrasive cleaner - Inventory

Inspecting the contact surface conrod small end/conrod 010.040.010-14
shank
2018-09-11 - de

Starting position Contact surface on conrod small end and conrod shank cleaned and inspec-
ted respectively. See Work Instructions 010.040.010-14.
Locating pin and connecting rod shank bolts have been removed from the
conrod small end.
Work sequence
General, M010.040.010-15-0002 1 (6)

Danger of chemical burns

From cleaning agents poisonous gases and fumes can develop, which
may cause light to severe person injuries.
• Do not inhale developed gases and fumes
• Observe Safety Data Sheets or Operating Instructions of the relevant
manufacturer
1. Smooth all fretting areas (even the smallest ones) using the universal ab-
rasive cleaner.
2. Visually document fretting spots and report to MAN PrimeServ.
Grinding out fretting spots

For a complete removal of the damaged material and to ensure the op-
timal preparation for the necessary crack test, the areas that were not
smoothed with the universal abrasive cleaner must be ground out. In
the process, the fretting spots (elevations and depressions) are ready
to be ground out until there is no more visible fretting and the contact
surfaces are shiny metallic, typically a few 1/100 mm deep. The extent
of the grinding out is to be restricted to a minimum.
3. Assess the areas to be ground out. The contact surfaces (F) are grouped
into two zones (A and B) in order to assess the maximum permissible

surfaces that may be ground. See Fig. 2.
Grouped zones - Zone A

Zone A (red marked surfaces)
• in this area, a maximum of 160 mm2 (~10%) of each red marked sur-
face may be ground out, including pre-existing grinding out
• two grindings must have at least a 10 mm distance from each other
2018-09-11 - de
Grouped zones - Zone B

Zone B (grey marked surface)
• in this area, a maximum of 6500 mm2 (18%) of the grey marked surface
may be ground out including pre-existing grinding out
• the extent of each individual grinding out may not be greater than
40 mm by 40 mm
2 (6) General, M010.040.010-15-0002

Exceeding the maximum permissible grinding out

If the surface area is so heavily affected by fretting that more than
160 mm2 must be ground out in one of the red marked surfaces (zone
A), including pre-existing grinding out or more than 6500 mm2 in the
grey marked surface (zone B), including pre-existing grinding out, then
the connecting rod may no longer be used.
In this case, make an agreement for a possible reconditioning of the
connecting rod with MAN PrimeServ.

grinding machine.
Risk of injury
Parts flying around as a result of rotation of the tool with high speed
can damage eyes, and rotating parts can catch long hair and loose
clothing.
• Wear safety goggles!
• Fasten long hair on back!
• Do not wear loose clothing!

4. Do not grind out smoothed areas or fretting spots with a portable grinder
or fan grinder.
5. Polish ground out areas with non-woven fabric.

ted.
2018-09-11 - de
6. Check contact surface (F) for cracking with magnetic particle inspection.
Contact surfaces without cracks

Provided that no crack indications have been detected after magnetic
particle inspection, the connecting rod can be reused.
General, M010.040.010-15-0002 3 (6)

Contact surfaces with cracks

If crack indications are detected through magnetic particle inspection,
the connecting rod is not approved for engine operation without re-
working. In this case, make an agreement for a possible reconditioning
with MAN PrimeServ.
7. Mark existing crack indications, visually document and report to MAN

PrimeServ.
Boundary conditions for the grinding out of crack indications

Every grinding out must comply with the following boundary condi-
tions:
• maximum machining depth 1 mm
• round edges of the ground out areas with a radius greater than 5 mm
• every grinding out, including rounding, must lie within the surface of the
already partially ground fretting spot
• Distance of two grindings must be at least 10 mm apart

grinding machine.
Risk of injury
Parts flying around as a result of rotation of the tool with high speed
can damage eyes, and rotating parts can catch long hair and loose
clothing.
• Wear safety goggles!
• Fasten long hair on back!
• Do not wear loose clothing!
8. Grind out crack indications with a portable grinding machine, grinding

2018-09-11 - de
cap holder and attached grinding cap.

9. Ground out areas to be checked for cracking by a qualified professional
by means of magnetic particle inspection. See Work Instructions
010.000.003-09.
4 (6) General, M010.040.010-15-0002

Death from connecting rod breakage

Owing to existing cracks, escape of components from the engine can
occur as a result of connecting rod breaking. This can cause fatal injur-
ies.
• Replace the connecting rod
used.
Reworked connecting rods

Reworked connecting rods must be checked, assessed and possibly
reworked (Work sequence 1 to 9) after every 6000 operating hours at
the latest. It is strongly advised to have an overhaul by means of re-
machining performed by an MAN Energy Solutions specialist work-
shop.
Non-woven fabric with resin-bonded ab- Scotch-BriteTM WR-RL, Type A fine

rasive

Universal abrasive cleaner HOLEX 55 7660, fine
2018-09-11 - de
General, M010.040.010-15-0002 5 (6)

1 Conrod small end F Contact surface

2 Conrod shank
Figure 1: Conrod small end and conrod shank
2018-09-11 - de
A red zone C Diameter 62 mm

B grey zone D Diameter 71 mm
Figure 2: Assessment zones on the contact surfaces of conrod small end and
conrod shank
18014412288754059
6 (6) General, M010.040.010-15-0002

Contact surface conrod shank/big-end bearing cover

inspecting
Summary
Contact surfaces conrod shank/big-end bearing cover must be cleaned and
checked after each release of this connection (e.g. during inspection of big-
end bearing shells).
Safety requirements
Tools/aids required


Reworking the contact surface conrod shank/big-end bear- 010.040.010-17
ing cover
Work Sequence - Cleaning and checking the contact surfaces

Starting position Conrod shank and big-end bearing cover removed.
2014-12-17 - de
Protection during cleaning work!

Wear safety goggles and protective gloves for cleaning work!
Follow instructions issued by the manufacturing companies!
Work Steps 1. Apply slushing oil or clean diesel oil onto contact surfaces (F) on conrod
shank (1) or big-end bearing cover (2). Clean contact surfaces using fibre
mat (3) until it is absolutely dirt-free. To facilitate cleaning, wrap fibre mat
around a type of support.
L58/64CD, M010.040.010-16-0002 1 (3)

2. Check contact surfaces (F) on conrod shank (1) or big-end bearing cover
(2) completely and thoroughly for fretting (G). Fretting can easily be identi-
fied by running one's finger nail over suspicious surfaces. If in doing so
rough or uneven surfaces are felt/detected, these are indications of fret-
ting.
Fretting areas
If there is no fretting on the cleaned contact surfaces (F), conrod small
end or big-end bearing cover may continue to be used.
If there are fretting areas, these must be reworked. See Work Instruc-
tions 010.040.010-17.
3. Clean contact surfaces (F) on conrod shank (1) or big-end bearing cover
(2) with a solvent cleaner. Contact surfaces must be absolutely free of dirt
and oil residues.
Tool name Manufacturer (example).
Fibre mat with resin-bonded abrasive Scotch-BriteTM WR-RL, Type A medium
Anticorrosive agent ANTICORIT 1

13798455947
2014-12-17 - de
2 (3) L58/64CD, M010.040.010-16-0002


1 Conrod shank F Contact surface
Figure 1: Conrod shank and big-end bearing cover ready for inspection
13798455947
2014-12-17 - de
L58/64CD, M010.040.010-16-0002 3 (3)

13798455947
2014-12-17 - de
L58/64CD, M010.040.010-16-0002

reworking
Summary
surfaces conrod shank/big-end bearing cover, the contact surfaces must be
reworked.
Safety requirements
1 Fan grinder Ø40x10 mm - Inventory

1 Grinding cap Ø15 mm - Inventory

Inspecting the contact surface conrod shank/big-end bear- 010.040.010-16
ing cover
2018-09-14 - de

Initial situation Contact surface on conrod shank and conrod bearing cover cleaned and in-
spected. See Work Instructions 010.040.010-16.
Locating pin and connecting-rod bearing bolts have been removed from the
connecting-rod bearing cover.
Work steps
General, M010.040.010-17-0002 1 (7)

Acid burn risk

• Wear protective clothing.
manufacturer
1. Smooth all fretting areas (even the smallest ones) using the universal ab-
rasive cleaner.
2. Visually document fretting spots and report to MAN PrimeServ.
Grinding out fretting spots

For a complete removal of the damaged material and to ensure the op-
timal preparation for the necessary crack test, the areas that were not
smoothed with the universal abrasive cleaner must be ground out. In
the process, the fretting spots (elevations and depressions) are ready
to be ground out until there is no more visible fretting and the contact
surfaces are shiny metallic, typically a few 1/100 mm deep. The extent
of the grinding out is to be restricted to a minimum.
3. Assess the areas to be ground out. The contact surfaces (F) are grouped
into two zones (A and B) in order to assess the maximum permissible
surfaces that may be ground. See Fig. 2.
Grouped zones - Zone A

Zone A (red marked surfaces)
• in this area, a maximum of 230 mm2 (~10%) of each red marked sur-
2018-09-14 - de
Grouped zones - Zone B

Zone B (grey marked surfaces)
• in this area, a maximum of 2000 mm2 (~18%) of each grey marked sur-
• the extent of each individual grinding out may not be greater than
25 mm by 25 mm
2 (7) General, M010.040.010-17-0002

Exceeding the maximum permissible grinding out

If the surface area is so heavily affected by fretting that more than
230 mm2 must be ground out in one of the red marked surfaces (zone
A), including pre-existing grinding out or more than 2000 mm2 in one of
the grey marked surfaces (zone B), including pre-existing grinding out
then the connecting rod may no longer be used.
In this case, make an agreement for a possible reconditioning of the
connecting rod with MAN PrimeServ.

grinding machine.
Risk of injury

4. Do not grind out smoothed areas or fretting spots with a portable grinder
or fan grinder.
5. Polish ground out areas with non-woven fabric.

ted.
2018-09-14 - de
6. Check contact surface (F) for cracking with magnetic particle inspection.
Contact surfaces without cracks

Provided that no crack indications have been detected after magnetic
particle inspection, the connecting rod can be reused.
General, M010.040.010-17-0002 3 (7)

Contact surfaces with cracks

If crack indications are detected through magnetic particle inspection,
the connecting rod is not approved for engine operation without re-
working. In this case, make an agreement for a possible reconditioning
with MAN PrimeServ.
7. Mark existing crack indications, visually document and report to MAN

PrimeServ.
Boundary conditions for the grinding out of crack indications

Every grinding out must comply with the following boundary condi-
tions:
• maximum machining depth 1 mm
• round edges of the ground out areas with a radius greater than 5 mm
• every grinding out, including rounding, must lie within the surface of the
already partially ground fretting spot
• Distance of two grindings must be at least 10 mm apart


grinding machine.
Risk of injury
8. Grind out crack indications with a portable grinding machine, grinding

2018-09-14 - de
cap holder and attached grinding cap.

9. Ground out areas to be checked for cracking by a qualified professional
by means of magnetic particle inspection. See Work Instructions
010.000.003-09.
4 (7) General, M010.040.010-17-0002

Death from connecting rod breakage

Owing to existing cracks, escape of components from the engine can
occur as a result of connecting rod breaking. This can cause fatal injur-
ies.
• Replace the connecting rod
used.
Reworked connecting rods

Reworked connecting rods must be checked, assessed and possibly
reworked (Work sequence 1 to 9) after every 6000 operating hours at
the latest. It is strongly advised to have an overhaul by means of re-
machining performed by an MAN Energy Solutions specialist work-
shop.

Non-woven fabric with resin-bonded ab- Scotch-BriteTM WR-RL, Type A fine
rasive

2018-09-14 - de
General, M010.040.010-17-0002 5 (7)

1 Conrod shank F Contact surface

2 Conrod bearing cover

in image shows 48/60B)
2018-09-14 - de
6 (7) General, M010.040.010-17-0002


A red zone D Diameter 88 mm
B grey zone
Figure 2: Assessment zones on the contact surfaces of conrod shank and
connecting-rod bearing cover
18014412307941515
2018-09-14 - de
General, M010.040.010-17-0002 7 (7)

18014412307941515
2018-09-14 - de
General, M010.040.010-17-0002

51353836043
1 (1)

Piston
Summary
sure the work is carried out correctly, check the components as to their
state / extent of their wear.
The pistons are to be disassembled within the scope of maintenance and re-
pair work.
Safety requirements
l Engine stopped
Tools/aids required
1 Carrier 034.092-1 Standard
1 Tapered sleeve for inserting the piston rings 034.094 Standard
1 Tap 034.080 Standard
1 Tap wrench 034.098 Standard
1 Securing clip 030.811 Standard
1 Retaining device 030.811-1 Standard
1 Thrust piece 030.811-2 Standard
2018-12-18 - de

1 Extension piece 12.5x250 001.912 Standard
Piston
1 Socket spanner insert 24x12.5 001.757 Standard

L48/60CR, M010.040.050-01-0022 1 (17)


1 Rope - Inventory

Loosening and tightening the conrod shank bolts 010.040.010-03
Checking the piston 010.040.050-03
Removing and installing top land ring 010.050.010-01
Technical data
Piston with connecting rod small end Weight 597,5 kg
Work Sequence 1 - Removing the piston

Initial situation Top land ring removed.

Work steps 1. Turn the running gear until the piston (6) is at TDC.
2. Clean the threaded bores on the piston’s upper side with the tap
(034.080).
Wrong suspension point on the tool

2018-12-18 - de
If an incorrect suspension point on the tool is used during the removal

or installation as well as during lifting, the component may swing out
due to the changed centre of gravity and thus cause injuries to per-
sons or material damage.
• for correct suspension point see respective figure in these Work In-
structions
• observe an identification that may be present on the used tool
Piston
• if available, use a pilot rod to guide the component
2 (17) L48/60CR, M010.040.050-01-0022

3. Place the support (034.092-1) on the piston (6). Screw two hex bolts (19)
into the piston and tighten them with a torque of 60 Nm. Fasten the sup-
port with a hex nut (20). See Fig. 2.
4. Attach the rope (18) with the shackle (002.453) on the support.
Working in crankcase
Working in the crankcase during the turning operation poses a danger
to life.
• Do not work in the crankcase during the turning operation
optical signals
5. Turn the running gear until the piston (6) is exactly at BDC.
6. Attach the rope (18) to the lifting tackle.
7. Fasten the grab handle (011.013) to the cylinder crankcase (16).
8. Insert the foot board (011.012 for a normal oil sump or 011.011 for a V oil
9. Release the connecting rod shank bolts (10). See work instructions
010.040.010-03.
10.Place the support (030.811-1) around the connecting rod shank (11).
Fasten it to the counterweight (14) with two hex bolts (23). See Figs. 3
and 4.
11.Screw two hex bolts (22) into the retaining device until they make contact
with connecting rod shank (11).
12.Fit the thrust piece (030.811-2) on the bracket, turn the hex bolt (24) until
it makes contact with the counterweight (14) and the thrust piece on the
connecting rod shank (11). See Fig. 4.
13.Unscrew the nuts (12) from the connecting rod shank bolts (10).
14.Pull the piston (6) upwards over the cylinder liner (9) until the pilot rod
(034.006) can be screwed into the support. See Fig. 5.
15.Carefully pull the piston (6) out of the cylinder liner (9). Ensure that the cyl-
inder head bolts (5) and connecting rod shank bolts (10) are not dam-
aged. Guide the pistons with a pilot rod. See Fig. 6.
16.Place the piston (6) onto a clean surface. In doing so, make sure that the
2018-12-18 - de
connecting rod shank bolts (10) are not damaged.

17.Detach the tool from the piston (6).
18.Close the lubricating oil bore in the connecting rod shank (11) to prevent
the ingress of dirt.
19.Cover the resulting opening in the cylinder liner (9) using suitable equip-
ment.
20.Clean and check the piston (6). See work instructions 010.040.050-03.
Piston
21.Clean the connecting rod small end (7).
L48/60CR, M010.040.050-01-0022 3 (17)

Work Sequence 2 - Installing the piston

Starting position Piston is cleaned, checked, possibly overhauled and assembled with big-end
bearing head, cylinder liner and joint faces on big-end bearing head and con-
necting rod shank are cleaned, connecting rod is fixed to balance weight with
a locating clamp. Handle fitted to cylinder crankcase casing, foot board is fit-
ted in oil sump.

Work steps 1. Remove the cover for the cylinder liner bore.
2. Place the guide bush (034.094) on cylinder liner (9) and lubricate the inner
surface thoroughly.

structions
Alignment of the guide rod

When applying the suspension device make sure that the branch sock-
ets for the pilot rod (034.006) are on the counter exhaust side.
2018-12-18 - de
3. Place the support (034.092-1) on the piston (6). Screw two hex bolts (19)
into the piston and tighten them with a torque of 60 Nm. Fasten the sup-
port with a hex nut (20).
4. Fasten the rope (18) with shackle (002.453) on the support, and suspend
it from the lifting tackle.
5. Carefully lift up the piston (6).
Piston
6. Screw on two guide tubes (030.210) until they make contact with the
connecting rod shank bolts (10). See Fig. 8.
7. Screw the pilot rod (034.006) into the support.
4 (17) L48/60CR, M010.040.050-01-0022

8. Apply clean lubricating oil to the piston rings and the running surface of
the piston (6).
9. Arrange the position of piston ring joints (1 to 4) for piston rings in relation
to the control side (PC) according to the figure. See Fig. 7.
10.Open the lubricating oil bore in the connecting rod shank (11).
Observe the installation position!

Turn the piston in such a way that the marking (ST) on the piston top
side points to the control side.
11.Move the piston (6) with the lifting tackle over the cylinder liner (9) and
carefully lower it into the guide bush, guiding the piston with the pilot rod
until the lower section of the piston slides into the cylinder liner. See
Fig. 9.
12.Unscrew the pilot rod.
13.Lower piston (6) carefully to allow the piston rings to slide through the
guide bush into the cylinder liner (9).
Alignment between connecting rod and connecting rod small

end
To be able to guide in the piston more easily, slacken the hex bolts (22)
on the bracket (030.811-1) to allow the self-alignment between the
connecting rod and connecting rod small end.
14.Continue to lower the piston (6) carefully until the connecting rod small
end (7) rests on the connecting rod shank (11). See Fig. 10.
15.Use a feeler gauge (000.451) to check that the parting line along the en-
tire circumference is less than 0.05 mm.
16.Unscrew the guide tubes.
17.Check that the connecting rod shank bolts (10) are screwed in hand-tight
so that the collar rests on the connecting rod small end (7). See Fig. 11.
18.Screw nuts (12) hand-tight onto the connecting rod shank bolts (10).
19.Detach the securing clip (030.811).
20.Tension the connecting rod shank bolts (10). See work instructions
2018-12-18 - de
010.040.010-03.
21.Remove the foot board (011.011 or 011.012) from oil sump (15).
22.Detach the handle (011.013).
Piston
L48/60CR, M010.040.050-01-0022 5 (17)

Working in crankcase
Working in the crankcase during the turning operation poses a danger
to life.
• Do not work in the crankcase during the turning operation
optical signals
9007228975864459
23.Turn the running gear until the piston (6) is at TDC.

24.Unhook the rope (18), remove the support.
25.Detach the guide bush.
2018-12-18 - de
Piston
6 (17) L48/60CR, M010.040.050-01-0022

2018-12-18 - de
5 Cylinder head bolt 10 Connecting rod shank 15 Oil sump

bolt
6 Piston 11 Connecting rod shank 16 Cylinder crankcase
7 Connecting rod small 12 Nut 17 Locating pin
end
8 Backing ring 13 Connecting rod bearing PC Control side
cover
Piston
9 Cylinder liner 14 Counterweight

Figure 1: Piston and connecting rod - Illustration shows the engine 48/60B with normal oil sump
L48/60CR, M010.040.050-01-0022 7 (17)

6 Piston 19 Hex bolt M16x90

9 Cylinder liner 20 Hex nut M16
18 Rope PC Control side
Figure 2: Removing the piston
2018-12-18 - de
Piston
8 (17) L48/60CR, M010.040.050-01-0022

2018-12-18 - de
6 Piston 12 Nut 21 Hex bolt M20x40

7 Connecting rod small 14 Counterweight PC Control side
end
10 Connecting rod shank 15 Oil sump
Piston
bolt
11 Connecting rod shank 16 Cylinder crankcase
Figure 3: Removing the piston - Illustration shows the engine 48/60B with normal oil sump
L48/60CR, M010.040.050-01-0022 9 (17)


14 Counterweight 24 Hex bolt M12 x 45
22 Hex bolt M12 x 45
Figure 4: Removing the piston – detail of Fig. 3
2018-12-18 - de
Piston
10 (17) L48/60CR, M010.040.050-01-0022

2018-12-18 - de
5 Cylinder head bolt 9 Cylinder liner 18 Rope

6 Piston 10 Connecting rod shank PC Control side
bolt
7 Connecting rod small 11 Connecting rod shank
Piston
end
Figure 5: Removing the piston - Illustration shows the engine 48/60B with normal oil sump
L48/60CR, M010.040.050-01-0022 11 (17)

Figure 6: Removing the piston

2018-12-18 - de
Piston
12 (17) L48/60CR, M010.040.050-01-0022

1-4 Position of the piston ring joints

PC Control side
Figure 7: Installation of the piston - Position of the piston ring joints
2018-12-18 - de
Piston
L48/60CR, M010.040.050-01-0022 13 (17)

5 Cylinder head bolt 9 Cylinder liner 20 Hex nut M16

6 Piston 10 Connecting rod shank PC Control side
bolt
7 Connecting rod small 18 Rope
end
2018-12-18 - de
8 Backing ring 19 Hex bolt M16x90

Figure 8: Installing the piston
Piston
14 (17) L48/60CR, M010.040.050-01-0022

6 Piston 11 Connecting rod shank

7 Connecting rod small end 18 Rope
9 Cylinder liner PC Control side
bolt
Figure 9: Installing the piston
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Piston
L48/60CR, M010.040.050-01-0022 15 (17)

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6 Piston 10 Connecting rod shank 17 Locating pin

bolt
7 Connecting rod small 11 Connecting rod shank PC Control side
end
Piston
Figure 10: Installation of the piston - Illustration shows the engine 48/60B with normal oil sump
16 (17) L48/60CR, M010.040.050-01-0022

7 Connecting rod small end

Figure 11: Connecting rod shank bolt
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Piston
L48/60CR, M010.040.050-01-0022 17 (17)

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Piston
L48/60CR, M010.040.050-01-0022
Piston
inspection
Summary
The pistons and piston rings are to be checked with regard to the appearance
of their contact faces as well as the lubricating and wear condition.
measuring components and
assessing the wear surface appearance / wear condition.
Tools/aids required
1 Piston ring tightening device 034.086-UC Standard

Honing cylinder liner 010.050.010-07
Evaluate piston rings 010.040.050-06
Evaluate piston rings with chrome ceramic coating 010.040.050-07
Work sequence 1 - Checking the piston

Initial situation Piston has been removed and placed on a suitable wooden support.
Work steps
Wear surface appearance of the piston running surface

The piston running surface should have a uniform wear surface ap-
pearance and be free of machining marks and other damage.
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Deep grooves or seizure points indicate engine overloading, faulty

cooling, insufficient lubrication, or foreign bodies lodged between the
piston and cylinder liner.
1. Check the piston (1) and the piston rings (2 to 4) for condition.
Piston
48/60CR;48/60B, M010.040.050-03-0005 1 (7)

Graphite layer on the piston skirt

The graphite layer on the piston skirt must not be damaged while
cleaning.
2. Clean the piston (1) from carbon residue, without roughening the surface
of the piston skirt. Clean the running surface carefully.
3. Measure and note the axial clearance of the piston rings (2 to 4) in the
piston ring grooves, compare with the maximum permissible clearance
and record the results in operating log sheets. For this purpose, determ-
ine the axial clearance at four places using feeler gauges (000.451) (con-
trol side/exhaust-gas side/coupling side/free engine end ) in quarter pis-
ton ring groove depth. See also Fig. 2/see Volume 010.005 Engine - Op-
erating Manual sheet 010.000.035-04.
4. For assessment of piston rings, see Work Instructions 010.040.050-06
and 010.040.050-07.
Work sequence 2 - Removing and installing the piston rings

Initial situation
Removal of piston rings

When checking the pistons, the piston rings are to be removed due to
wear condition or contamination; otherwise they would be under heavy
strain during removal and fitting.
Work steps
Removal and marking
Sharp component edges

Components to be serviced have sharp component edges. This can
cause cuts if touched.
• Avoid direct contact with sharp component edges
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1. Individually remove the piston rings (2 to 4) using the tensioner (034.086-

UC), clean and label using a felt marker / marker pen (cylinder no. and
piston ring groove no.). See Fig. 3.
Identification of piston rings

If the piston rings are used again, the cylinder number and the piston
Piston
ring groove must be marked on the corresponding piston ring using a

felt-tip pen/marking pen to prevent them from getting mixed up.
2 (7) 48/60CR;48/60B, M010.040.050-03-0005

Checking and measuring 2. Check the piston rings (2 to 4) accurately, replace if necessary. See Work
Instructions 010.040.050-06 and 010.040.050-07.
Conically worn piston ring grooves

Conically worn piston ring grooves indicate that the cylinder liner is
worn significantly.
Worn piston ring grooves can be reworked! We recommend you con-
sult MAN Energy Solutions in this regard. Install replacement piston
rings to fit the refinished piston ring grooves and record the new height
of the piston rings in operating log sheets.
3. Clean the piston ring grooves in the piston (1) carefully and check them
for wear with a suitable dial gauge (6) at four points (control side / ex-
haust side / coupling side / free engine end) at quarter piston ring groove
depth. For dimensions and clearances of the piston ring grooves see
Volume 010.005 Engine - Operating Manual sheet 010.000.035-04. See
Fig. 4.
Installation and measuring 4. Pull the piston rings (2 to 4) onto the piston (1) using the tensioner. Pay
attention to the position according to the identification mark.
5. Measure the axial clearance of the piston rings (2 to 4) in its piston ring
grooves and note it in the operational records.
Observe the running-in guidelines

If a piston with piston rings that has already been in use is installed
into a different cylinder liner, the compression rings and the oil control
rings must be replaced and the cylinder liner will need to be rehoned
(see Work Instructions 010.050.010-07). The engine must then be run-
in again. See run-in guidelines in Volume 010.005 Engine - operating
manual, Sheet 010.000.024.-05.
Arrangement of the piston rings (see Figure 5):

▪ Chrome-ceramic coated compression rings (2 and 3) are installed in the
first and second piston ring groove from the top (piston ring groove 1 and
2). The ring flank with the designation "TOP" is the top flank.
▪ An oil control ring (4) is installed in the third piston ring groove from the
top (piston ring groove 3).
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Piston
48/60CR;48/60B, M010.040.050-03-0005 3 (7)

1 Piston
2 Compression ring
3 Compression ring
4 Oil control ring
5 Connecting rod small end
Figure 1: Piston with connecting rod small end
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Piston
4 (7) 48/60CR;48/60B, M010.040.050-03-0005

1 Piston 3 Compression ring A Piston ring groove

depth
2 Compression ring 4 Oil control ring B Measuring location –
1/4 piston ring groove
depth (A)
Figure 2: Measuring the axial clearance of the piston rings
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Piston
48/60CR;48/60B, M010.040.050-03-0005 5 (7)

Figure 3: Piston ring tensioner
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1 Piston A Piston ring groove depth

6 Dial gauge B Measuring location – 1/4
piston ring groove depth
(A)
Figure 4: Measuring the piston ring groove height (determine the wear)
Piston
6 (7) 48/60CR;48/60B, M010.040.050-03-0005

1 Piston
2 Compression ring
3 Compression ring
4 Oil control ring
Figure 5: Arrangement of the piston rings
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Piston
48/60CR;48/60B, M010.040.050-03-0005 7 (7)

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Piston
48/60CR;48/60B, M010.040.050-03-0005
Piston
disassembling and assembling
Summary
Carry out the work in good time according to the maintenance schedule,
check the components as to their state / extent of their wear.
Pistons are to be dismantled within the scope of maintenance and repair
work.
disassembling the piston,
smoothing out the contact surface between the piston crown and the piston
skirt,
assembling the piston.
Tools/aids required
1 Hemp rope - Inventory
1 Honing stone - Option
1 Nylon rope - Inventory
1 Oil stone - Inventory
1 Scriber - Inventory
1 Emery paper - Inventory
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1 Molykote HSC - Inventory
1 Lubricant (Copa Slip) - Inventory
Related Work Instructions

Piston
Remove and install/check the piston pin and piston pin 010.040.050-05
bush
48/60B, M010.040.050-04-0006 1 (7)

Technical data
Piston crown Weight 180,5 kg
Piston skirt Weight 223 kg
Work Sequence 1 - Dismantling the piston

Starting position Piston disassembled, cleaned externally and set down on a wooden support
(piston skirt / small end face up).

Work steps 1. Remove the piston pin and the connecting rod small end. See Work In-
structions 010.040.050-05.
2. Loosen and unscrew four nuts (5), remove the thrust pieces (6).
Damage to components
When lifting the piston skirt do not damage piston bolts. Do not place
the piston skirt on the guide shoe.
3. Suspend piston skirt (9) from the lifting tackle through the piston pin
bores using a cable. Lift carefully. Place onto a clean wooden surface.
When removing or fitting the locking ring, always make sure that it is
not overstressed, i.e. is not spread wider than it is necessary to re-
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move or to fit the ring over the guide shoe.
4. Remove locking ring (17). When doing so, hold guide shoe (10) by hand.
5. Push the guide shoe (10) out of the guide.
6. Detach supporting rings (14 and 16) and compression spring (15).
7. Unscrew studs (7) from piston crown (13).
Piston
8. Remove O-ring (11).

9. Clean piston crown (13) and piston skirt (9) carefully.
2 (7) 48/60B, M010.040.050-04-0006

– Clean the cooling chambers (internally) to produce a polished metallic

surface with rotating wire brushes or emery paper belts.
– Blow out the oil bores with compressed air.
– Check the parts for damage (cracks).
10.Check the contact surface between piston crown (13) and skirt (9), and
smooth out any material bumps (see work sequence 2).
Work Sequence 2 - Smoothing out the contact surface between the piston crown and
the piston skirt
Preliminary remark There may be local spot welds between piston crown and skirt during engine
operation, which cause material bumps on the contact faces during the dis-
mantling of the piston.
As the exact starting position can no longer be reached during assembly of
the piston, the material bumps must be removed or smoothened.
Initial situation Piston dismantled and cleaned.
Work steps 1. Check the contact surface of the piston crown (16) and piston skirt (10)
for raised points in the material.
2. Remove any material bumps using several working steps, using emery
paper with increasingly fine grain size (100 - 180).
3. Smooth the contact surfaces using oil stone or a honing stone.
Removing raised points in the material

In doing so, ensure in particular that the material bumps are com-
pletely removed from the contact surfaces of the piston crown and the
piston skirt, since any remaining bumps may lead to high selective
point compressive stress.
Work Sequence 3 - Assembling the piston

Starting position Piston components cleaned, checked and replaced if required, piston crown
placed on wooden supports.
Assembling the piston

Carry out steps 1 to 16 if the parts have been replaced, and steps 1 to
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10 and 14 to 16 generally after dismantling the piston.

Piston
48/60B, M010.040.050-04-0006 3 (7)


Work steps 1. Fit the supporting ring (14) and compression spring (15) on the guide
shoe (10).
2. Place supporting ring (16) over guide shoe (10) and rest it on compres-
sion spring (15).
3. Slightly coat the guide shoe (10) running surface with clean lubricating oil.
When removing or fitting the locking ring, always make sure that it is
not overstressed, i.e. is not spread wider than it is necessary to re-
move or to fit the ring over the guide shoe.
4. Insert guide shoe (10) in piston skirt (9) and install locking ring (17) in the
groove using pliers (002.122).
5. Screw studs (7) into piston crown (13) with tightening torque of 50 Nm.
6. Lubricate new O-ring (11) with clean lubricating oil and insert it into the
ring groove. In doing so, ensure that the entire circumference of the O-
ring is tightened equally and that it is not twisted.
7. Check the contact surface of piston crown (13) and skirt (9); they must
be absolutely clean and dry.
Fitting the piston skirt

Before fitting the piston skirt, ensure the correct alignment of the hole
in the piston skirt with the dowel pin in the piston crown.
Do not damage piston bolts when fitting the piston skirt on the piston
crown.
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8. Suspend the piston skirt (9) from the lifting tackle through the piston pin
bores using a cable, lift it, and carefully place it on the piston crown (13).
9. Insert the thrust pieces (6) into the bore holes via the studs (7).
10.Apply Molykote HSC or lubricant "Copa Slip" to the threads and resting
surface of nuts (5) and screw on until they come to rest.
11.Tighten nuts (5) with tightening torque 350 Nm, in the order 1-2-3-4.
Piston
12.Undo the nuts (5) again.

13.Check the tightening of the studs (7) with 50 Nm torque.
4 (7) 48/60B, M010.040.050-04-0006

14.Carry out the final tightening process in two steps:

– Tighten the nuts (5) to a tightening torque of 90 Nm, in the order
1-2-3-4.
– Continue turning the nuts (5) to a torque angle of 120°, in the order
4-3-2-1.
Inspection of hex nuts

It must not be possible to further rotate the hex nuts with 250 Nm
torque.
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15.Check the mobility of the guide shoe (10).

16.Install piston pin and conrod small end. See Work Instructions
010.040.050-05.
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Piston
48/60B, M010.040.050-04-0006 5 (7)

5 Nut 11 O-ring 17 Locking ring

6 Thrust piece 12 Clamping sleeve 18 Compression ring
7 Stud bolt 13 Piston crown 19 Compression ring
8 Sleeve 14 Supporting ring 20 Oil control ring
9 Piston skirt 15 Compression spring
10 Guide shoe 16 Supporting ring
Figure 1: Piston
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Piston
6 (7) 48/60B, M010.040.050-04-0006

1-4 Tightening sequence

Figure 2: Tightening sequence of the studs/nuts
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Piston
48/60B, M010.040.050-04-0006 7 (7)

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Piston
48/60B, M010.040.050-04-0006
Piston pin and piston pin bush

removing and installing/checking
Summary
Piston pin and piston pin bush are to be checked at regular intervals and, are
hence to be dismounted.
Tools/aids required
1 Removal and fitting fixture 034.144 Option
1 Pliers for locking ring 002.165 Standard
1 Rope - Inventory
Technical data
Connecting rod small end Weight 146,5 kg
Piston pin Weight 101 kg
Work sequence 1 - Removing the gudgeon pin
Starting position Piston disassembled, cleaned externally and set down on a wooden support
(piston skirt / small end face up).
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48/60CR;48/60B, M010.040.050-05-0003 1 (7)

Work steps 1. Screw the lifting eye bolt (000.155) into the connecting rod small end (6).
Attaching the tool See fig. 2/I.
2. Fasten the rope (9) with the shackle (002.453) on the lifting eye bolt and
suspend it from the lifting tackle.
Removal of connecting rod 3. Raise the connecting rod small end (6) slightly so that the piston pin (4) is
small end free from load.
4. Remove the locking rings (3) using pliers (002.165).
5. Push out the piston pin (4) until the connecting rod small end (6) can be
removed. Protect the piston (1) from tilting by the use of a wooden sup-
port (8). See fig. 2/I.
6. Lift the connecting rod small end (6) carefully out of the piston (1) and
place it on a clean support surface. In doing so, make sure that connect-
ing rod shank bolts (7) are not damaged. See fig. 2/II.
7. Detach the tool.
Attaching the tool 8. Fasten the rope (9) by means of a shackle (002.453) to the removal and
installation device (034.144) and suspend it from the lifting tackle.
9. Fit the removal and installation device into the piston pin (4). See fig. 3/I.
Removal of piston pin 10.Dismantle the piston pin (4) carefully from the piston (1) and place it on a
clean support surface. See fig. 3/II.
11.Detach the tool.
Cleaning and control 12.Clean the piston pin (4) and piston pin bush (5) and check them for wear.
For maximum allowable clearance, see volume 010.005 Engine – Oper-
ating Manual 010.000.035-04.
Replacing the piston pin bush

If the piston pin bush must be replaced, the replacement must be per-
formed in a customer service workshop or by MAN Energy Solutions
personnel.
13.Check all parts for damage, renew/replace if necessary.
Work sequence 2 - Installing the gudgeon pin

Starting position Piston, small end and piston pin are cleaned.
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Work steps 1. Check the movability of the guide shoe (2) in the piston (1).
2 (7) 48/60CR;48/60B, M010.040.050-05-0003

Attaching the tool 2. Fasten the rope (9) by means of a shackle (002.453) to the removal and
installation device (034.144) and suspend it from the lifting tackle.
Installation of the piston pin 3. Fit the removal and installation device into the piston pin (4). Raise the
piston pin. See Fig. 3/II.
4. Set the piston pin (4) on the piston (1) and push it in carefully to the ex-
tent that connecting rod small end (6) can still be installed. See Fig. 3/I.
5. Protect the piston (1) from tilting with wooden supports (8). See Fig. 3/I.
6. Detach the tool.
Attaching the tool 7. Screw the lifting eye bolt (000.155) into the connecting rod small end (6).
8. Fasten the rope (9) with the shackle (002.453) on the lifting eye bolt and
suspend it from the lifting tackle. Raise the connecting rod small end. See
Fig. 2/II.
9. Slightly lubricate the piston pin bush (5) running surface using clean lub-
ricating oil.
Marking on piston and small end

Before installing the conrod small end into the piston, observe mark-
ings denoting control side (ST) or exhaust side (AS).
36028803933186443
Installation of the connect- 10.Install the connecting rod small end (6) carefully in the piston (1). Make
ing rod small end sure that the markings made for the control side (ST) or the exhaust side
(AS) on the piston and connecting rod small end are aligned. See Fig. 2/I.
11.Push the piston pin (4) completely into the piston (1), raising or lowering
the connecting rod small end (6) a little if necessary.
12.Insert the locking rings (3) into their grooves using pliers (002.165).
13.Detach the tool.
14.Rotate the locking rings (3) so that their gap points towards the piston
floor or piston skirt. See Fig. 4.

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48/60CR;48/60B, M010.040.050-05-0003 3 (7)

1 Piston 5 Piston pin bush

2 Guide shoe 6 Connecting rod small end
3 Locking ring 7 Connecting rod shank
bolt
4 Piston pin
Figure 1: Piston with connecting rod small end
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4 (7) 48/60CR;48/60B, M010.040.050-05-0003


1 Piston 6 Connecting rod small 9 Rope
end
4 Piston pin 8 Wooden support I-II Work steps
Figure 2: Removing/fitting the connecting rod small end
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48/60CR;48/60B, M010.040.050-05-0003 5 (7)

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1 Piston 9 Rope
4 Piston pin I-II Work steps
8 Wooden support
Figure 3: Removing/fitting the piston pin
6 (7) 48/60CR;48/60B, M010.040.050-05-0003

1 Piston 3 Locking ring

Figure 4: Position of locking ring gap (gap direction: piston skirt – illustration
left, or piston crown – illustration right)
36028803933186443

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48/60CR;48/60B, M010.040.050-05-0003 7 (7)

36028803933186443
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48/60CR;48/60B, M010.040.050-05-0003
Piston rings
assessing
Summary
ule; evaluate contact pattern/wear condition.
Asses the piston rings at regular intervals on the basis of the wear pattern.
The work includes:
Checking parts/components.
Preliminary remarks
The piston rings must be replaced after the operating hours listed in the main-
tenance schedule. They are also to be replaced if, during intermediate checks,
damage to the running surface is detected or there is too much clearance.
Compression rings and an oil control ring are used. See Table 1.
In the case of chrome plated rings, the appearance of the coating during con-
tinuous wear shows no any changes or slight change only. For piston rings
with chrome ceramic coating, the appearance changes in another way. The
running surface of these piston rings when not worn has a smooth metallic
appearance and a uniform grey colour. After several hundred operating hours,
a net of cracks becomes visible. This is normal. This is the result of hard metal
oxide ceramic particles burying themselves into the network structure of the
chrome coat.
The piston ring version can be identified by the item number stamped on the
upper side of the piston rings.
Piston ring Running surface Appearance
Compression rings
Groove 1 Chrome-ceramic coated net of cracks later
Groove 2/3 Chrome coated uniformly grey
Oil control ring
Groove 4 Chrome coated uniformly grey

Table 1: Piston rings/Surface coating
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Wear patterns of piston rings

As a result of the shape of the running surface, new compressing rings do not
wear along the entire running surface, but only along running pattern area A.
As the wear increases, the running pattern area becomes wider and wider.
Piston rings
General, M010.040.050-06-0002 1 (3)

A Running pattern height B Ring height

Figure 1: Running surface of chrome coated piston rings (operating hours >
1,000 h)
Figure 2: Network of cracks in chrome-ceramic coated piston rings (operating

hours > 8,000 h)
At the end of its working life the running pattern reaches up to the chamfers or
radii of the ring flanks. Figure 3.
Figure 3: Piston ring with a well-formed running pattern at the end of its work-
ing life
The piston ring shown in figure 3 shows chamfers or radii, which can still be
clearly identified. Coated compression rings must be replaced once the run-
ning pattern height extends to cover the entire height of the piston ring, i.e.
the chamfers or radii are barely visible. In this condition, the next scheduled
maintenance interval cannot be completed safely given the remaining coating
thickness.
Burn marks (C) can be identified by local discolouration on the running sur-
face. Piston rings in this condition must be replaced. Figure 4.
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Figure 4: Piston ring with burn marks in the running surface

Piston rings
Coated compression rings and oil control rings must also be replaced once
the coating has been worn off in one location.
2 (3) General, M010.040.050-06-0002

Figure 5: Piston ring with coating worn away
Figure 5 shows a chrome plated compression ring. The layer of chrome has
been partially worn away at (D).
Once breakaways or cracks are visible in the coating of a piston ring it also
should be replaced.
Chrome-ceramic coated compression rings must be replaced once the
closed surface traversed by microcracks has dissolved into a structure that
looks similar to a cobblestone surface. At this point, the cracks have reached
the base material and there is a risk of breakaways.
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Piston rings
General, M010.040.050-06-0002 3 (3)

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2014-04-25 - de
Piston rings
General, M010.040.050-06-0002
Piston rings with chrome ceramic coating

Assessing
Summary
ule; check the components’ quality/wear condition.
Asses the piston rings at regular intervals on the basis of the wear pattern.
The work includes:

Evaluate piston rings 010.040.050-06
Preliminary remarks
The piston rings must be replaced after the operating times listed in the main-
tenance schedule. They are also to be replaced if, during intermediate checks,
damage to the running surface is detected or there is too much clearance.
Piston rings with a chrome ceramic coated running surface are used in ring
groove 1 and 2. The piston ring version can be identified by the item number
stamped on the upper side of the piston rings.
The surface appearance of chrome ceramic coated rings changes significantly
when subjected to continuous wear. The running surface of these piston rings
in a new condition has a smooth metallic appearance and is uniformly silver
grey in colour. After several hundred hours in operation, a network of cracks
or individual longitudinal and transverse cracks becomes visible. This is nor-
mal and is the result of hard metal oxide ceramic particles burying themselves

into the network structure of the chrome coat. As a result, very high levels of
wear resistance and a significantly improved thermal load capacity with min-
imal wear on the cylinder liners are achieved. The characteristic network of
cracks in this case serves the purpose of providing a reservoir of lube oil.
The following sequence of images shows the piston rings, magnified approx.
five times. The sequence of images is provided to facilitate the assessment of
coated piston rings and supplements the Work Instructions 010.040.050-06.
2014-04-25 - de
General, M010.040.050-07-0002 1 (4)

1. Normal wear pattern. Piston ring can be used without reservations
Figure 1: Wide network of cracks
This running surface appearance shows the normal state of wear for a
chrome-ceramic coated piston ring.
Assessing: The piston ring can be used without restrictions and can continue
to be used.
Figure 2: Tight network of cracks
This running surface appearance also shows a normal state of wear. The en-
2014-04-25 - de
tire surface is smooth. Wave-forms in the running layer in the direction of the
cracks are not visible. This pattern will not result in any flaking of the coating.
Assessing: The piston ring can be used without restrictions and can continue
to be used.
2 (4) General, M010.040.050-07-0002

Figure 3: Narrow longitudinal cracks in the running direction
This running surface appearance also shows a normal state of wear. The en-
tire surface is smooth.
Assessing: If the crack width is < approx. 0.1 mm, the piston ring can be used
without any restrictions and can continue to be used.
2. Critical wear - the piston ring must be replaced
Figure 4: Burn spot

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The appearance of this running surface shows a normal state of wear how-
ever, in this case, it shows a burn spot, which cannot be rectified. In addition,
there is risk of a so-called blow-by.
Assessing: The piston ring can no longer be used and must be replaced.
General, M010.040.050-07-0002 3 (4)

Figure 5: Severe cobblestone formation
This running surface shows pronounced cobblestone formation with a wide

area of cracks. The surface is no longer smooth throughout, but instead
shows bulging around the cracks.
Assessment: The piston ring can no longer be used and must be replaced.
Figure 6: Wide longitudinal cracks in the running direction
This running surface shows an extensive formation of longitudinal cracks with

the risk of the coating flaking off, even though the surface may be entirely
smooth.
Assessment: Since the crack width is approx. > 0.1 mm, the piston ring can
no longer be used and must be replaced.
3. Terminal damage. The piston ring must be replaced.

If the piston ring shows terminal damage, for example:
▪ Ring fracture
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▪ Flaking of the running layer

▪ Spallings, etc.
the piston ring must be replaced. Check the adjoining parts, such as the cylin-
der liner, piston, cylinder head, for damage.
4117249419
4 (4) General, M010.040.050-07-0002


010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas
010.050 Cylinder
51353840267
1 (1)

010.050 Cylinder

51353844491
1 (1)

Top land ring

Summary
The top land ring must always be removed when the corresponding piston is
to be removed or if the seal ring needs to be changed.
Safety requirements
l Engine stopped
l Fuel systems drained
Tools/aids required
1 Removal and fitting device 050.116 Standard
3 Hexagon head bolt 050.116-14 Standard
1 Rope - Inventory
2016-11-21 - de
Technical data
Top land ring
Top land ring Weight 117,5 kg
Work sequence 1 - Disassembling the top land ring

Initial situation
L48/60B, M010.050.010-01-0002 1 (10)

Reuse coolant
Coolant must not be pumped into the bilges or into the sewage sys-
tem! Coolant must be pumped into its own individual tank and be re-
used (coolant treatment agent)!
Cooling water has been drained off completely. Cylinder head detached. Run-
ning gear turned, piston is about 60° before/after TDC.

Work steps
Cover gap between piston and cylinder liner

Cover the gap between the piston and the cylinder liner to prevent for-
eign substances from falling into it.
1. Remove carbon residue from the top land ring (3) and from the upper
area of the cylinder liner (7).
2. Place the support (050.116-1) on the backing ring (4). In doing so, make
sure that the centring pins (10) are inserted in the fixing hole (C). See Fig.
2/Section V.
3. Tightly screw the hex bolts (050.116-14) into the tapped blind hole in the
top land ring (3) by hand. See Fig. 2.
4. Screw in hex bolts (9) until they rest on the backing ring (4).

2016-11-21 - de

Top land ring
structions
2 (10) L48/60B, M010.050.010-01-0002

5. Fasten the rope (8) with shackle (002.453) on the support, and suspend it
from the lifting tackle.
7. Press off the top land ring (3) by screwing in the hex bolts (9) evenly and
in alternating sequence. See Fig. 3.
8. Carefully pull the top land ring (3) out upwards, using the pilot rod as a
guide. See Fig. 4.
9. Place the top land ring (3) on a clean surface.
10.Detach the tool.
11.Remove the O-rings (2).
12.Clean the top land ring (3).
Work sequence 2 - Fitting the top land ring

Initial situation Piston fitted, top land ring cleaned.

Work steps 1. Insert the new O-rings (2) lubricated with new and clean lubricating oil
into the ring grooves. In doing so, ensure that the O-rings are tightened
equally and are not twisted around the entire circumference.
2. Turn back the hex bolts (9 and 050.116-14).
3. Place the support (050.116-1) onto the top land ring (3). Observe the po-
sition of the support in relation to the mark (M) on the top land ring. See
Fig. 5.
4. Tightly screw the hex bolts (050.116-14) into the tapped blind hole in the
top land ring (3) by hand. See Fig. 2.
2016-11-21 - de

Top land ring

structions
L48/60B, M010.050.010-01-0002 3 (10)

9007206175358475
6. Fasten the rope (8) with shackle (002.453) on the support, and suspend it
7. Lift the top land ring (3), move it over the cylinder liner (7) and carefully in-
sert it into the backing ring (4). Make sure that the parallel pins (10) are in-
serted in the fixing hole (C) on the backing ring (4).
8. Detach the tool.
9. Turn back the thrust bolts (11) in the support (050.085-1).
10.Place the support onto the backing ring (4) and fasten it to the backing
ring with hex bolts (12). See Fig. 6.
11.Screw in the thrust bolts (11) until they reach the top edge of the top land
ring (3).
12.Push down the top land ring (3) until it rests on the cylinder liner (7) by
screwing in the thrust screws (11) evenly and in alternating sequence.
13.Detach the tool.
14.After removing all of the engine parts (cylinder head, etc.), fill cooling wa-
ter into the engine, and bleed the cooling water pipe.
15.After completing the installation/assembly work and re-establishing the
cooling water pressure, check whether the O-rings (2) are OK - water
must not emerge from the inspection holes (A and B). See Fig. 1.
16.With the engine running, check the cylinders at the inspection holes (A)
for gas tightness. See Fig. 1.
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Top land ring
4 (10) L48/60B, M010.050.010-01-0002

2016-11-21 - de
1 Cylinder head bolt 5 Cylinder crankcase B Inspection hole

2 O-ring 6 Piston C Fixing hole in the back-
ing ring
Top land ring
3 Top land ring 7 Cylinder liner M Marking

4 Backing ring A Inspection hole ST Control side
Figure 1: Backing ring/cylinder liner with top land ring
L48/60B, M010.050.010-01-0002 5 (10)

3 Top land ring 8 Rope C Fixing hole in the back-

ing ring
4 Backing ring 9 Hex bolt M20x140 ST Control side
7 Cylinder liner 10 Centring bolt
Figure 2: Removing/fitting the top land ring
2016-11-21 - de
Top land ring
6 (10) L48/60B, M010.050.010-01-0002

3 Top land ring 9 Hex bolt M20x140

4 Backing ring ST Control side
7 Cylinder liner
Figure 3: Removing the top land ring
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Top land ring
L48/60B, M010.050.010-01-0002 7 (10)

Figure 4: Removing the top land ring
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Top land ring
8 (10) L48/60B, M010.050.010-01-0002

3 Top land ring M Marking

Figure 5: Installing the top land ring – position of the support in elation to the
mark on the top land ring
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Top land ring
L48/60B, M010.050.010-01-0002 9 (10)

3 Top land ring 11 Thrust bolt

4 Backing ring 12 Hex bolt M24x50
7 Cylinder liner ST Control side
Figure 6: Installing the top land ring
2016-11-21 - de
9007206175358475
Top land ring
10 (10) L48/60B, M010.050.010-01-0002

Cylinder liner
measure
Summary
Check the components as to their state / extent of their wear, prevent opera-
tional problems / damage.
The cylinder liners are to be checked within the scope of maintenance and re-
pair work.
Measuring components and
Assessing contact pattern /wear condition.
Tools/aids required
1 Gauge bar 32/40 050.164 Option
1 Gauge bar 48/60 050.162 Option
1 Micrometer (Internal) 48/60 050.062 Option
1 Micrometer (Internal) 32/40 050.038 Option
Preliminary remarks
Cylinder liners are not evenly worn all the way around their surface or along
the running surface. The wear values are limited both with regard to ovality as
well as to the maximum wear. This way, any sealing problems and overloads
on the piston rings may be avoided.
Regular inspection will provide ideas for optimising the operating conditions
and will be decision-making factors for any necessary cylinder liner replace-
ment.
Work sequence 1 - measuring the cylinder liner

Initial situation Cylinder head is detached, top land ring is disassembled, piston and conrod
(in engine 32/40) or small end (in engine 48/60) are disassembled. Cylinder
liner thoroughly cleaned, particularly in the upper area and on top (in the con-
tact area of the gauge bar).
Work steps 1. Insert gauge bar (050.162 or 050.164) into cylinder liner (10).
2012-11-06 - de
Measuring rail
The calibrated rail is held magnetically to the running surface and to
Cylinder liner
the upper surface of the collar. The quantity and location of the meas-
uring points (2 to 6) are defined by the bores in the gauge bar.
2. Bring internal micrometer (050.038 or 050.062) up to the temperature of

the cylinder liner (10)
48/60;32/40, M010.050.010-03-0003 1 (3)

3. Insert the internal micrometer into each of the bores in the gauge bar,
take measurements and make a note of the measured values.
Measuring the dimensions

Measure the dimensions in the transverse and longitudinal direction of
the engine.
4. Determine the temperature of cylinder liner (10) during the measurement

and make a note of the value.
5. Record the measurements in the operation notes and compare them to
the maximum permitted values. See 010.0005 Engine – operating
manual 010.000.035-04.
Exceeding the measured values

If the measured values exceed the maximum permitted values for wear
or out-of-roundness then the cylinder liner must be replaced.
The wear is calculated by subtracting the nominal dimension from the meas-
ured values. The ovality is the difference between the measured values (in the
transverse and longitudinal direction of the engine) in one plane.
2012-11-06 - de
Cylinder liner
2 (3) 48/60;32/40, M010.050.010-03-0003

2 – 6 measuring points 10 Cylinder liner

Figure 1: Measuring the cylinder liner – left figure shows 32/40; right figure shows 48/60
Cylinder diameter (mm)

Measuring plane
Cyl. 1 Cyl. 2 Cyl. 3
etc.
transverse longitud- trans- longitud- trans- longitud-
inal verse inal verse inal
2 480.36 480.28
3 480.52 480.45
4 480.24 480.16
5 480.18 480.15
6 480.07 480.05
2012-11-06 - de
Cylinder liner temperature during

the measurement 30 °C
Running surface condition perfect

Table 1: Measurement report - Example for engine 48/60
Cylinder liner
9007203445751819
48/60;32/40, M010.050.010-03-0003 3 (3)

9007203445751819
2012-11-06 - de
Cylinder liner
48/60;32/40, M010.050.010-03-0003
Cylinder liner (with backing ring)

Summary
ensure the work is carried out correctly,
check the components as to their state / extent of their wear.
The cylinder liners must be removed at regular intervals to be cleaned.
Safety requirements
l Engine stopped
Tools/aids required
1 Transport device 050.209 Standard
1 Stop piece 050.209-1 Standard
2 Lifting eye bolt M30x2 000.146 Standard
4 Wooden support - Inventory
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2 Rope - Inventory

Measure the cylinder liner 010.050.010-03
L48/60B, M010.050.010-04-0004 1 (12)


Removal and installation of cylinder head 010.060.020-03
Technical data
Backing ring Weight 830 kg
Cylinder liner Weight 690 kg
Cylinder liner with backing ring Weight 1520 kg
Work sequence 1 - Removing the cylinder liner with backing ring

Initial situation Cooling water has been drained off completely.
Reuse cooling water

Cooling water must not be pumped into the bilges or into the sewage
system. Cooling water must be pumped into its own individual tank
and be reused (cooling water treatment agent).
Cylinder head removed, top land ring and pistons with connecting rod small
end removed, connecting rod shank secured at counterweight with securing
clip.

Work steps 1. Clean the cylinder liner (6).

2. Measure the cylinder liner (6). See Work Instructions 010.050.010-03.
3. Remove all pipes and pipe unions from the backing ring (2).
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4. Unscrew and remove two hexagon socket bolts (8) from backing ring (2).
See Fig. 1.
5. Turn back the thrust bolts (10) in the support (050.085-1).
6. Fit the support on the backing ring (2) and fasten with hex bolts (9), mak-
ing sure that the branch socket for the pilot rod (034.006) is on the con-
trol side (ST). See Fig. 2/I.
7. Screw in the thrust bolts (10) until they reach the top edge of the cylinder
liner (6). See Fig. 2/I.
2 (12) L48/60B, M010.050.010-04-0004


structions
8. Fasten the rope (11) with shackle (002.455) on the support and suspend
9. Screw the pilot rod into the branch socket on the support. See Fig. 2/I.
10.Cover the crankcase using suitable equipment, especially at the sides, to
prevent dirt penetration from the cooling chambers in the big-end and
crankshaft bearings.
11.Pull the cylinder liner (6) and backing ring (2) parallel to the centre axis of
the cylinder up and out of cylinder crankcase (5), using the pilot rod to
guide the cylinder liner. See Figs. 2/II and 3.
Improperly placed down cylinder liner

An improperly placed down cylinder liner may tilt due to vibrations or
shocks, resulting in accidents with severe injuries.
• Place the cylinder liner on a clean, flat and suitable surface.
• Secure cylinder liner using suitable equipment to prevent it from tilting.
• Isolate the setting down area
12.Place the cylinder liner (6) and the backing ring (2) down on wooden sup- Cylinder liner (with backing ring)
ports (12, approx. 140 mm high). See Fig. 4/I.
13.Screw two lifting eye bolts (000.146) into the backing ring (2). See Fig. 4/
I.
14.Disconnect the rope (11) from the support.
15.Fasten two ropes (11) with shackle (002.454) on the lifting eye bolts, and
2017-06-14 - de
suspend it from the lifting tackle. Tension the ropes.

16.Turn the thrust bolts (10) a few turns back, slacken the lifting tackle
slightly, and tap the backing ring (2) carefully to release it (use a wooden
or copper base).
17.Remove the support and lower the backing ring (2) onto the wooden
supports (13). See Fig. 4/II.
18.Detach the tool.
19.Slide the support (050.209-2) under the cylinder liner (6). See Fig. 5/I.
20.Fit the stop piece (050.209-1) onto the cylinder liner (6)
L48/60B, M010.050.010-04-0004 3 (12)

21.Plug the support onto the threaded rod (16), screw the hex nut (17) onto
the threaded rod and tighten it. See Fig. 5/II.
22.Hook the lifting tackle (14) into the swivel eye bolt (15). See Fig. 5/II.
23.Lift the cylinder liner (6) out of the backing ring (2) and place it onto the
wooden support. See Fig. 5/III.
24.Detach the tool.
25.Remove all O-rings (3 and 7).
26.Clean the cylinder liner (6).
27.Blow out the oil bores with compressed air.
Work sequence 2 - Installing the cylinder liner with backing ring

Initial situation Cylinder liner is thoroughly cleaned internally and externally. Cylinder liner is
measured. See Work Instructions 010.050.010-03.
Lubricating oil bores blown out; sealing surfaces thoroughly cleaned and un-
damaged. Cylinder liner placed on wooden supports (approx. 140 mm high)
and secured to prevent it from tipping. Crankcase covered using suitable
equipment.

Work steps 1. Slide the support (050.209-2) under the cylinder liner (6).
2. Fit the stop piece (050.209-1) onto the cylinder liner (6)
3. Plug the support onto the threaded rod (16), screw the hex nut (17) onto
the threaded rod and tighten it.

4. Hook the lifting tackle (14) into the swivel eye bolt (15).
5. Lift up the cylinder liner (6).
6. Lubricate new O-rings (3 and 7) with clean lubricating oil and insert them
into the ring grooves. In doing so, make sure that they are tensioned
2017-06-14 - de
evenly along their entire circumference and not twisted.

7. Place the cylinder liner (6) into the backing ring (2). Make sure that the
mark (M) on the cylinder liner and the backing ring line up. See Fig. 5.
8. Detach the transport fixture (050.209).
9. Screw two lifting eye bolts (000.146) into the backing ring (2). See Fig. 4.
10.Fasten two ropes (11) with shackle (002.454) on the lifting eye bolts, and
11.From below, pull the backing ring (2) over the cylinder liner (6). Make sure
that the O-rings (3 and 7) are not damaged and that the markings (M) on
the backing ring and cylinder liner match.
4 (12) L48/60B, M010.050.010-04-0004

12.Turn back the thrust bolts (10) in the support (050.085-1).

13.Place the support onto the backing ring (2) and fasten it to the backing
ring with hex bolts (9). Make sure that the branch sockets for the pilot rod
(034.006) are on the control side (ST). See Fig. 4.
14.Screw in the thrust bolts (10) until they reach the top edge of the cylinder
liner (6). See Fig. 4.
15.Detach the ropes (11) from the lifting eye bolts, unscrew and remove the
lifting eye bolts.

structions
16.Fasten the rope (11) with shackle (002.455) on the support and suspend
17.Screw the pilot rod into the branch socket on the support. See Fig. 3.
18.Lift and move the backing ring (2) with cylinder liner (6) until it is above the
locating bore in the cylinder crankcase (5).
19.Carefully insert the backing ring (2) including cylinder liner (6) into the cyl-
inder crankcase (5). Ensure that the locating pin (4) is aligned correctly
with the bore in the cylinder crankcase.
20.Detach the tool.
21.Insert two hexagon socket bolts (8) through he backing ring (2), screw
them into the cylinder crankcase (5) and tighten them.
22.Remove the cover from the crankcase. Cylinder liner (with backing ring)
23.Measure the cylinder liner (6). See Work Instructions 010.050.010-03.
24.Attach all pipes and pipe unions.
25.After completing the installation work (installing the cylinder head and
tightening the cylinder head bolts, see Work Instructions 010.060.020-02
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and 010.060.020-03), fill coolant into the engine and bleed the cooling
water line.
26.If cooling water pressure is present, check whether the O-rings (3) are OK
- water must not emerge from the inspection holes (A and B). See Fig. 1.
L48/60B, M010.050.010-04-0004 5 (12)


If a new cylinder liner has been fitted, it may be run in according to
specifications. See Volume 010.005 Engine – Operating Manual,
010.000.024-05.
18014405430109195
2017-06-14 - de
6 (12) L48/60B, M010.050.010-04-0004


2017-06-14 - de
1 Cylinder head bolt 5 Cylinder crankcase A Inspection hole

2 Backing ring 6 Cylinder liner B Inspection hole
3 O-ring 7 O-ring M Marking
4 Locating pin 8 Hexagon socket bolt ST Control side
Figure 1: Cylinder liner with backing ring
L48/60B, M010.050.010-04-0004 7 (12)

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1 Cylinder head bolt 6 Cylinder liner ST Control side

2 Backing ring 9 Hex bolt M24x50 I-II Work steps
4 Locating pin 10 Thrust bolt
5 Cylinder crankcase 11 Rope
Figure 2: Removing/installing the cylinder liner with backing ring
8 (12) L48/60B, M010.050.010-04-0004


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Figure 3: Removing/installing the cylinder liner with backing ring
L48/60B, M010.050.010-04-0004 9 (12)

2017-06-14 - de
2 Backing ring 10 Thrust bolt ST Control side

4 Locating pin 11 Rope I-II Work steps
6 Cylinder liner 12 Wooden support
9 Hex bolt M24x50 13 Wooden support
Figure 4: Setting down the cylinder liner with backing ring / lowering the backing ring
10 (12) L48/60B, M010.050.010-04-0004


2017-06-14 - de
2 Backing ring 12 Wooden support 16 Threaded rod

3 O-ring 13 Wooden support 17 Hex nut M16
6 Cylinder liner 14 Lifting tackle I-III Work steps
7 O-ring 15 Swivel eye bolt
Figure 5: Removing/fitting the cylinder liner at the backing ring
L48/60B, M010.050.010-04-0004 11 (12)

2 Backing ring M Marking

6 Cylinder liner
Figure 6: Inserting the cylinder liner into the backing ring - Position of the
markings on the support ring and cylinder liner
18014405430109195
2017-06-14 - de
12 (12) L48/60B, M010.050.010-04-0004

Cylinder liner (without backing ring)

Summary
Carry out the work in due time according to the maintenance schedule, meas-
ure components, assess surface/wear condition.
The cylinder liners must be removed and cleaned at regular intervals.
Safety requirements
l Engine stopped
1 Transport device 050.209 Standard
1 Stop piece 050.209-1 Standard
1 Forcing-out fixture 050.205 Standard
2 Threaded rod 050.205-15 Standard
1 Carrier (lower) 050.184 Standard
1 Carrier (upper) 050.183 Standard
1 High-pressure pump 009.342 Standard Cylinder liner (without backing ring)
2 hollow piston cylinder 009.022 Standard
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1 Rope - Inventory

L48/60CR;L48/60B, M010.050.010-05-0004 1 (14)


Technical data
Cylinder liner Weight 690 kg
Work sequence 1 - Removing the cylinder liner

Initial situation Cooling water has been drained off completely.
Reuse cooling water

Cylinder head detached, piston top land ring and piston removed with con-
necting rod small end, connecting rod shank fastened to balance weight with
locating clamp. Running gear is turned such that cylinder liner can be easily
accessed from below.
Check that the piston of the hollow piston cylinder is fully re-
tracted
Before attaching the hollow piston cylinder, check that the piston is
fully retracted (stroke = zero), and reset the piston if necessary.

2018-12-19 - de


2. Measure the cylinder liner (5). See Work Instructions 010.050.010-03.
3. Fasten the rope (7) with the shackle (002.454) on the lifting eye bolt of the
lower support (050.184). Guide the rope through the cylinder liner (5) and
hook it onto the lifting tackle.
2 (14) L48/60CR;L48/60B, M010.050.010-05-0004

4. Insert the lower beam carefully through the crankcase opening, pull up,
and insert into the cylinder liner (5). Hold the support in this position. See
Fig. 2.
5. Screw the threaded rods (050.205-15) into the lower support until they
make contact. See Fig. 2.
6. Insert the upper support (050.183) over the threaded rods and place it on
the backing ring (2). See Fig. 3.
7. Insert the hollow piston tensioning cylinder (009.022) through the
threaded rods and place them on the upper support. See Fig. 3.
8. Screw the hex nuts (8) hand-tight onto the threaded rods until they come
to rest on the hollow piston tensioning cylinder.
9. Unhook the rope (7) from the bottom support and from the lifting tackle
and remove it from the crankcase.
10.Cover the crankcase using suitable equipment, especially at the sides, to
prevent dirt penetration from the cooling chambers in the big-end and
crankshaft bearings.
11.Connect the high-pressure hoses (009.306) to the hollow piston tension-
ing cylinder and the high-pressure pump (009.342).
Hazardous area in case of failure in axial direction

When using a hollow piston cylinder, high working pressure may result
in high forces being released in axial direction in case of failure and
thus cause severe personal injuries.
• Staying in the axial direction of the hollow piston cylinder is prohibited.

ceeded.
12.Start the high-pressure pump (see Work Instructions 015.000.003-01) Cylinder liner (without backing ring)
and pump up the hydraulic hollow piston tensioning cylinders slowly until
the cylinder liner (5) releases from the cylinder crankcase (4). See Fig. 4.
14.Disconnect the high-pressure hoses from the hollow piston tensioning
cylinder and the high-pressure pump.
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15.Remove / detach the tool.

16.Fit the stop piece (050.209-1) onto the cylinder liner (5) See Fig. 5/I.
17.Insert the support (050.209-2) carefully through the opening in the crank-
case and fit it onto the threaded rod (9). Screw hex nuts (10) onto the
threaded rod and tighten them. See Fig. 5/II.
18.Hook the lifting tackle (11) into the swivel eye bolt (12). See Fig. 6/I.
19.Pull the cylinder liner (5) parallel to the cylinder centre axis upwards out of
the cylinder crankcase (4). See Fig. 6/II.
L48/60CR;L48/60B, M010.050.010-05-0004 3 (14)

Improperly placed down cylinder liner

An improperly placed down cylinder liner may tilt due to vibrations or
shocks, resulting in accidents with severe injuries.
• Place the cylinder liner on a clean, flat and suitable surface.
• Secure cylinder liner using suitable equipment to prevent it from tilting.
• Isolate the setting down area
20.Set aside the cylinder liner (5) on wooden supports (13, about 140 mm
high). See Fig. 7.
21.Detach the tool.
22.Remove all O-rings (3 and 6).
23.Clean the cylinder liner (5).
Work sequence 2 - Installing the cylinder liner

Initial situation Cylinder liner is thoroughly cleaned internally and externally. Cylinder liner is
measured. See Work Instructions 010.050.010-03.
Lubricating oil bores blown out; sealing surfaces thoroughly cleaned and un-
damaged. Cylinder liner placed on wooden supports (approx. 140 mm high)
and secured to prevent it from tipping / falling over.
Crankcase covered using suitable equipment.


Work steps 1. Slide the support (050.209-2) under the cylinder liner (5).
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2. Fit the stop piece (050.209-1) onto the cylinder liner (5)
3. Plug the support onto the threaded rod (9), screw the hex nut (10) onto
the threaded rod and tighten it. See Fig. 8.
4. Hook the lifting tackle (11) into the swivel eye bolt (12).
5. Lift up the cylinder liner (5).
6. Insert new O-rings (3 and 6) lubricated with clean lubricating oil into the
ring grooves; in doing so, make sure that they are evenly tensioned all
around the circumference and that they are not twisted.
7. Guide the cylinder liner (5) over the locating bore in the cylinder crank-
case (4). See Fig. 6/II.
4 (14) L48/60CR;L48/60B, M010.050.010-05-0004

8. Insert the cylinder liner (5) carefully parallel to the cylinder centre axis into
the backing ring (2) and the cylinder crankcase (4). Make sure that the
mark (M) on the backing ring and the cylinder liner match. See Fig. 9.
9. Detach or remove the transport fixture (050.209).
10.Remove the cover from the crankcase.
11.Measure the cylinder liner (5). See Work Instructions 010.050.010-03.
12.Attach all pipes and pipe unions.
13.After completing the installation work (installing the cylinder head and
tightening the cylinder head bolts, see Work Instructions 010.060.020-02
and 010.060.020-03), fill coolant into the engine and bleed the cooling
water line.
14.If cooling water pressure is present, check whether the O-rings (3) are OK
- water must not emerge from the inspection holes (A and B). See Fig. 1.

If a new cylinder liner has been fitted, it may be run in according to
specifications. See Volume 010.005 Engine – Operating Manual,
010.000.024-05.
36028803946525323

2018-12-19 - de
L48/60CR;L48/60B, M010.050.010-05-0004 5 (14)

2018-12-19 - de
1 Cylinder head bolt 6 O-ring

2 Backing ring A Inspection hole
3 O-ring B Inspection hole
4 Cylinder crankcase M Marking
Figure 1: Cylinder liner
6 (14) L48/60CR;L48/60B, M010.050.010-05-0004

2 Backing ring 7 Rope


Figure 2: Removing the cylinder liner
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L48/60CR;L48/60B, M010.050.010-05-0004 7 (14)

2 Backing ring 8 Hex nut M30

4 Cylinder crankcase ST Control side
5 Cylinder head
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8 (14) L48/60CR;L48/60B, M010.050.010-05-0004


5 Cylinder liner
Figure 4: Removing the cylinder liner Cylinder liner (without backing ring)
2018-12-19 - de
L48/60CR;L48/60B, M010.050.010-05-0004 9 (14)


9 Threaded rod I-II Work steps
10 Hex nut M16
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10 (14) L48/60CR;L48/60B, M010.050.010-05-0004


2018-12-19 - de
1 Cylinder head bolt 11 Lifting tackle

2 Backing ring 12 Swivel eye bolt
5 Cylinder liner I-II Work steps
Figure 6: Removing/installing the cylinder liner
L48/60CR;L48/60B, M010.050.010-05-0004 11 (14)

3 O-ring 10 Hex nut M16

5 Cylinder liner 11 Lifting tackle
6 O-ring 12 Swivel eye bolt
9 Threaded rod 13 Wooden support
Figure 7: Placing down the cylinder liner
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12 (14) L48/60CR;L48/60B, M010.050.010-05-0004

3 O-ring 11 Lifting tackle

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5 Cylinder liner 12 Swivel eye bolt

6 O-ring 13 Wooden support
9 Threaded rod M Marking
10 Hex nut M16
Figure 8: Installation of the cylinder liner - Position of the stop piece for mark-
ing on the cylinder liner
L48/60CR;L48/60B, M010.050.010-05-0004 13 (14)

2018-12-19 - de
1 Cylinder head bolt 9 Threaded rod

3 O-ring 11 Lifting tackle
4 Cylinder crankcase M Marking
6 O-ring
Figure 9: Installation of the cylinder liner
36028803946525323
14 (14) L48/60CR;L48/60B, M010.050.010-05-0004

Cylinder liner
honing
Summary
check the components as to their state / extent of their wear, restore running
surface to operational state, ensure the tasks are carried out correctly.
The cylinder liners are to be checked at regular intervals and the original run-
ning surface geometry is to be restored to how it was.
The work / work steps consist of:
Honing the reversal point of the piston rings,
honing the entire running surface.
Tools/aids required
1 Honing device 050.087 Option
1 Rope pull with remote control 050.087-1 Option
1 Cross tie 050.087-2 Option
2 Extension pipe 050.087-3 Option
2 Extension pipe 050.087-4 Option
2 Intermediate piece 050.087-5 Option
4 Stop for stroke limiter 050.087-6 Option
1 Guide arm with control valve 050.087-7 Option
1 Extension 050.087-8 Option
1 Drive unit 050.087-9 Option
1 Air connection with universal joint 050.087-10 Option
1 Honing head 050.087-11 Option
1 Tank 050.087-12 Option
1 Funnel 050.087-13 Option
1 Additional mass 050.087-14 Option
2 Spring strap 050.087-16 Option
1 Air supply station 050.087-17 Option
1 injection nozzle 050.087-20 Option
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3 Cleaning brush 050.087-21 Option

2 Threaded piece 050.087-22 Option
1 Oil for air oiler 050.087-23 Option
1 Support 050.087-24 Option
Cylinder liner
1 Honing stone (set) for laser-hardened cylinder - Option

liners
1 Honing stone (set) for unhardened cylinder - Option
liners
1 Collecting tank - Inventory
1 Lift gear with rope - Inventory
L51/60DF;L48/60, M010.050.010-07-0004 1 (11)


1 Cleaning agent (diesel oil / kerosene) - Inventory

Preliminary remark
Cylinder liners must be re-honed when the piston rings are replaced, or once
the maintenance interval has elapsed. Honing restores the original surface fin-
ish on the running surface of the liner. This roughness is necessary to ensure
a sufficiently thick and adhesive lubricating film. While for the most part the
microgeometry can be returned to its original state, it is not possible to influ-
ence the wear profile, i.e. the macrogeometry of the cylinder liner.
Typically, the TDC area of the piston rings is honed during the first work step.
In the second work step, work is performed to the entire piston ring running
surface.
Honing the cylinder liner is not a very time-consuming task. However, operat-
ing the device and the work itself, as well as correctly assessing the results,
do require concentration and a certain amount of experience. We therefore
recommend that you have this work carried out by MAN Energy Solutions
personnel, on at least one occasion, for the purposes of instruction.
Structure and mode of operation

In essence, the honing device consists of:
▪ the rope pull (1) - see figure 1
▪ the drive unit (15)
▪ the honing head (20)
▪ the lubrication installation (17 and 24)
▪ the guide elements (2 to 4, 6 to 8 and 10) and
▪ the portable air supply station (23).
Drive and control of the fixture are operated on compressed air (pmax = 18
bar).
The fittings of the air supply station (23) serve for air filtering and water re-
moval as well as the addition of oil. See Fig. 2.
Use the control valves on the compressed air outlets to make a pre-setting of
2019-05-09 - de
the hoisting speed and of the honing head speed (20) as well as pre-setting of
the pressure of the grinding element (18). The rope pull contol engine is activ-
ated for lifting and lowering movements using the buttons on the remote con-
trol (5).
Using the ball cock on the guide arm (7) the drive unit (15) is switched on and
Cylinder liner
off. The pressing power of the grinding element is regulated by means of the
slide valve located next to it.
Using the lubrication installation, consisting of tank (24) and injection nozzles
(17) the grinding area can be lubricated and cleansed of abrasion particles.
The lubricating -/cleaning medium is collected in a funnel (22), fixed to the
2 (11) L51/60DF;L48/60, M010.050.010-07-0004

lower edge of the cylinder liner (14), and transported to the outside from there.
When switching from grinding strips to cleaning brushes (19), it is possible to
mechanically clean the cylinder liner (14).
The fixture can be set for various diameters and adapted to suit various stroke
lengths by using extension pipes and intermediate pieces.
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Cylinder liner
L51/60DF;L48/60, M010.050.010-07-0004 3 (11)

1 Rope pull 13 Cylinder head bolt

2 Cross tie 14 Cylinder liner
3 Extension pipe 15 Drive unit
4 Stop for stroke limiter 16 Air connection with uni-
versal joint
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5 Remote control 17 injection nozzles

6 Extension pipe 18 Grinding element with
honing stones
7 Guide arm with control 19 Cleaning brushes
valves
Cylinder liner
8 Threaded piece 20 Honing head

9 Additional mass 21 Spring strap
10 Intermediate piece 22 Funnel
11 Extension 23 Air supply station
12 Support 24 Tank
Figure 1: Pneumatic honing device when mounted
4 (11) L51/60DF;L48/60, M010.050.010-07-0004

23 Air supply station A Compressed air supply

26 Filter/water separator B Compressed air to rope-
pull motor (hoisting speed)
27 Oiler C Compressed air to drive
unit (rotational speed)
28 Pressure regulating valve D Compressed air to guide
arm/honing head (contact
pressure)
29 Pressure gauge
Figure 2: Air supply station (side view and view from above)
Work sequence 1 - Honing the piston ring reversal point in the top dead centre (nip
area)
Cylinder head removed. Piston with small end removed. Connecting rod
shank fastened on balance weight by means of locating clamp and turned to
side so that funnel (22) can be mounted. See figure 3, Cylinder liner cleaned
(carbon residue and lubricant free) and measured accurately (cylinder liner has
not yet reached maximum wear, for threshold values see Operating Instruc-
tions /Technical Data). Exits of channels for cylinder lubricant closed off with
kneadable compound (plasticine) or heavy grease. Crank mechanism covered
with suitable material. Funnel fastened to bottom of cylinder liner and hose
(31) directed outwards into collector (32). Honing device set up and adjusted
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according to separate description.
Honing with short honing stones

Cylinder liner
The piston ring reversal points are to be honed as a first work step us-
ing short honing stones before the entire running surface of the piston
ring is honed during a subsequent work step (see work sequence 2).
Work Steps 1. Clamp honing stones, about 20 mm long, in each grinding element (18)
at the same height in the area of centre of contact strip.
L51/60DF;L48/60, M010.050.010-07-0004 5 (11)

Manufacture of short honing stones

Lengths can be broken off the longer honing stones to make short
honing stones. To do so, notch the honing stone using a steel saw
blade, clamp it into a vice and break off.
2. Guide honing head (20) carefully into cylinder liner (14).

3. Adjust the stroke movement of the honing head in cylinder liner with
stops (4) so that the top edge of the honing stones is about 10 mm
above the top dead centre of the first piston ring and the resultant stroke
is 60-80 mm.
4. Align spray nozzles (17) so that lubricant coats the honing area on exiting.
5. Close the shut-off cock for the tank (24) and fill it with lubricant (diesel oil,
gas oil or petroleum).
Flammable and explosive mixtures!

Fires or explosions can lead to severe material damage and personal
injury resulting in death.
• No smoking.
• Do not use open flame.
6. Open the tank's shut-off cock. Check that lubricant is discharged from
the injection nozzles and wetting the honing area. Check that lubricant
reaches collecting tank (32) via funnel (22) without leaking.
Lubricant quantity required for honing

Roughly 4 - 6 litres of lubricant are required to hone one cylinder liner.
Always make sure a sufficient quantity of lubricant is used when per-
forming the honing process. It is advantageous to wash away abraded
material immediately.
The lubricant may be used several times if it flows into the collecting
tank through a fleece mat. Clean lubricant/cleaning agent must be
used for subsequent cleaning of the cylinder liner following the actual
honing process.
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7. Bring the honing device into operation using a tried-and-tested setting.

Bring the honing stones into contact. Hone with short up and down
strokes (each about 20-30 double strokes) until the short honing stones
are consumed. This lasts about 1-1.5 minutes. Speed of the honing head
Cylinder liner
should be about 35 1/min, contact pressure 2.5 bar. Due to the short
stroke, only a shallow honing angle is achieved. If honing marks start to
appear in the TDC area of the first piston ring, cancel the honing process.
If a rounded ledge is still present at the reversal point of the first piston
ring, this is permissible. If required, the operation must be repeated using
a second set of short honing stones.
6 (11) L51/60DF;L48/60, M010.050.010-07-0004

8. As soon as a satisfactory surface condition has been established, stop

the honing process and cut off the lubricant inlet.
9. Move the honing head out of the cylinder liner and secure in the upper
position.
Work sequence 2 - Honing the entire running surface of the cylinder liner
Starting position Reversal area of piston rings at TDC honed, or cylinder liner available with low
wear shoulders in the TDC area.
Honing the running surface of cylinder liner

This task is intended to roughen up the upper area of the cylinder liner
on which no further honing grooves are visible after many operating
hours. The lower section should be honed as little as possible, but two
double strokes must be directed along the entire running surface of the
piston rings once this operation is complete. In case of laser hardened
cylinder liners, pay attention to a fluent transition of the hardened run-
ning surfaces to the underlying soft part of the cylinder liner.
Work Steps 1. Mount six long honing stones onto honing head (20).
2. Insert the honing head carefully into cylinder liner (14).
3. Set reciprocating movement of the honing head with stops (4) such that
the honing stones move in their upper half of the stroke area of the piston
(running area of the piston rings) i.e. the upper and lower edges of the
stone overrun about 100 mm over it.
4. Align spray nozzles (17) so that lubricant coats the honing area on exiting.
Fill tank (24) with lubricant (diesel oil, gas oil or petroleum).
Fire hazard
The use of flammable lubricants means a potential fire hazard.
• Smoking and handling with open fire is prohibited.
• Any spark generating work is prohibited.
• The parts must be cooled down up to below the flash point of the lub-
ricant used (see Safety Data Sheet for lubricant)
• Measures for fire fighting must be available
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5. Open the tank's shut-off cock. Check that lubricant is discharged from
the injection nozzles and wetting the honing area. Check that lubricant
reaches collecting tank (32) via funnel (22) without leaking.
Cylinder liner
L51/60DF;L48/60, M010.050.010-07-0004 7 (11)

Lubricant quantity required for honing

Approx.10 litres of lubricant are needed for the honing process of one
cylinder liner.
Always make sure a sufficient quantity of lubricant is used when per-
forming the honing process. It is advantageous to wash away abraded
material immediately.
6. Bring the honing device into operation using a tried-and-tested setting.

Bring the honing stones into contact. Honing a cylinder liner needs about
75-80 up and down movements each at a hoisting speed of about 10
double strokes per minute. See Table 2. The total honing time for a cylin-
der liner is normally about 4-8 minutes, where the higher values are valid
for the laser hardened cylinder liners.
Speed of the honing head - see Table 2, contact pressure 2.5 bar. Con-
trol the stroke movement so that a honing angle (α) of 45-60° (22.5-30°
to the horizontal) is achieved. For template see Fig. 4. A surface rough-
ness Rz of 10-15 µm should ideally be achieved with laser-hardened cyl-
inder liners and normal cylinder liners.
7. Stop fixture. Evaluate roughness, honing angle and honing pattern. See
Table 1.
If the analysis appears to be satisfactory, two final double strokes are to
be carried out over the entire running surface of the piston rings. In doing
so, adjust stops (4) so that the honing stones run partially out of the cylin-
der liner. The honing head must however not collide with the funnel (22).
8. After honing, measure the cylinder liner (see Work Instructions
010.050.010-03). If the maximum permissible wear at TDC of the first
piston ring, or the maximum permissible out-of-roundness, is exceeded
(for limit values see Volume 010.005 Engine – Operating manual
010.000.035-04), the cylinder liner must be replaced. Change grinding
elements for hard cleaning brushes (19).
9. Run in honing head and, at reduced contact pressure of 0.5-1 bar care-
fully remove (free and rinse away) all grinding residues at the same rota-
tional speed and stroke speed. Repeat the procedure using soft cleaning
brushes if necessary. Use plenty of lubricant when carrying out the clean-
ing. Perform roughly 50 double strokes in total. Perform the last cycle us-
ing fresh lubricant. No abrasive particles should be left behind. Check
with the finger tips!
10.Remove the honing device. Proceed to the next cylinder, or clean the
device and store it safely, or stow it away in a packing box.
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11.Remove kneading compounds or grease plugs from the outlets for cylin-
der lubrication.
12.Separate lubricating oil pipes of the cylinder lubrication from cylinder
crankcase, blow bores for cylinder lubrication free using compressed air.
Cylinder liner
Connect lubricating oil pipes again.

13.Detach funnel (22), ensuring that no impurities enter the running gear.
14.Then clean the cylinder liner manually.
8 (11) L51/60DF;L48/60, M010.050.010-07-0004


After installing the piston and fitting the cylinder head, observe the in-
structions for commissioning the engine (see Volume 010.005 Engine –
Operating Manual 010.000.024-05) when starting up.
27021604699037835
14 Cylinder liner 32 Collecting tank

22 Funnel α Honing angle
31 Hose
Figure 3: Cylinder liner honing (starting position)
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As an alternative
Characteristic Test/Measurement 1 2
Roughness Rzmeasured in the Measuring device Technovit imprint Finger nail test and visual
Cylinder liner
TDC area of piston ring 1 and (hardened plastic) - allows assessment

at centre of stroke of piston subsequent assessment of
ring 1 all the three parameters
Honing angle Protractor Angle template
L51/60DF;L48/60, M010.050.010-07-0004 9 (11)

As an alternative
Characteristic Test/Measurement 1 2
Honing pattern, i.e. groove Judging fax film imprints Observation with a magni-
profile and distribution, so- (Cellulose acetate film) fier,
called sheet metal jacket form- under the microscope visual assessment/
ation (smudging and tearing (50-times magnification) Experience necessary
along honing marks),
residual unhoned "holes"
Table 1: Assessment of cylinder liner running surfaces after honing
27021604699037835
Type Stroke height Rotational speed Number of double Time per double Number of double
(mm) (1/min) strokes stroke * strokes required
per minute (s)
48/60 700 23 10 6 70-75
* Valid for a honing angle (α) of 45°

Table 2: Processing parameters for cylinder liner honing
27021604699037835
2019-05-09 - de
Cylinder liner
10 (11) L51/60DF;L48/60, M010.050.010-07-0004

2019-05-09 - de
X 135° ≙ 45° honing angle Y 120° ≙ 60° honing angle

Figure 4: Auxiliary material required to manufacture a honing angle template
Cylinder liner
27021604699037835
L51/60DF;L48/60, M010.050.010-07-0004 11 (11)

27021604699037835
2019-05-09 - de
Cylinder liner
L51/60DF;L48/60, M010.050.010-07-0004
Sealing groove in the top land ring

grinding
Summary
Check components for condition/wear condition, prevent operating problems/
damage.
The sealing groove in the top land ring must be checked every time the cylin-
der head is removed, and, if necessary, re-worked.
The work includes:
Grinding the sealing groove.
Tools/aids required
1 Grinding-in fixture 050.163 Option
1 Grinding wheel 050.163-2 Option
1 Grinding paste, silicon-free - Inventory
Work sequence - Grinding the sealing groove in the top land ring
Initial situation Cylinder head is dismantled, sealing ring is removed.
Work steps 1. Clean the sealing groove (B) in the top land ring (3). See Fig. 2
Grinding disc can be used for both top land ring and cylinder
head
The grinding disc can be used for the top land ring and the cylinder
head. The correct side of the grinding disc can be seen in Fig. 3. Sealing groove in the top land ring
2. Fasten holder (050.163-1) to grinding disc (050.163-2). See Fig. 3

3. Apply grinding paste to the grinding disc; do not apply too much grinding
paste.
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4. Place grinding tool (050.163) on top of the top land ring (3).
Grinding of sealing groove

The minimum possible amount of grinding should be done, as a flat
surface is difficult to achieve by grinding. If necessary, the top land
ring must be machined on a lathe.
5. Move the grinding tool up and down, lifting it occasionally so that the
grinding paste can be distributed.
V48/60TS, M010.050.010-08-0002 1 (5)

6. Remove the grinding tool after the grinding is over.

7. Carefully remove all grinding paste residue from sealing groove (B) and
top land ring (3).
8. Dismantle grinding tool and clean it.
9. Measure top land ring (3), sealing ring (2) and cylinder head (1) to determ-
ine gap dimension (A). See Fig. 1
Gap dimension between top land ring and cylinder head

The reground sealing surfaces (B) must have a gap dimension (A)
between top land ring and cylinder head of at least 0.5 mm.
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2 (5) V48/60TS, M010.050.010-08-0002


2018-06-12 - de
1 Cylinder head 3 Top land ring

2 Sealing ring A Gap dimension
Figure 1: Cylinder head and top land ring
V48/60TS, M010.050.010-08-0002 3 (5)

3 Top land ring 6 Backing ring

4 Cylinder head bolt B Sealing groove
5 Cylinder liner
Figure 2: Sealing groove in the top land ring
2018-06-12 - de
4 (5) V48/60TS, M010.050.010-08-0002

3 Top land ring 6 Backing ring

4 Cylinder head bolt 7 Wing screw M10x50
Figure 3: Top land ring - grinding in the sealing groove
9007206193666187

2018-06-12 - de
V48/60TS, M010.050.010-08-0002 5 (5)

9007206193666187
2018-06-12 - de
V48/60TS, M010.050.010-08-0002
Cylinder liner - fretting

assessing and reworking
Summary
Ensure/ restore operational safety, Ensure correct execution of work.
If during removal of the cylinder liner fretting spots are detected, they must be
assessed and reworked if necessary.
Assessing the components.
Reworking the components.
Safety requirements
Tools/aids required
1 Emery paper - Inventory
1 File - Inventory
1 Abrasive cap - Inventory
Preliminary remarks
Depending on the operational conditions of the engine, the cylinder liner and
cylinder crankcase may be affected by fretting. These fretting traces occur in
the area of the lower centring device of the cylinder liner and the lower bore of
the cylinder crankcase. See Figs. 1 and 2. These abnormalities are caused by
2018-03-16 - de
relative movements between the cylinder liner and cylinder crankcase initiated
by a combination of dynamic forces and prevailing vibrations. They are visible
to the naked eye, however they do not affect functioning.
General, M010.050.010-12-0001 1 (4)

Figure 1: Fretting traces: illustration on the left – bore of the cylinder crank-
case; illustration on the right – cylinder liner
Fretting can easily be identified by running a fingernail over suspicious sur-

faces. If in doing so rough or uneven surfaces are felt/detected, these gener-
ally are indications of fretting. The area affected is marked in Fig. 2. The entire
circumference of the cylinder liner and of the bore in the cylinder crankcase
must be investigated within the marked area.
2018-03-16 - de
1 Top land ring 3 Cylinder crankcase

2 Cylinder liner F Area of fretting traces
Figure 2: Area where fretting traces may be visible around the lower centring
device of the cylinder liner (illustration in figure shows engine V32/40)
Work Sequence 1 - Assessment of the cylinder liner in relation to fretting

Initial situation Cylinder liner removed. Bore for the cylinder liner in the cylinder crankcase is
free for access.
2 (4) General, M010.050.010-12-0001

2. Assess cylinder liner (2).

3. Assess bore in cylinder crankcase (3).
Pattern for assessment of the cylinder liner and of bore in the cylinder crank-
case:
usable unrestricted
The strips between the O-ring seal in the cylinder liner and the bore in cylinder
crankcase have no fretting traces. The surface is flat, and no rough spots may
be felt over the entire circumference.
Figure 3: Perfect pattern – the cylinder liner can be used in the cylinder crank-
case without restriction
Polishing required
The strips between the O-ring seals in the cylinder liner or the bore in cylinder
crankcase have fretting traces. The surface is uneven, and isolated rough
spots may be felt.
Figure 4: Contact pattern with fretting – polishing, cleaning (abrasive paper or

grindstone) of cylinder liner and cylinder crankcase required
Inspection of the surrounding components

2018-03-16 - de
After removal of the cylinder liner, the surrounding components must

be inspected also. In particular, pay attention to the condition of the
contact surface between the outer surface of the cylinder liner and the
cylinder crankcase.
Work Sequence 2 - Reworking the cylinder liner

Initial situation The cylinder liner and bore in the cylinder crankcase must be assessed using
the pattern. Decision: remove the fretting by polishing, cleaning. Depending
on the results, the following work steps may need to be carried out.
General, M010.050.010-12-0001 3 (4)

Material removal when polishing, cleaning

Injuries to the eyes or skin due to material removal when grinding.
• Wear safety goggles and protective gloves for grinding work.
Work steps 1. Removal of O-ring seals of the cylinder liner (2).
Surface quality of reworked areas

Ensure that an undulating surface is not created as a result of rework-
ing the fretting spots. To achieve roundness and dimensional stability
of the bore in the cylinder crankcase and of the cylinder liner, it is
solely necessary to remove protruding/raised material by polishing/
cleaning.
2. Remove protruding/raised material from the fretting spots on the cylinder

liner (2) by polishing/cleaning.
3. Cover the crankcase with suitable means.
4. Remove protruding/raised material from the fretting spots on bores in the
cylinder crankcase (3) by polishing/cleaning.
5. Clean cylinder liner (2) and bore in cylinder crankcase (3) using a solvent
cleaner. Surfaces must be absolutely free of foreign matter and oil
residues.

45036009104785675
2018-03-16 - de
Figure 5: Contact pattern after reworking

45036009104785675
4 (4) General, M010.050.010-12-0001

Cylinder liner - running surface

inspecting
Summary
Inspection of components for surface defects, to avoid damage.
After an engine emergency stop due to high oil mist concentration in the
crankcase and/or activation of splash oil temperature monitoring, the running
surface of all cylinder liners must be inspected.
inspecting the components.
Safety requirements
l Engine stopped
Tools/aids required
1 Rags - Inventory
1 Torch - Inventory
Work Sequence - Inspection

Starting condition All crankcase covers are detached.
Inspecting the running surface

The running surfaces on all engine cylinders must be inspected.
Work steps
Working in the crankcase

2016-09-20 - de
Danger to life due to working in the crankcase during turning opera-

tion.
optical signals
1. Turn piston to TDC position.

2. Clean the cylinder liner (1) of lubricating oil.
General, M010.050.010-13-0001 1 (3)

Inspecting the running surface

The cylinder liner running surface must be inspected, especially on the
pressure side of the piston.
Definition of the pressure V engines rotating clockwise:

side ▪ Cylinder bank A: Pressure side is on the control side
▪ Cylinder bank B: Pressure side is on the exhaust side
V engines rotating anti-clockwise:
▪ Cylinder bank A: Pressure side is on the exhaust side
▪ Cylinder bank B: Pressure side is on the control side
In-line engines rotating clockwise:
▪ the pressure side is on the left , when looked at from the coupling side
In-line engines rotating anti-clockwise:
▪ the pressure side is on the right side, when looked at from the coupling
side
Oil smears on the running surface

Oil smears (3) on the running surface, especially beneath the oil bores
(2) are not seizure marks and not critical.
3. Visually inspect the running surface (5) and check for irregularities (seizure
marks, lapping).
Irregularities on the running surface

In the case of irregularities on the running surface, contact MAN
PrimeServ; additional inspections are required.
2016-09-20 - de
2 (3) General, M010.050.010-13-0001

1 Cylinder liner 3 Oil smear 5 Running surface

2016-09-20 - de
2 Lube oil bore 4 Seizure points

Figure 1: Cylinder liner (depiction in image shows example on an engine 48/60B)
Oil bores in figure 1

Depending on the engine version and engine type, the oil bores which
can be seen on figure 1 may vary, be concealed or not present at all.
9007218962347019
General, M010.050.010-13-0001 3 (3)

9007218962347019
2016-09-20 - de
General, M010.050.010-13-0001

010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas 010.060 Cylinder head, complete
51353848715
1 (1)


51353853323
1 (1)

Cylinder head bolts

inspection
Summary
Cylinder head screws must be checked at regular intervals using hydraulic
tensioners.
Safety requirements
l Engine stopped
l Operating media system blocked / depressurised
l Operating media system drained
Tools/aids required
1 Body 055.569-1 Standard
1 Pin 055.569-3 Standard
1 Guard bracket 055.569-5 Standard
2 Tension screw 055.244 Standard
1 Socket wrench insert 012.043 Standard
2021-02-22 - de

Cylinder head bolts

1 Lubricating agent (Molykote G-N Plus) - Option

General, M010.060.020-01-0016 1 (17)


Values for screw tightening

Item Pretension Tightening torque and torsion angle Note
force Tightening 1st stage 2nd stage 3rd + 4th Lubricant/screw
torque stage locking
kN Nm Nm Nm Nm
25 85
27 110
Work Sequence - Checking the cylinder head bolts

pressure hoses.
Material damage may result from the use of damaged protect-

ive devices or safety systems
If a cylinder head screw breaks, the protective device or safety system
may become deformed or damaged. Use of damaged protective
devices or damaged safety systems may result in material damage if a
second cylinder head screw breaks.
• If a cylinder head screw breaks, the protective device or safety system
must be replaced in its entirety.
2021-02-22 - de
Cylinder head bolts

Initial situation Rocker arm casing with rocker arms detached; push rods removed. Piping
support removed.
Work steps 1. Remove insulation (21, inline engine) or insulation cover (V engine) for in-
dicator valve (19). See Fig. 1.
2. Remove any installed outlet and inlet pipes (15 and 16) for fuel injection
nozzles cooling.
2 (17) General, M010.060.020-01-0016

3. Remove the protective caps (17 and 22) for the cylinder head bolts (11).
See Fig. 3.
4. Unscrew the nuts (18). See Figs. 4 and 5.
5. Remove the retainer plates (20).
6. Clean the threads of the cylinder head bolts (11).
7. Mark the position of the indicator cable (28) with suitable means. See
Fig. 8.
8. Release the union nut (29) and remove the indicator cable (28).
9. Remove the cotter pin (24) and bolt (055.569-3). See Fig. 7.
10.Move mount (055.569-2) into mount (055.569-1) until the bore spacing of
the mounts matches that of the cylinder head (12).
11.Fit the bolt and cotter pin (24).
12.Position the mount on the cylinder head (12). See Fig. 8.
13.Screw in the hex bolt (25) with washer (26) and tighten to the specified
torque. See table “Values for bolt tightening”.
14.Screw in the hex bolts (27) and tighten to the specified torque. See table
“Values for bolt tightening”.
15.Screw in the tension bolts (055.244) until they abut the cylinder head
bolts (11) at bolt positions 1 and 5. See Figs 6, 9 and 13.
16.Fit the thrust pieces (055.243) over the tension bolts and the nuts (10).
17.Screw the hydraulic tensioners (009.632) onto the tension bolts. In doing
so, ensure that the thrust pieces are centrally aligned by the hydraulic
tensioners.
18.Place thrust pieces (055.242) over the cylinder head bolts (11) and
nuts (10) at bolt positions 3 and 7.
19.Screw the hydraulic tensioners (009.631) onto the cylinder head bolts
(11) at bolt positions 3 and 7. In doing so, ensure that the thrust pieces
are centrally aligned by the hydraulic tensioners.
20.Turn the hydraulic tensioners (009.631 and 009.632) back by the turn-
back angle. See Work Instruction 010.000.003-05.
21.Place the protective bracket (055.569-5) on the mount. Secure the pro-
tective bracket with the locking pin (30). See Fig. 10.
struction 015.000.002-01.
2021-02-22 - de
sioners.
Cylinder head bolts
NOTICE Material damage may result from the use of damaged protective
devices or safety systems.
from turning the tensioner back. See Work Instruction 015.000.003-01.
24.Pump up the hydraulic tensioners until the nuts (10) can be released.
pressure. The release pressure must not exceed 7% below or 5% above
the tensioning pressure. See Work Instructions 010.000.003-05 and
015.000.001-01.
General, M010.060.020-01-0016 3 (17)


Work Instruction 010.000.003-05.
29.Remove the locking pin (30). Remove the guard bracket from the mount.
31.Screw in the tension bolts up to contact with the cylinder head bolts (11)
at bolt position 4 and 8. See Figs 6, 11 and 13.
tensioners.
36.Turn the hydraulic tensioners (009.631 and 009.632) back by the turn-
back angle. See Work Instruction 010.000.003-05.
37.Fit guard bracket onto the body. Secure the protective bracket with the
locking pin (30). See Fig. 12.
sioners.
40.Pump up the hydraulic tensioners until the nuts (10) can be released.
015.000.001-01.
2021-02-22 - de

Cylinder head bolts
47.Unscrew the hex bolts (25 and 27) and remove the washer (26). See
Fig. 8.
4 (17) General, M010.060.020-01-0016

48.Remove the frame from the cylinder head (12).

49.Position the indicator cable (28) in accordance with the applied marking
and tighten the union nut (29).
NOTICE Bent or damaged catch plates must be replaced.
50.Place the retainer plates (20) over the cylinder head bolts (11) on the
nuts (10). See Fig. 5.
51.Coat the thread and contact surface of the nuts (18) with lubricant.
52.Screw the nuts (18) onto the cylinder head bolts (11). Ensure that the col-
lar of the nuts points towards the retainer plates (20) and that the retainer
plates are centred by the nuts. See Fig. 2.
53.Tighten the nuts (18) to the specified torque. See Work Instruction
010.000.003-05. See Fig. 4.
54.Place protective caps (17 and 22) on the cylinder head bolts (11). See
Fig. 3.
55.Install any removed outlet and inlet pipes (15 and 16) for the fuel injection
nozzle cooling. See Fig. 1.
56.Install insulation (21, inline engine) or insulation cover (V engine) for indic-
ator valve (19).
2021-02-22 - de
Cylinder head bolts
General, M010.060.020-01-0016 5 (17)

10 Nut 18 Nut
11 Cylinder head bolt 19 Indicator valve
12 Cylinder head 20 Retainer plate
15 Drain line 21 Insulation
16 Feed pipe 22 Protective cap
17 Protective cap
Figure 1: Cylinder head*
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Cylinder head bolts
6 (17) General, M010.060.020-01-0016

18 Nut 20 Retainer plate

Figure 2: Cylinder head* – Centring the retainer plate with the nuts
2021-02-22 - de
Cylinder head bolts
General, M010.060.020-01-0016 7 (17)

10 Nut 18 Nut
11 Cylinder head bolt 22 Protective cap
17 Protective cap
Figure 3: Cylinder head* – Detaching/attaching the protection caps
2021-02-22 - de
Cylinder head bolts
8 (17) General, M010.060.020-01-0016

11 Cylinder head bolt 20 Retainer plate 23 Ratchet tool

18 Nut
Figure 4: Cylinder head* – Loosening/tightening the nuts
2021-02-22 - de
Cylinder head bolts
General, M010.060.020-01-0016 9 (17)

10 Nut 18 Nut
11 Cylinder head bolt 20 Retainer plate
Figure 5: Cylinder head* – Detaching/attaching the retainer plates
2021-02-22 - de
Cylinder head bolts
10 (17) General, M010.060.020-01-0016

1–8 Bolt position/tightening 11 Cylinder head bolt

sequence
10 Nut 12 Cylinder head
Figure 6: Cylinder head bolts* – Bolt position
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Cylinder head bolts
24 Cotter pin
Figure 7: Guard body
General, M010.060.020-01-0016 11 (17)

12 Cylinder head 26 Washer 28 Indicator line

25 Hex bolt 27 Hex bolt 29 Union nut
Figure 8: Fitting/removing the body on the cylinder head*
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Cylinder head bolts
12 (17) General, M010.060.020-01-0016

1 Bolt position/tightening 5 Bolt position/tightening 10 Nut

sequence sequence
3 Bolt position/tightening 7 Bolt position/tightening 12 Cylinder head
sequence sequence
Figure 9: Cylinder head bolts with attached hydraulic tensioners* – The illustration shows the arrangement
2021-02-22 - de
for bolt positions 1-3-5-7

Cylinder head bolts
General, M010.060.020-01-0016 13 (17)

12 Cylinder head 30 Plug bolts

Figure 10: Fitted guard bracket*
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Cylinder head bolts
14 (17) General, M010.060.020-01-0016


sequence sequence
4 Bolt position/tightening 8 Bolt position/tightening
sequence sequence
Figure 11: Cylinder head bolts with installed hydraulic tensioners* – The illustration shows the arrangement
for bolt position 2-4-6-8
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Cylinder head bolts
General, M010.060.020-01-0016 15 (17)


2021-02-22 - de
Cylinder head bolts
16 (17) General, M010.060.020-01-0016

1–8 Bolt position/tightening 11 Cylinder head bolt 12 Cylinder head

sequence
10 Nut
Figure 13: Cylinder head with attached hydraulic tensioner – The illustration on the left shows the arrange-
ment for bolt positions 2-3-6-7 / the illustration on the right shows the arrangement for bolt positions
1-4-5-8
*The illustration in the figures shows an in-line engine

9007221625397003
2021-02-22 - de
Cylinder head bolts
General, M010.060.020-01-0016 17 (17)

9007221625397003
2021-02-22 - de
Cylinder head bolts
General, M010.060.020-01-0016
Cylinder head bolts

Summary
During maintenance, cylinder head screws must be released and tensioned
using hydraulic tensioners.
Safety requirements
l Engine stopped
l Operating media system blocked / depressurised
l Operating media system drained
Tools/aids required
1 Pin 055.569-3 Standard
1 Guard bracket 055.569-5 Standard
2 Tension screw 055.244 Standard
1 Socket wrench insert 012.043 Standard
2021-02-22 - de

Cylinder head bolts


General, M010.060.020-02-0016 1 (18)


Values for screw tightening

Item Pretension Tightening torque and torsion angle Note
force Tightening 1st stage 2nd stage 3rd + 4th Lubricant/screw
torque stage locking
kN Nm Nm Nm Nm
25 85
27 110
Warning messages

pressure hoses.
Material damage may result from the use of damaged protect-

ive devices or safety systems
If a cylinder head screw breaks, the protective device or safety system
may become deformed or damaged. Use of damaged protective
devices or damaged safety systems may result in material damage if a
second cylinder head screw breaks.
• If a cylinder head screw breaks, the protective device or safety system
must be replaced in its entirety.
2021-02-22 - de
Work Sequence 1- Releasing the cylinder head bolts

Cylinder head bolts
Initial situation Rocker arm casing with rocker arms detached; push rods removed. Piping
support removed.
Work steps 1. Remove insulation (21, in-line engine) or insulation cover (V engine) for in-
dicator valve (19). See Fig. 1.
2 (18) General, M010.060.020-02-0016

2. Remove any installed outlet and inlet pipes (15 and 16) for fuel injection
nozzles cooling.
3. Remove protection caps (17 and 22) for cylinder head bolts (11). See
Fig. 3.
4. Unscrew the nuts (18). See Figs. 4 and 5.
5. Remove retainer plates (20).
6. Clean the threads of cylinder head screws (11).
7. Mark the position of the indicator cable (28) with suitable means. See
Fig. 8.
8. Unscrew the union nut (29) and remove the indicator cable (28).
9. Remove the cotter pin (24) and bolt (055.569-3). See Fig. 7.
10.Move mount (055.569-2) in mount (055.569-1) until the bore spacing of
11.Fit the bolt and cotter pin (24).
12.Position the body on cylinder head (12). See Fig. 8.
13.Screw in the hex bolts (25) including washers (26) and tighten to the spe-
cified torque. See table “Values for bolt tightening”.
14.Screw in hex bolts (27) and tighten it to the prescribed torque. See table
15.Screw in the tension bolts (055.244) until they abut the cylinder head
16.Fit the thrust pieces (055.243) over the tension screws and nuts (10).
17.Screw the hydraulic tensioners (009.632) onto the tension screws. In do-
tensioners.
18.Place thrust pieces (055.242) over cylinder head bolts (11) and nuts (10)
at bolt positions 3 and 7.
20.Turn hydraulic tensioners (009.631 and 009.632) back by the turn-back
angle. See Work Instruction 010.000.003-05.
21.Fit guard bracket (055.569-5) onto the body. Secure guard bracket with
plug bolts (30). See Fig. 10.
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struction 015.000.002-01.
Cylinder head bolts

sioners.
General, M010.060.020-02-0016 3 (18)

015.000.001-01.
25.Using a tommy bar (000.262), turn the nuts (10) back by the turning-back
angle through the cut-out in the thrust pieces. See Work Instruction
010.000.0003-05.
28.Remove plug bolt (30). Remove the guard bracket from the mount.
31.Fit the thrust pieces (055.243) over the tension screws and nuts (10).
32.Screw the hydraulic tensioners (009.632) onto the tension screws. In do-
tensioners.
33.Place thrust pieces (055.242) over cylinder head bolts (11) and nuts (10)
at bolt positions 2 and 6.
35.Turn hydraulic tensioners (009.631 and 009.632) back by the turn-back
angle. See Work Instruction 010.000.003-05.
36.Fit guard bracket onto the body. Secure guard bracket with plug bolts
(30). See Fig. 12.
sioners.
2021-02-22 - de

Cylinder head bolts
015.000.001-01.
40.Using a tommy bar, turn the nuts (10) back by the turning-back angle
through the cut-out in the thrust pieces. See Work Instruction
010.000.003-05.
43.Remove plug bolt (30). Remove the guard bracket from the mount.
4 (18) General, M010.060.020-02-0016


45.Unscrew hex bolts (25 and 27) and remove washer (26). See Fig. 8.
46.Remove the body from cylinder head (12).
Work Sequence 2 - Tightening the cylinder head bolts

Initial situation Nuts screwed on and tightened by hand. Cylinder head bolt threads have
been cleaned.
Work steps 1. Remove the cotter pin (24) and bolt (055.569-3). See Fig. 7.
2. Move mount (055.569-2) into mount (055.569-1) until the bore spacing of
3. Fit the bolt and cotter pin (24).
4. Position the mount on the cylinder head (12). See Fig. 8.
5. Screw in the hex bolt (25) with washer (26) and tighten to the specified
torque. See table “Values for bolt tightening”.
6. Screw in the hex bolts (27) and tighten to the specified torque. See table
7. Screw in the tension bolts (055.244) until they abut the cylinder head
9. Screw the hydraulic tensioners (009.632) onto the tension bolts. In doing
tensioners.
12.Place the protective bracket (055.569-5) on the mount. Secure the pro-
tective bracket with the locking pin (30). See Fig. 10.
2021-02-22 - de
struction 015.000.002-01.
Cylinder head bolts
sioners.
14.Operate the high-pressure pump and tighten the cylinder head bolts (11)
with the specified tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.003-01.
General, M010.060.020-02-0016 5 (18)


tensioners.
25.Fit guard bracket onto the body. Secure the protective bracket with the
locking pin (30). See Fig. 12.
sioners.
27.Operate the high-pressure pump and tighten the cylinder head bolts (11)
with the specified tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.003-01.
33.Unscrew the hex bolts (25 and 27) and remove the washer (26). See
Fig. 8.
34.Remove the frame from the cylinder head (12).
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35.Position the indicator cable (28) in accordance with the applied marking
Cylinder head bolts
and tighten the union nut (29).

NOTICE Bent or damaged catch plates must be replaced.
36.Place the retainer plates (20) over the cylinder head bolts (11) on the
nuts (10). See Fig. 5.
37.Coat the thread and contact surface of the nuts (18) with lubricant.
38.Screw the nuts (18) onto the cylinder head bolts (11). Ensure that the col-
lar of the nuts points towards the retainer plates (20) and that the retainer
plates are centred by the nuts. See Fig. 2.
6 (18) General, M010.060.020-02-0016

39.Tighten the nuts (18) to the specified torque. See Work Instruction
010.000.003-05. See Fig. 4.
40.Place protective caps (17 and 22) on the cylinder head bolts (11). See
Fig. 3.
41.Install any removed outlet and inlet pipes (15 and 16) for the fuel injection
nozzle cooling. See Fig. 1.
42.Install insulation (21, inline engine) or insulation cover (V engine) for indic-
ator valve (19).
10 Nut 18 Nut
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11 Cylinder head bolt 19 Indicator valve

Cylinder head bolts
12 Cylinder head 20 Retainer plate

15 Drain line 21 Insulation
16 Feed pipe 22 Protective cap
17 Protective cap
Figure 1: Cylinder head*
General, M010.060.020-02-0016 7 (18)

18 Nut 20 Retainer plate

Figure 2: Cylinder head* – Centring the retainer plate with the nuts
2021-02-22 - de
Cylinder head bolts
8 (18) General, M010.060.020-02-0016

10 Nut 18 Nut
11 Cylinder head bolt 22 Protective cap
17 Protective cap
Figure 3: Cylinder head* – Detaching/attaching the protection caps
2021-02-22 - de
Cylinder head bolts
General, M010.060.020-02-0016 9 (18)

11 Cylinder head bolt 20 Retainer plate 23 Ratchet tool

18 Nut
Figure 4: Cylinder head* – Loosening/tightening the nuts
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Cylinder head bolts
10 (18) General, M010.060.020-02-0016

10 Nut 18 Nut
11 Cylinder head bolt 20 Retainer plate
Figure 5: Cylinder head* – Detaching/attaching the retainer plates
2021-02-22 - de
Cylinder head bolts
General, M010.060.020-02-0016 11 (18)

1–8 Bolt position/tightening 11 Cylinder head bolt

sequence
10 Nut 12 Cylinder head
Figure 6: Cylinder head bolts* – Bolt position
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Cylinder head bolts
24 Cotter pin
Figure 7: Guard body
12 (18) General, M010.060.020-02-0016

12 Cylinder head 26 Washer 28 Indicator line

25 Hex bolt 27 Hex bolt 29 Union nut
Figure 8: Fitting/removing the body on the cylinder head*
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Cylinder head bolts
General, M010.060.020-02-0016 13 (18)

1 Bolt position/tightening 5 Bolt position/tightening 10 Nut

sequence sequence
sequence sequence
Figure 9: Cylinder head bolts with attached hydraulic tensioners* – The illustration shows the arrangement
2021-02-22 - de
for bolt positions 1-3-5-7

Cylinder head bolts
14 (18) General, M010.060.020-02-0016


2021-02-22 - de
Cylinder head bolts
General, M010.060.020-02-0016 15 (18)


sequence sequence
4 Bolt position/tightening 8 Bolt position/tightening
sequence sequence
Figure 11: Cylinder head bolts with installed hydraulic tensioners* – The illustration shows the arrangement
for bolt position 2-4-6-8 2021-02-22 - de
Cylinder head bolts
16 (18) General, M010.060.020-02-0016


2021-02-22 - de
Cylinder head bolts
General, M010.060.020-02-0016 17 (18)

1–8 Bolt position/tightening 11 Cylinder head bolt 12 Cylinder head

sequence
10 Nut
Figure 13: Cylinder head with attached hydraulic tensioner – The illustration on the left shows the arrange-
ment for bolt positions 2-3-6-7 / the illustration on the right shows the arrangement for bolt positions
1-4-5-8
*The illustration in the figures shows an in-line engine

18014420880141195
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Cylinder head bolts
18 (18) General, M010.060.020-02-0016

Cylinder head
Summary
Check components for condition/wear condition, prevent operating problems/
damage.
Cylinder heads are to be dismantled within the scope of maintenance and re-
pair work.
fitting components.
Safety requirements
l Engine stopped
l Operating media systems drained
Tools/aids required
1 Offset screwdriver 050.120 Standard
1 Rope - Inventory
2016-10-25 - de

Cylinder head
Cleaning the cooling water system 010.000.002-04

Preparing cylinder head with turning device 010.060.020-10
Removing and installing inlet valve/exhaust valve 010.060.030-02
Removal and installation of fuel injection pipe 010.110.052-01
Check the exhaust pipe 010.180.010-01
48/60CR, M010.060.020-03-0011 1 (12)

Technical data
Cylinder head with valves Weight 1200 kg
Work sequence 1 - Removing the cylinder head

Initial situation
Reuse coolant
Coolant must not be pumped into the bilges or into the sewage sys-
tem! Coolant must be pumped into its own individual tank and be re-
used (coolant treatment agent)!
Cooling water drained completely, cooling water for injection valve cooling
system (if any) drained.
Running gear turned so that the piston of the concerned cylinder is at ignition
TDC (all valves closed). Rocker arm casing detached; push rods removed.

Work steps
Prevent mixing up of the pipes and pipe unions

To prevent mixing up of the pipes and pipe unions during their installa-
tion, pipes/pipe unions and their joints must be marked before loosen-
ing/removing. This is applicable particularly to the rocker arm lube oil
pipe and the control air pipe to starting valve
2016-10-25 - de
1. Mark all pipes/pipe unions to be removed and their joints.

Cylinder head
2. Unscrew hex bolt (32) and remove two-part holder (33). See Fig. 2.
3. Release and detach all pipes and pipe unions from relevant cylinder head
(5).
4. Detach the exhaust pipe covering partially.
5. Open the pipe clamp (on in-line engine) or quick coupling (on V-engine)
on the exhaust pipe connection. See Work Instructions 010.180.010-01.
6. Dismantle the fuel injection pipe. See Work Instructions 010.110.052-01.
2 (12) 48/60CR, M010.060.020-03-0011

7. Release cylinder head bolts (1). See Work Instructions 010.060.020-02.

8. Unscrew and remove nuts (2).
9. Place the support (055.207-1) onto cylinder head (5) and fasten it with
hexagon socket bolts (22 and 23). See Fig. 3.
Suspension point on the tool

When an incorrect suspension point on the tool is used during the re-
moval or installation, or during lifting, the component may swing out
due to the changed centre of gravity and thus cause personnel injuries
and/or material damage.
structions
10.Fasten rope (24) with shackle (002.455) on the carrier, and suspend it
11.Screw the pilot rod (034.006) into the carrier.
12.Lift cylinder head (5) carefully, guiding with a pilot rod. Make sure that en-
gine components (cylinder head bolts, cylinder head sealing face, etc.)
are not damaged.
13.Detach the cylinder head (5) and place it on a clean support surface or
clamp it in the turning device. See Work Instructions 010.060.020-10.
14.Detach the tool.
15.Remove sealing ring (8) with offset screwdriver (050.120). See Fig. 6.
16.Remove O-rings (18 and 21) from sleeves (19 and 20).
17.Cover all openings on the engine by suitable means, as well as the open-
ing of push rod casings (11).
18.Block the exhaust pipe connection to the exhaust pipe with a closing
cover.
19.Remove O-rings (4, 6, and 7).
20.Clean cylinder head (5) (see Work Sequence 2).
Work sequence 2 - Cleaning the cylinder head

2016-10-25 - de
Initial situation Cylinder head is detached.

Work steps 1. Remove the inlet and exhaust valves. See Work Instructions
010.060.030-02.
2. Check the inlet and exhaust channels as well as the side opposite the
Cylinder head
combustion chamber in terms of deposits and clean them of adhering

deposits, without damaging the surface.
3. Check the cooling chambers for deposits; if needed, remove the deposit
layer. See Work Instructions 010.000.002-04.
4. Clean the cylinder head top free of oil sludge.
48/60CR, M010.060.020-03-0011 3 (12)

5. Installing the inlet and exhaust valves. See Work Instructions

010.060.030-02.
Work sequence 3 - Installing the cylinder head

Initial situation Cylinder head cleaned.

Work steps 1. Place the support (055.207-1) onto cylinder head (5) and fasten it with
hexagon socket bolts (22 and 23). See Fig. 3.
Suspension point on the tool

When an incorrect suspension point on the tool is used during the re-
moval or installation, or during lifting, the component may swing out
due to the changed centre of gravity and thus cause personnel injuries
and/or material damage.
structions
2. Fasten rope (24) with shackle (002.455) on the carrier, and suspend it
3. Screw the pilot rod (034.006) into the carrier.
4. Lift up cylinder head (5).
5. Insert new O-rings (4, 6 and 7) lubricated with clean lube oil in the ring
grooves, ensuring that they are tensioned equally on the entire periphery
2016-10-25 - de
and are not twisted. See Fig. 1 and 5.

6. Remove all coverings/closing covers for openings on the engine (see
Work Sequence 1 / Items 17 and 18).
7. Clean sealing faces on backing ring (10), top land ring (9) and on exhaust
Cylinder head
pipe section.
8. Insert a new sealing ring (8) in the groove.
9. Insert new O-rings (18 and 21) oiled with clean lube oil in the ring
grooves; in doing so, make sure that they are evenly tensioned all around
the circumference and that they are not twisted. See Fig. 1.
10.Loosen hexagon socket bolts (12) at push rod casings (11) and hexagon
head bolts (36) to allow them to align with cylinder head (5).
4 (12) 48/60CR, M010.060.020-03-0011

11.Move cylinder head (5) over the middle of the cylinders. See Fig. 5.
Observe points for installation

Remember the following points when fitting the cylinder head:
• Pay attention to alignment of parallel pin (16) and sleeves (19 and 20).
• Pay attention to alignment of flanges (3)/push-rod coverings (11).
• Pay attention to alignment of pipe section (17)/quick-fitting coupling (on
in-line engine) or axial compensator (25)/pipe clamp (an V-engine).
12.Carefully lower/attach cylinder head (5), guiding it with the pilot rod in the
process. Make sure that engine components (cylinder head bolts, cylin-
der head sealing face, etc.) are not damaged.
13.Detach the tool.
14.Screw nuts (2) onto cylinder head bolts (1) and tighten them hand-tight.
See Fig. 1.
15.Tighten cylinder head bolts (1). See Work Instructions 010.060.020-02.
16.Tighten hexagon socket bolts (12) on push rod casings (11). See Fig. 1.
17.Tighten hexagon head bolts (36).
18.Attach the fuel injection pipe. See Work Instructions 010.110.052-01.
19.Connect the exhaust pipe to cylinder head (5). See Work Instructions
010.180.010-01.
20.Attach the covering of the exhaust pipe.
21.Fit all pipes and pipe unions to their respective cylinder head, observing
applied marks. See Work Sequence 1 / Item 1.
22.Attach two-part holder (33) to rocker arm lube oil line (31) and control air
line (34), and fix with hexagon head bolt (32) to cylinder head (5). See Fig.
2.
23.After installation/attachment of all engine parts (push rods, rocker arm
casing etc.) fill coolant into the engine, and vent the cooling water line.
Personal injuries due to coolant or gas escaping on the inspec-

tion holes
In case of damaged O-ring seals / damaged sealing ring, coolant or
gas under pressure may escape on the backing ring on the inspection
2016-10-25 - de
hole, which may result in personal injuries.

• Carry out an inspection from a point aside of the inspection holes
• do not look at the inspection holes directly
Cylinder head
• Wear protective clothing (protective helmet, facial protection, safety

shoes, protective gloves)
24.After completing the assembly work, check whether the O-rings are OK,
and that there is no water escaping from inspection holes (A and B) when
coolant pressure is applied. See Fig. 1.
48/60CR, M010.060.020-03-0011 5 (12)

Leaking cylinder head

If the cylinder head is still leaking although the cylinder head bolts
have been correctly tightened, it will need to be taken off again and the
sealing ring will need to be checked.
18169371275
2016-10-25 - de
Cylinder head
6 (12) 48/60CR, M010.060.020-03-0011

2016-10-25 - de
1 Cylinder head bolt 9 Top land ring 17 Pipe section

2 Nut 10 Backing ring 18 O-ring
3 Flange 11 Push rods - casing 19 Sleeve
Cylinder head
4 O-ring 12 Hexagon socket bolt 20 Sleeve

5 Cylinder head 13 Cylinder crankcase 21 O-ring
6 O-ring 14 Piston A Inspection hole
7 O-ring 15 Cylinder liner B Inspection hole
8 Sealing ring 16 Parallel pin ST Control side
Figure 1: Cylinder head – the figure shows an in-line engine
48/60CR, M010.060.020-03-0011 7 (12)

5 Cylinder head 33 Holder, two-part

11 Push rods - casing 34 Control air pipe (starting
valve)
30 Screw connection 35 Screw connection
31 Rocker arm lube oil pipe 36 Hex bolt
32 Hex bolt
Figure 2: Rocker arm lube oil pipe and control air pipe – the figure shows an
in-line engine
2016-10-25 - de
Cylinder head
8 (12) 48/60CR, M010.060.020-03-0011

5 Cylinder head 23 Hexagon socket bolt

M24x150
22 Hexagon socket bolt ST Control side
M30x160
Figure 3: Fitting the suspension device - the figure shows an in-line engine
2016-10-25 - de
Cylinder head
48/60CR, M010.060.020-03-0011 9 (12)

5 Cylinder head 25 Axial compensator ST Control side

17 Pipe section A Illustration for in-line
engine
24 Rope B Illustration for V engine
Figure 4: Detach/ attach cylinder head - Suspension point for an in-line engine or V-engine
2016-10-25 - de
Cylinder head
10 (12) 48/60CR, M010.060.020-03-0011

1 Cylinder head bolt 9 Top land ring

4 O-ring 10 Backing ring
5 Cylinder head 15 Cylinder liner
6 O-ring 24 Rope
7 O-ring ST Control side
8 Sealing ring
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Figure 5: Removal/installation of cylinder head – the illustration shows an in-

line engine
Cylinder head
48/60CR, M010.060.020-03-0011 11 (12)

2016-10-25 - de
Cylinder head
8 Sealing ring ST Control side

9 Top land ring I-II Work steps
Figure 6: Removal of sealing ring – the figure shows an in-line engine
18169371275
12 (12) 48/60CR, M010.060.020-03-0011

Cylinder head seat surfaces

grinding
Summary
Ensure correct execution of work, evaluate contact pattern /wear state, re-
store contact pattern.
If the contact pattern of a seat surface is incorrect, regenerate it by grinding
(closed, bearing surface).
The work includes:
Creating a correct contact pattern.
Safety requirements
l Engine stopped
Tools/aids required
1 Milling and grinding tool 055.202 Standard
1 Tool bar 055.202-1 Standard
1 Guide tube 055.202-2 Standard
1 Bearing retainer 055.202-3 Standard
1 Guide bush 055.202-5 Standard
1 Extension 055.202-6 Standard
1 Grinding wheel 055.202-9 Standard
1 Grinding wheel 055.202-10 Standard
1 Wooden box 055.202-11 Standard
1 Tap wrench 055.202-15 Standard
1 Guide bush 055.202-18 Standard

1 Small grinding plates (Set) 055.202-34 Standard
2016-09-30 - de
1 Pliers for locking rings 055.202-36 Standard

1 Cleaning tool 055.133 Standard
1 Torch - Inventory
1 Quick-acting cleanser Loctite 7061 - Option
1 Touching-test ink - Inventory
General, M010.060.020-05-0002 1 (9)


Removal and installation of fuel injection valve 010.060.060-01
Removal and installation of the starting valve 010.060.070-01
Preliminary remark
Seat surface in the cylinder head

Every time the inlet and fuel injection valve is removed, its seat surface
in the cylinder head must be checked with a touch test. This test must
show a continuous surface capable of bearing a load. If this is not the
case, the seat surface must be re-ground.
Work sequence - Grinding the seat surface
Labelling on tool components

To simplify assignment of guide washers, guide bushing and grinding
discs to the individual valves, these are labelled as follows:
• AS ….. Starting valve
• E ….. Fuel injection valve
Initial condition The corresponding valve (inlet or fuel injection valve) or both valves has/have
been removed. See Work Instructions 010.060.060-01 and 010.060.070-01.
Work Steps
Used grinding pads

Remove used grinding pads from the grinding disc. Remove any re-
maining adhesive with quick cleaner Loctite 7061. Stick new small
grinding discs to the grinding wheel.

Number of grinding pads:
2016-09-30 - de
• Grinding disc for starting valve..... 10 pcs. (see Fig. 3.)

• Grinding disc for fuel injection valve...... 9 pcs. (see Fig. 7.)
1. Check the grinding pad (055.202-34) on the grinding disc (055.202-9

and 055.202-10).
2. Insert the feather key (6) in the groove and attach any necessary grinding
disc into the tool holder (055.202-1). See Figure 2 or 6.
3. Attach the disc (5), screw and tighten the hex nut (4) onto the tool holder.
2 (9) General, M010.060.020-05-0002

4. Attach any necessary guide bushing (055.202-5 or 055.202-18) until the

stop on the locking ring (8) on the guide tube (055.202-2) and secure
with the second locking ring (7). See Figure 2 or 6.
5. Place the tool holder with attached grinding disc into the valve hole or in-
sert (2) and fit on the seat surface (A).
6. Place the guide tube with attached guide bushing above the tool holder
and insert until the stop in the valve hole or insert (2).
7. Place the guide washer (055.202-3) above the guide tube, ensuring
proper fit (diameter of guide/attached label on the guide washer). Place
the guide washer on the cylinder head (1) or insert (3). See Figure 2 or 6.
8. Insert the extension (055.202-6) and tap wrench (055.202-15) on the tool
holder.
Grinding down the seat surface

Remove only enough material that the seat surface is shiny and un-
damaged over the entire width; check valve seating surface regularly
during the grinding process.
9. Move the grinding disc back and forth by moving the tap wrench in a cir-
cular motion.
10.After grinding is complete, remove the tool.
11.Carefully clean the seat surface (A) with the cleaning device (055.133).
See Figure 4 or 8.
12.Dismantle the tool, clean it and store it in the wooden box (055.202-11).
13.After grinding a seat surface (A) several times, remove the cylinder head
(1) (see work instruction 010.060.020-03) and take and note down the
measurement (B). See Figure 5 and 9.
Changing the cylinder head or insert

If the seat surface has been ground down far enough that the meas-
urement is lower than the lowest permitted measurement, the cylinder
head or insert must be changed.
Minimum permitted dimension:
• Starting valve..... 77.6 mm

• Fuel injection valve...... 51.5 mm
2016-09-30 - de
General, M010.060.020-05-0002 3 (9)

1 Cylinder head 3 Insert

2 Insert A Seating surface
Figure 1: Cylinder head - valve hole for starting valve (left illustration) and insert
for fuel injection valve (right illustration)
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4 (9) General, M010.060.020-05-0002

1 Cylinder head 6 Feather key

4 Hex nut M10 7 Locking ring
5 Washer 8 Locking ring
Figure 2: Valve hole for starting valve - grinding the seat surface

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Figure 3: Grinding disc for starting valve seat surface - number and arrange-
ment of grinding pads
General, M010.060.020-05-0002 5 (9)

1 Cylinder head
Figure 4: Valve hole for starting valve - cleaning the seat surface
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1 Cylinder head
B Dimension
C Lower edge of cylinder head
Figure 5: Valve hole for starting valve - measurement to be taken (lower edge
of cylinder head/seat surface) after grinding the seat surface several times
6 (9) General, M010.060.020-05-0002

1 Cylinder head 5 Washer

2 Insert 6 Feather key
3 Insert 7 Locking ring
4 Hex nut M10 8 Locking ring
Figure 6: Valve hole for fuel injection valve - grinding the seat surface
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Figure 7: Grinding disc for fuel injection valve seat surface - number and ar-
rangement of grinding pads
General, M010.060.020-05-0002 7 (9)

1 Cylinder head
2 Insert
3 Insert
Figure 8: Valve hole for fuel injection valve - cleaning the seat surface
2016-09-30 - de
1 Cylinder head
2 Insert
B Dimension
C Lower edge of cylinder head
Figure 9: Valve hole for fuel injection valve - measurement to be taken (lower
edge of cylinder head/seat surface) after grinding the seat surface several
times
8 (9) General, M010.060.020-05-0002

9007206211619723

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General, M010.060.020-05-0002 9 (9)

9007206211619723
2016-09-30 - de
General, M010.060.020-05-0002
Sealing face on the cylinder head

grinding
Summary
Check components for quality/wear condition, prevent operating problems/
damages.
The sealing face on cylinder head is to be checked every time the cylinder
head is removed and reworked if necessary.
The work extends to:
Grinding the sealing face.
Tools/aids required
1 Grinding-in fixture 050.163 Option
1 Grinding wheel 050.163-2 Option
Work sequence - Grinding the sealing face on the cylinder head

Initial situation Cylinder head removed and clamped in the turning device.
Work steps 1. Clean the sealing surface (B) on cylinder head (1). See Fig. 2.
Grinding disc can be used for both top land ring and cylinder
head
The grinding disc can be used for the top land ring and the cylinder
head. The correct side of the grinding disc can be seen in Fig. 3. Sealing face on the cylinder head
2. Fasten holder (050.163-1) to grinding disc (050.163-2). See Fig. 3.

3. Apply grinding paste to the grinding disc; do not apply too much grinding
paste.
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4. Place grinding tool (050.163) on the cylinder head (1).
Grinding the sealing surface

The minimum possible amount of grinding should be done, as a flat
surface is difficult to achieve by grinding. If necessary, the cylinder
head must be machined on a lathe.
5. Move the grinding tool up and down, lifting it occasionally so that the
grinding paste can be distributed.
V48/60TS, M010.060.020-08-0003 1 (5)

6. Remove the grinding tool after the grinding is over.

7. Carefully remove all grinding paste residue from sealing surface (B) and
cylinder head (1).
8. Dismantle grinding tool and clean it.
9. Measure cylinder head (1), sealing ring (2) and top land ring (3) and de-
termine gap dimension (A). See Fig. 1.
Gap dimension between top land ring and cylinder head

The reground sealing surfaces (B) must have a gap dimension (A)
between top land ring and cylinder head of at least 0.5 mm.
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2 (5) V48/60TS, M010.060.020-08-0003


1 Cylinder head 3 Top land ring
2 Sealing ring A Gap dimension
Figure 1: Cylinder head and top land ring
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V48/60TS, M010.060.020-08-0003 3 (5)

1 Cylinder head B Sealing surface

Figure 2: Sealing surface on the cylinder head
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4 (5) V48/60TS, M010.060.020-08-0003

1 Cylinder head 7 Wing screw M10x50

Figure 3: Cylinder head - Grinding in the sealing surface
18014405468377611
2018-06-07 - de
V48/60TS, M010.060.020-08-0003 5 (5)

18014405468377611
2018-06-07 - de
V48/60TS, M010.060.020-08-0003
Valve seat rings

removal and installation
Summary
Execute work on time according to the maintenance schedule, impart the ne-
cessary knowledge, ensure correct execution of work.
Replace inlet and exhaust valve seat rings at regular intervals, or when their
wear limit is reached.
Tools/aids required
1 Extractor device 114.058 Standard
1 Claw, 3-piece 114.058-2 Standard
1 Guide piece with spindle 114.058-4 Standard
1 Sleeve 114.058-5 Standard
1 Support 114.058-6 Standard
1 Mounting device 113.287 Standard
1 Guide piece 113.205-2 Standard
1 Handle 113.205-3 Standard
1 Clamping piece 113.205-4 Standard
1 Hollow piston cylinder 009.022 Standard
1 Single ended open-jaw spanner 46 000.568 Option
1 Inside micrometer - Inventory
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1 Neoprene gloves - Inventory

1 High temperature HSC plus lubricant - Inventory
Valve seat rings
1 Abrasive paper 120–180 - Inventory

Check of the valve seat ring 010.060.030-04
48/60CR;48/60B, M010.060.020-09-0006 1 (16)

Rework of the valve seat ring 010.060.030-05

Technical data
Inlet valve Max. permiss- 178,026 mm
ible dimension
(B)
Exhaust valve Max. permiss- 181,530 mm
ible dimension
(B)
Safety Instructions
High operating pressures during work with high-pressure

High operating pressures are used during work with the high pressure
pump, hydraulic tensioners and high pressure hoses. Lack of informa-
tion and non-observance of information may cause serious injury to
persons and serious damage to property.
• Observe the working and safety instructions when using high-pressure
Preliminary remark
Inlet or outlet valve seat rings must be removed and replaced
▪ if there are corrosion and impact spots, which cannot be removed by
turning,
▪ if there are breakaway or burn-through or tension cracks, and
▪ if the rework limit has been reached. See Work Instructions
010.060.030-05.
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Using turning device

To make the work easier, the cylinder head can be installed in the turn-
Valve seat rings
ing device. See Work Instructions 010.060.020-10.
Work Sequence 1 - Preparation of the extractor

Work Steps 1. Slide claws (114.058-2) into the guide slot on guide piece (114.058-4)
and secure with O-ring seal (9). See Fig. 2/I.
2 (16) 48/60CR;48/60B, M010.060.020-09-0006

2. Screw on threaded piece (114.058-1) onto spindle (8) until it makes con-
tact with the claws, and then turn back by two rotations. See Fig. 2/II.
3. Screw sleeve (114.058-5) two threads onto spindle (8).
Work Sequence 2 - Removal of an intake or exhaust valve seat ring

Initial situation Cylinder head removed, loaded into cylinder head turning device (if available)
and carefully cleaned of oil and fuel. Corresponding valve is removed. Com-
bustion chamber side faces upwards.
tracted
Work steps
Removal of an inlet valve seat ring

The following Work Steps describe the removal of an exhaust valve
seat ring. The removal of an inlet valve seat ring is in principle the
same as the removal of an outlet valve seat ring; the only point that is
not performed is "Remove O-ring seal". See Points 1 to 17/see Figure
3.
1. Insert the partly mounted extractor (see Work Sequence 1) into exhaust
valve seat ring (1). See Fig. 4/I.
2. Hold spindle (8) so that the lugs on the claws (114.058-2) are in front of
the gap (A) between exhaust valve seat ring (1) and cylinder head (5).
Engaging of the claws

Make sure that the claws engage in the gap between the valve seat
ring and cylinder head.
3. Screw the threaded piece (114.058-1) with size 46 single-ended open-

2017-09-18 - de
jaw spanner (000.568) onto the spindle. In doing so, push the claws
(114.058-2) out into the gap (A).
4. Screw threaded piece on so far that claws are in a tight contact with ex-
Valve seat rings
haust valve seat ring (1). See Fig. 4/II.

5. Screw sleeve (114.058-5) on up to the contact with the claws.
6. Place support (114.058-6) and hollow piston cylinder (009.022) over the
spindle (8). Screw the hex nut (10) onto the spindle until hand-tight. See
Fig. 4/III.
7. Connect the high-pressure hose (009.306) to the hollow piston cylinder
and the high-pressure pump (009.342). See Work Instructions
015.000.002-01.
48/60CR;48/60B, M010.060.020-09-0006 3 (16)


in high forces being released in the axial direction in case of failure,
thereby causing severe injuries to personnel.
8. Put the high-pressure pump into operation. Pump up the hollow piston
cylinder slowly. See Work Instructions 015.000.003-01.

ceeded.
9. Carefully pull out the exhaust valve seat ring (1) from the cylinder head (5).
Resetting the hollow piston cylinder

The hollow piston cylinder automatically moves back into the zero pos-
ition thanks to the integrated spring return.
10.Release the pressure. See Work Instructions 015.000.003-01.

11.Disconnect high pressure hose from the high pressure pump and hollow
piston cylinder.
12.Unscrew the hex nut (10) from the spindle. Remove the hollow piston cyl-
inder and support.
13.Place exhaust valve seat ring (1) onto a clean base with tool.
14.Unscrew sleeve using tommy bar. In doing so, hold the threaded piece in
place using a single ended open-jaw wrench.
15.Unscrew the threaded piece.
16.Remove the spindle including claws.
Risk to health when removing O-ring seals

Skin irritation may occur when removing the O-ring seals.
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• Avoid direct contact with the skin

• Neoprene gloves must be worn
Valve seat rings
17.Remove O-rings (2 and 3).

Check and measure the 18.Check the locating hole in the cylinder head (5) for damage. Check the
locating hole dimensions (B) at multiple locations. See Fig. 5 and 6 / see section
“Technical data”.
4 (16) 48/60CR;48/60B, M010.060.020-09-0006

Work Sequence 3 - Fitting an intake valve seat ring

Initial situation Cylinder head clamped in the cylinder head turning device (if available), com-
bustion chamber side facing upwards. Locating hole in the cylinder head
cleaned and measured.
tracted
Work steps 1. Slightly break the edges of the locating hole in the cylinder head (5) with
abrasive paper.
2. Carefully clean the locating hole in cylinder head (5) of the abrasion
residues.
3. Push guide piece (113.205-2) into valve guide (6). Position clamping
piece (113.205-4) and screw on hex nut (11) by hand (without open-
ended or ring spanner) up to contact.
4. Screw the handle (113.205-3) into the thrust piece (113.287-1) up to
contact.
5. Thinly coat the contact areas (F) on the new inlet valve seat ring (7) with
high-temperature lubricant “Molykote HSC Plus”. See Fig. 7.
6. Place the thrust piece onto inlet valve seat ring (7), insert them together
over the guide piece, and centre in the locating hole by hand. See Fig. 8/
I.
7. Fix the inlet valve seat ring (7) in the locating hole with a light tap with the
thrust piece.
8. Unscrew the handle from the thrust piece.
9. Place the hollow piston cylinder (009.022) over the guide piece, and
tighten the hex nut (10) hand-tight. See Fig. 8/II.
10.Connect high-pressure hose (009.306) to the hollow piston cylinder and
high-pressure pump (009.342), and secure. See Work Instructions
015.000.002-01.

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Valve seat rings
11.Activate the high-pressure pump and slowly pump up the hollow piston
cylinder. See Work Instructions 015.000.003-01.
48/60CR;48/60B, M010.060.020-09-0006 5 (16)

Installing the valve seat ring

ceeded.
Press in the valve seat ring in a uniform manner. A large increase in
pressure when pressing in indicates that the valve seat ring is tilted.
Stop installation process. Only continue installing the valve seat ring
once the tilting has been rectified.
A substantial pressure increase indicates that the valve seat ring is in
position.
12.Pump up the hollow piston cylinder until the inlet valve seat ring (7) is in
position. See Fig. 8/III.


14.Disconnect the high-pressure hose from the hollow piston cylinder and
high-pressure pump.
15.Detach or remove the tool.
16.Check gap (A) for uniform width at several places.
17.Machine inlet valve seat ring (7) using a valve seat lathe, and touch up
with new valve cone. See Work Instructions 010.060.030-04 and
010.060.030-05.
18.Install the inlet valve with a new or reground valve cone. See Work In-
structions 010.060.030-02.
Work Sequence 4 - Fitting an exhaust valve seat ring

Initial situation Cylinder head clamped in the cylinder head turning device (if available), com-
bustion chamber side facing upwards. Locating hole in cylinder head and
socket cleaned. Locating hole measured.
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tracted
Valve seat rings
Work steps 1. Slightly break the edges of the locating hole in the cylinder head (5) and
the socket (4) with abrasive paper.
2. Carefully clean the locating hole in the cylinder head (5) and the socket (4)
of any abrasion residues.
6 (16) 48/60CR;48/60B, M010.060.020-09-0006

3. Push guide piece (113.205-2) into valve guide (6). Position clamping
piece (113.205-4) and screw on hex nut (11) by hand (without open-
ended or ring spanner) up to contact.
4. Screw the handle (113.205-3) into the thrust piece (113.287-1) up to
contact.
5. Insert new O-ring (2), lubricated with clean lube oil, into the ring groove.
Make sure that it is not twisted.
6. Insert new O-ring (3), lubricated with clean lube oil, into the ring groove.
Make sure that it is evenly tensioned around the entire circumference and
is not twisted.
7. Thinly coat the contact areas (F) on the new exhaust valve seat ring (1)
with high-temperature lubricant “Molykote HSC Plus”. In doing so, ensure
that no high-temperature grease is applied to the O-ring (3) and ring
groove. See Fig. 7.
8. Place the thrust piece onto exhaust valve seat ring (1), insert them to-
gether over the guide piece, and centre in the locating hole by hand. See
Fig. 9/I.
9. Fix the exhaust valve seating ring (1) in the locating hole with a light tap
with the thrust piece.
10.Unscrew the handle from the thrust piece.
11.Place the hollow piston cylinder (009.022) over the guide piece, and
tighten the hex nut (10) hand-tight. See Fig. 9/II.
12.Connect high-pressure hose (009.306) to the hollow piston cylinder and
high-pressure pump (009.342), and secure. See Work Instructions
015.000.002-01.

13.Activate the high-pressure pump and slowly pump up the hollow piston
Installing the valve seat ring

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ceeded.
Press in the valve seat ring in a uniform manner. A large increase in
Valve seat rings
pressure when pressing in indicates that the valve seat ring is tilted.
Stop installation process. Only continue installing the valve seat ring
once the tilting has been rectified.
A substantial pressure increase indicates that the valve seat ring is in
position.
48/60CR;48/60B, M010.060.020-09-0006 7 (16)

14.Pump up the hollow piston cylinder until the exhaust valve seat ring (1) is
in position. See Fig. 9/III.

27021604721317259

16.Disconnect the high-pressure hose from the hollow piston cylinder and
high-pressure pump.
17.Detach or remove the tool.
18.Check gap (A) for uniform width at several places.
19.Machine exhaust valve seat ring (1) using a valve seat lathe, and touch up
with new valve cone. See Work Instructions 010.060.030-04 and
010.060.030-05
20.Install the exhaust valve with a new or reground valve cone. See Work In-
structions 010.060.030-02.
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Valve seat rings
8 (16) 48/60CR;48/60B, M010.060.020-09-0006

1 Exhaust valve seat ring 5 Cylinder head

2 O-ring 6 Valve guide
3 O-ring 7 Inlet valve seat ring
4 Socket A Gap between cylinder
head and valve seat ring
Figure 1: Intake and exhaust valve seat ring in the cylinder head
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Valve seat rings
48/60CR;48/60B, M010.060.020-09-0006 9 (16)

2017-09-18 - de
Valve seat rings
8 Spindle 10 Hex nut M30

9 O-ring I-III Work steps
Figure 2: Extractor
10 (16) 48/60CR;48/60B, M010.060.020-09-0006

2017-09-18 - de
5 Cylinder head 8 Spindle A Gap between cylinder

head and valve seat
Valve seat rings
ring
7 Inlet valve seat ring 10 Hex nut M30 I-IV Work steps
Figure 3: Removal of inlet valve seat ring
48/60CR;48/60B, M010.060.020-09-0006 11 (16)

2017-09-18 - de
1 Exhaust valve seat ring 8 Spindle I-IV Work steps

4 Socket 10 Hex nut M30
Valve seat rings
5 Cylinder head A Gap between cylinder

head and valve seat
ring
Figure 4: Removal of an exhaust valve seat ring
12 (16) 48/60CR;48/60B, M010.060.020-09-0006

5 Cylinder head
B Dimension (diameter of locating hole)
Figure 5: Inlet valve seat ring - locating hole in cylinder head
5 Cylinder head
B Dimension (diameter of locating hole)
Figure 6: Exhaust valve seat ring - locating hole in cylinder head
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Valve seat rings
1 Exhaust valve seat ring 7 Inlet valve seat ring

3 O-ring F Contact surface
Figure 7: Inlet and exhaust valve seat ring
48/60CR;48/60B, M010.060.020-09-0006 13 (16)

2017-09-18 - de
Valve seat rings
5 Cylinder head 10 Hex nut M30 C Contact face on cylin-

der head
6 Valve guide 11 Hex nut M30 I-III Work steps
7 Inlet valve seat ring A Gap between cylinder
head and valve seat
ring
Figure 8: Installation of inlet valve seat ring
14 (16) 48/60CR;48/60B, M010.060.020-09-0006

2017-09-18 - de
Valve seat rings
1 Exhaust valve seat ring 5 Cylinder head A Gap between cylinder

head and valve seat
ring
2 O-ring 6 Valve guide C Contact face on cylin-
der head
3 O-ring 10 Hex nut M30 I-III Work steps
4 Socket 11 Hex nut M30
Figure 9: Installation of exhaust valve seat ring
48/60CR;48/60B, M010.060.020-09-0006 15 (16)

27021604721317259
2017-09-18 - de
Valve seat rings
16 (16) 48/60CR;48/60B, M010.060.020-09-0006

Cylinder head with turnover device

working/machining
Summary
Impart the necessary knowledge, ensure adequate application.
Various tasks must be performed on the cylinder heads at regular intervals.
The turnover stand is used to do this.
The work includes:
Chucking components.
Tools/aids required
1 Turnover stand 055.153 Option

Cylinder head cleaning 010.060.020-04
Grind cylinder head seat surfaces 010.060.020-05
Removal and installation of valve seat rings 010.060.020-09
Checking the valve guide 010.060.030-08
Removal and installation of the valve guide 010.060.030-09
Attaching rocker arm assembly to turning device using 010.100.030-06
bracket
Attach high pressure pump to turnover stand using adaptor 010.110.050-03
plate
installation and removal of work holding fixture on the
turnover stand
010.110.054-02
Preliminary remark
The turnover device is suitable for:
2017-06-20 - de
▪ Cleaning the cylinder head. See Work Instructions 010.060.020-04

▪ Grinding cylinder head seating surfaces. See Work Instructions
010.060.020-05
▪ Removal and installation of valve seat rings. See Work Instructions
010.060.020-09
▪ Removing and installing inlet valve/exhaust valve. See Work Instructions
010.060.030-02
▪ Checking valve seat rings. See Work Instructions 010.060.030-04
▪ Checking the valve guide. See Work Instructions 010.060.030-08
▪ Removal and installation of the valve guide. See Work Instructions
010.060.030-09
48/60CR, M010.060.020-10-0006 1 (3)

Other applications of the turnover device

Other applications of the turnover device are described in the following
work instructions:
• 010.100.030-06 Attaching rocker arm assembly to turning device using
bracket.
• 010.110.050-03 Attaching high-pressure pump to turning device using
adaptor plate.
• 010.110.054-02 Installation and removal of fixture to turnover device.
Work sequence - Mounting the cylinder head

Initial situation
Observe the Operating Manual issued by the manufacturer

Read the manufacturer’s operating manual carefully before using the
turnover device (055.130).

Cylinder head hooked to the lifting tackle with a suspension device.

Work steps 1. Attach adapter plates (7) with hex bolts (5) to cylinder head (9). The mark-
ing “AS” must point to the exhaust side.
2. Hoist cylinder head (9) into turnover device (055.130). Secure using
means provided.
3. Remove the suspension device.
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Rotation of the cylinder head

Owing to the non-axial weight distribution, the clamped cylinder head
may start rotating and cause injury to parts of the body in the process.
• When working on the cylinder head, always ensure that the locking
lever is engaged
• Staying within the minimum circumscribed circle is only permitted if the
locking lever is engaged
2 (3) 48/60CR, M010.060.020-10-0006

Fixing the cylinder head

The cylinder head can be fixed in 45°increments by inserting the lock-
ing lever into the groove of the ratchet disc.
4. With the locking lever (10) flipped upward, the cylinder head (9) may be
moved into any desired position by turning the handwheel (3).
1 Collecting trough 5 Hex bolt 10 Locking lever

2 Frame 6 Minimum circum- 11 Raster disc
scribed circle
3 Handwheel for shuttle 7 Adaptor plate
gearbox
4 Reversing shaft axis 9 Cylinder head
Figure 1: Turning device for cylinder head
9007217274842251
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48/60CR, M010.060.020-10-0006 3 (3)

9007217274842251
2017-06-20 - de
48/60CR, M010.060.020-10-0006
Cylinder head
check for tightness
Summary
The cooling water compartments of the cylinder head must be checked for
leaks after fitting the pre-chamber insert or the valve seat rings.
fitting the pressure testing set,
pressure testing the cylinder head,
removal of the pressure testing set.
Tools/aids required
2 clamping device 055.530 Option
2 Thrust disk 055.530-1 Option
2 Threaded rod 055.530-2 Option
1 Sealing plug 055.529 Option
1 Pressure pipe 055.528 Option
1 Ring 055.527 Option
1 Hose line 055.522 Option
1 Hand pump 055.521 Option
1 Hose line 055.518 Option
1 Pressure pipe 055.517 Option
1 Engine cooling water - Inventory
1 Receptacle - Inventory
Technical data
Cooling water Volume 30 L
Test pressure Weight 10 bar
2018-11-30 - de
Test duration Time 1 h
Work Sequence 1 - Fitting the pressure-testing set

Starting position Cylinder head detached.
Cylinder head
Work Steps 1. Place the ring (055.527) on square timbers.

2. Oil O-ring seal (3) from the tool scope with clean lube oil and insert it into
the O-ring seal groove of sealing plug (055.529). In doing so, make sure
that it is tensioned evenly along its entire circumference and is not twis-
ted. See Fig. 1.
General, M010.060.020-12-0004 1 (5)

3. Oil O-ring seals (4) from the tool scope with clean lube oil and insert them
into the O-ring seal groove of cylinder head (2). In doing so, make sure
that they are tensioned evenly along their entire circumference and not
twisted.
4. Place cylinder head (2) in the ring.
5. Insert both threaded spindles (055.530-2) through cylinder head (2) and
screw them into the ring.
6. Fit thrust disk (055.530-1) on cylinder head (2) over the threaded
spindles.
7. Screw nut (1) onto the threaded spindle and tighten it.
8. Screw pressure pipe (055.528) into cylinder head (2). See Fig. 2.
9. Connect pressure pipe (055.517) to the ring.
10.Connect hose line (055.518) to hand pump (055.521 and pressure pipe
(055.517).
11.Connect hose line (055.522) to pressure pipe (055.528) and insert the
free end in the hand pump container.
Work Sequence 2 - Pressure testing the cylinder head
Pressure testing procedure

The pressure test is performed at high pressure, therefore all bolted
connections must be rechecked prior to starting the pressure testing
procedure.
Initial Situation Ball valve (C) on water supply (E) is closed.

Work steps 1. Connect water supply to connection (E). See Figure 2/Y.
2. Open ball valves (A, B and D).
Filling the system

Keep the water supply opened until the hand pump container is filled.
3. Open ball valve (C).

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4. Fill pressure-testing set and cylinder head (2) with water.

5. Close ball valve (C).
6. Actuate lever (6) of the hand pump one to two times and thus press re-
maining air through hose line (055.522) out of the pressure-testing set.
Cylinder head
7. Close ball valve (D). See Fig. 2/Z.

8. Operate hand pump until the test pressure is achieved.
9. Close ball valve (B).
10.Observe the specified test duration.
2 (5) General, M010.060.020-12-0004

Reducing the test pressure

If the test pressure is decreasing or drop formation is observed during
the visual check, a leak is present. Eliminate this leakage and repeat
the pressure testing procedure.
Working Sequence 3 - Removing the pressure-testing set

Work steps 1. Disconnect water supply of connection (E).
2. Open ball valve (D) and relieve the pressure in the pressure-testing set
through hose line (055.522).
Reuse cooling water

18014413924397195
3. Place a receptacle underneath the water supply.

4. Open all ball valves.
5. Disconnect hose line (055.522) from pressure pipe (055.528).
6. Disconnect hose line (055.518) from hand pump (055.521) and pressure
pipe (055.517).
7. Disconnect pressure pipe (055.517) from ring (055.527).
8. Unscrew pressure pipe (055.528) from cylinder head (2).
9. Unscrew nuts (1) from threaded spindles (055.530-2).
10.Remove thrust disks (055.530-1).
11.Unscrew threaded spindles from the ring.
12.Remove the ring from cylinder head (2).
13.Pull sealing plug (055.529) out of cylinder head (2).
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Cylinder head
General, M010.060.020-12-0004 3 (5)

1 Nut 3 O-ring
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2 Cylinder head 4 O-ring

Figure 1: Fitting/removing the ring
Cylinder head
4 (5) General, M010.060.020-12-0004

2 Cylinder head A Ball valve - hand pump D Ball valve - venting

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6 Hand lever B Ball valve - pressure E Water supply

pipe
C Ball valve - water sup-
ply
Cylinder head
Figure 2: Attached pressure-testing set

18014413924397195
General, M010.060.020-12-0004 5 (5)

18014413924397195
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Cylinder head
General, M010.060.020-12-0004

51353857547
1 (1)

Valve rotator
Inspecting
Summary
Execute work on time according to the maintenance schedule, check com-
ponents for state/wear condition.
Valve rotators are to be assessed at regular intervals.
The work includes:
Checking parts/ components.

Tools/aids required

Disassembly and assembly of the valve rotator 010.060.030-03
Checking the valve rotators 010.060.030-06
Work Sequence – Checking the valve rotators

Starting position Engine at a standstill.
Work steps 1. Remove or open the cylinder head cover.
2. Make line markings on valve rotators (15) and thrust bearings (17) with a
felt-tip pen. See Fig. 2.
3. Fit the cylinder head cover and attach or close it.
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4. Start up the engine and run it for 1 minute at rated speed and 25 % to
30 % power output.
5. Shut down the engine.
Valve rotator
General, M010.060.030-01-0001 1 (3)

Hot surfaces
High surface temperatures developing during engine operation may
cause burns upon contact.
• Avoid direct contact with hot surfaces
• When working with certain surface temperatures, it is advisable to take
special care and to wear heat-resistant personal protective equipment
6. Remove or open the cylinder head cover.

7. Check the markings. If the valve rotators are working correctly, the mark-
ings will now be in a different position.
Non-rotating inlet and exhaust valves

If the position of the markings has not changed, repeat work steps 3
and 4 once.
If, after repeating the steps, the inlet and exhaust valve is still in the
same position, remove, dismantle and reassemble the valve rotators or
replace the thrust bearing. See Work Instructions 010.060.030-02 and
010.060.030-03.
In addition, check the condition of the valve cone and the valve seat
ring. See Work Instructions 010.060.030-04 and 010.060.030-06.
8. Fit the cylinder head cover and attach or close it.
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1 Base body
2 Ball
4 Cup spring
Valve rotator
5 Cover
6 Circlip
7 Pressure spring
Figure 1: Inlet valve rotator
36028801232204939
2 (3) General, M010.060.030-01-0001

8 Inlet valve seat ring 13 O-ring seal 18 Outlet valve cone with
valve propeller
9 Cylinder head 14 Compression spring 19 Exhaust valve seat ring
10 Inlet valve cone 15 Valve rotator
11 Valve guide 16 Valve tapered piece M Marking
(two-part)
12 Compression spring 17 Thrust bearing
Figure 2: Inlet and exhaust valve (Figure shows cylinder head 32/40)
36028801232204939
2016-11-24 - de
Valve rotator
General, M010.060.030-01-0001 3 (3)

36028801232204939
2016-11-24 - de
Valve rotator
General, M010.060.030-01-0001
Inlet/exhaust valve
Removing and installing
Summary
Carry out work on time in accordance with the maintenance schedule; make
sure the work is carried out correctly; check workmanship/wear of compon-
ents.
Remove the inlet and exhaust valves at regular intervals and overhaul if neces-
sary.
The work/work steps comprise the
removal and installation of components.
Safety requirements
l Engine stopped
Tools/aids required
1 Valve spring tensioner 113.204 Standard
1 Spindle 113.204-1 Standard
1 Deep groove thrust ball bearing 113.204-3 Standard
1 Spherical disc 113.204-4 Standard
1 Ball socket 113.204-5 Standard
1 Extension pipe 113.204-6 Standard
1 Blanking washer 113.204-7 Standard
1 Special anti-seize agent (Molykote G Rapid, - Inventory
Molykote G-n)

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Inlet/exhaust valve
Check valve rotator 010.060.030-01

Checking the valve rotators 010.060.030-06
Checking the valve guide 010.060.030-08
Technical data
Inlet valve cone Weight 9 kg
General, M010.060.030-02-0006 1 (10)


Exhaust valve cone Weight 10 kg
Work Sequence 1 - Monitoring the valve rotator

The valve rotator is operated when the cylinder head cover is closed and the
engine is running. See Work Instructions 010.060.030-01.
Work Sequence 2 – Removing the inlet and exhaust valve

Initial situation
Removing valve rotators, thrust bearings or compression

springs
If only the valve rotators, thrust bearings or the compression springs
are to be disassembled, the cylinder head remains attached and the
piston is in the ignition TDC.
The cylinder head is removed and clamped in the turning device (if available).
Work Steps
Removal/fitting
The work Steps in these Work Instructions explain how to remove and
fit the inlet valve. The exhaust valve is removed and installed in the
same way.
1. Screw in spindle (113.204-1) until it rests on valve cone (9).

2. Fit jumper (113.204-2) onto spindle. Position on the valve rotator (2).
Inserting blanking washer into spindle

The blanking washer prevents the spindle from working itself loose
from the valve cone during the removal/fitting procedure.
3. Insert blanking washer (113.204-7) into the spindle.

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Inlet/exhaust valve
Observe installation sequence

Installation sequence: Conical seat – Spherical washer – Axial grooved
ball bearing
4. Position the conical seat (113.204-5), spherical washer (113.204-4) and

axial grooved ball bearing (113.204-3).
5. Coat the thread of the spindle with “Molykote G-n” lubricant.
2 (10) General, M010.060.030-02-0006

6. Screw extension tube (113.204-6) onto spindle.

7. Using the tensioner (113.204), push down on the pressure springs (3 and
4) until the two-part tapered piece (1) can be removed. Brace the jumper
using a Tommy bar (000.264).
8. Remove both parts of the tapered piece (1).
9. Unscrew the extension tube to release the pressure springs (3 and 4).
Prevent the valve falling out

If the valve cone is not held, it will fall out of the valve guide upon re-
moval of the tensioner.
10.Detach the tensioner (113.204). When doing so, keep hold of the valve
cone (9).
Note the assignment of valve cone/valve guide

Note the assignment valve cone / valve guide, since valve cones that
are not overhauled (ground) must be assembled in the same valve
guide.
11.Remove valve cone (9) from valve guide (8). Set down on a clean surface.
12.Remove valve rotator (2) and compression springs (3 and 4).
13.Remove washer (6) and O-ring (5).
14.Clean all individual parts. Check for wear (for max. clearance see Volume
010.005 Engine – Operating manual 010.000.035-04), replace if neces-
sary.
15.Inspect the valve cone (9) and the position of the valve on the valve seat
ring (10). See Work Instructions 010.060.030-04 and 010.060.030-06.
16.Check the condition of valve guide (8). See Work Instructions
010.060.030-08.
Work sequence 3 - Fitting the inlet valve

Initial situation All individual parts cleaned, checked and replaced where necessary. Valve
guide hole cleaned.
Work Steps
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Inlet/exhaust valve
Removal/fitting
The work Steps in these Work Instructions explain how to remove and
fit the inlet valve. The exhaust valve is removed and installed in the
same way.
1. Place new O-ring (5) in the ring groove, whilst ensuring that it is not twis-
ted.
2. Treat the shaft of the valve cone (9) with Molykote spray G-Rapid.
General, M010.060.030-02-0006 3 (10)

3. Insert the valve cone (9) into valve guide (8) and hold in place.
4. Screw in spindle (113.204-1) until it rests on valve cone (9).
5. Place washer (6) in cylinder head (7).
6. Install compression springs (3 and 4) and set valve rotator (2) on the
compression springs.
7. Position the jumper (113.204-2) on the spindle and place it on the valve
rotator (2).
Inserting blanking washer into spindle

The blanking washer prevents the spindle from working itself loose
from the valve cone during the removal/fitting procedure.
8. Insert blanking washer (113.204-7) into the spindle.
Observe installation sequence

Installation sequence: Conical seat – Spherical washer – Axial grooved
ball bearing
27021604751345035
9. Position the conical seat (113.204-5), spherical washer (113.204-4) and

axial grooved ball bearing (113.204-3). See Fig. 2.
10.Coat the thread of the spindle with “Molykote G-n”.
11.Screw extension tube (113.204-6) onto spindle.
12.Using the tensioner (113.204), push down on the pressure springs (3 and
4) until the two-part tapered piece (1) can be inserted. Brace the jumper
using a Tommy bar (000.264).
13.Fit both parts of the tapered piece (1).
14.Check that both parts of the tapered piece (1) are correctly in place and
the gap between the two parts is the same all the way along.
15.Unscrew the extension tube to relieve compression springs (3 and 4).
16.Detach the tensioner (113.204). 2020-11-16 - de
Inlet/exhaust valve
4 (10) General, M010.060.030-02-0006

1 Tapered piece, two 6 Washer 10 Valve seat ring

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parts
2 Valve rotator 7 Cylinder head 11 Thrust bearing
Inlet/exhaust valve
3 Compression spring 8 Valve guide 12 Exhaust valve

4 Compression spring 9 Inlet valve 13 Valve seat ring
Figure 1: Inlet and exhaust valve
General, M010.060.030-02-0006 5 (10)

Figure 2: Valve spring tensioner

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Inlet/exhaust valve
6 (10) General, M010.060.030-02-0006

2 Valve rotator 4 Compression spring

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3 Compression spring 9 Valve cone

Inlet/exhaust valve
Figure 3: Fitted tensioner
General, M010.060.030-02-0006 7 (10)

1 Tapered piece, two parts 3 Compression spring

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2 Valve rotator 9 Valve cone

Inlet/exhaust valve
Figure 4: Removing/fitting the tapered piece
8 (10) General, M010.060.030-02-0006

2 Valve rotator 4 Compression spring

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3 Compression spring 9 Valve cone

Inlet/exhaust valve
Figure 5: Removing/fitting the inlet valve
General, M010.060.030-02-0006 9 (10)

2 Valve rotator 6 Washer 10 Valve seat ring

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3 Compression spring 7 Cylinder head

Inlet/exhaust valve
4 Compression spring 8 Valve guide

5 O-ring 9 Inlet valve
Figure 6: Removing/fitting the inlet valve
27021604751345035
10 (10) General, M010.060.030-02-0006

Valve rotator
Disassembly and reassembly
Summary
Carry out the work in good time according to the maintenance schedule; en-
sure the work is carried out correctly; check the components as to their
The valve rotator must be inspected at regular intervals to be cleaned.
disassembling components,
assembling components.
Tools/aids required
Work Sequence - Disassembling and reassembling the valve rotator

Initial situation Valve rotator removed and placed on the support (snap ring on top).
Work steps 1. Remove snap ring (6).
2. Remove cover (5) and cup spring (4).
3. Remove all balls (2) and compression springs (7) from basic body (1).
4. Wash all individual parts in a suitable cleaning agent, and then dry them.
Marking the basic body

When changing parts of the valve rotator, the basic body (1) must be
marked with the factory number of the used wear set.
New parts must be cleaned prior to installation.
5. Check individual parts for wear and ball indentations, and replace them if
necessary.
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Position of balls
Make sure that the balls are at the highest point of the inclined ball
pocket running surfaces and thus all point in the same direction.
Valve rotator
6. Insert balls (2) and compression springs (7) in the ball pocket running sur-
faces in the basic body (1).
7. Insert the cup spring (4), place on the cover (5) and install the snap ring
(6).
General, M010.060.030-03-0003 1 (2)

Lubrication of the valve rotator

Never fill the valve rotator with grease. Only use clean lubricating oil to
lubricate the valve rotator.
8. Place the valve rotator in clean lubricating oil and remove shortly before
installation.
Storage Parts kept in stock must be packaged well so they are protected against
dust, water, moisture and aggressive media. Dust acts as an adhesive agent
in the individual parts and prevents or inhibits rotation during start-up.
1 Basic body
2 Ball
4 Cup spring
5 Cover
6 Snap ring
Figure 1: Inlet valve rotator
27021601988389643
2017-09-14 - de
Valve rotator
2 (2) General, M010.060.030-03-0003

Valve seat ring

inspecting
Summary
ponents for state/wear condition, assess the contact pattern /wear status.
Inlet and exhaust valve cones and seat surfaces are to be checked at regular
intervals and overhauled or replaced if necessary.
executing touching tests ,
assessing contact pattern /wear status.
Tools/aids required
1 Touching bracket for engine L,V48/60B+CR: 114.033 Standard
51/60DF
1 Touching bow for engine 40/54 114.032 Standard
1 Touching up device for Engine 32/40, 113.224 Standard
32/44CR, 32/44K

Rework of the valve seat ring 010.060.030-05
Preliminary remark
Incorrect contact pattern

Outlet and inlet valves with an incorrect contact pattern will not have a
2016-12-20 - de
long service life. They must be overhauled or replaced.
The overhauling intervals specified in the maintenance schedule (see Volume

Valve seat ring
010.005 Engine - operating manual 010.000.047-03) are approximate values,

which are independent on the operating method and the condition of the en-
gine as well as the quality of the fuels used. The most expedient overhaul in-
tervals should be defined based on the prescribed inspection.
General, M010.060.030-04-0002 1 (5)

1 Cylinder head 4 Exhaust valve cone

2 Inlet valve cone 5 Valve seat ring
3 Valve seat ring
The valve seat angle (α) of the valve cone is 120° with a positive tolerance.
The valve seat angle (β) in the valve seat ring has been engineered with a neg-
ative tolerance which produces a small differential angle (γ). This ensures that
a seal against the hot gases at the outer edge of the valve seat area is main-
tained during operation. See Fig. 2.
The wear surface appearance is tested by performing a touching test.
2 Inlet valve cone α Angle at valve cone γ Differential angle

3 Valve seat ring β Angle at valve seat ring
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Figure 2: Relationship of geometric angle between valve seat ring and valve cone - illustration shows inlet
valve
Valve seat ring
Check machining tools

In case of older valve seat lathes, wear could result in clearances,
changing the valve seat angle and producing incorrect contact pat-
terns. We recommend checking using a touch test with a new original
valve cone. If deviations are identified, check the valve seat lathe.
2 (5) General, M010.060.030-04-0002

Work sequence 1 - Touching test

Starting position Cylinder head clamped in the cylinder head turnover stand, inlet and exhaust
valves dismantled.
2 Inlet valve cone

Figure 3: Touching bow or touching up device - figure shows inlet valve
Work Steps 1. Clean valve seating surfaces carefully.
Cleaning device
Do not damage valve cones by using the wrong cleaning device (e.g.
chipping hammer).
2. Fit touching bow or touching up device on valve cone (2 or 4). See Fig. 3.
3. Apply the thinnest possible layer of touching-test ink to the valve seating
surfaces of valve cone (2 or 4) and spread very thinly.
4. Introduce valve taper (2 or 4) in the associated valve guide in the cylinder
head (1) and move further by half a revolution with touching bow or
touching up device under pressure in vertical position.
5. Remove valve cone (2 or 4).
6. Check valve seating surfaces in valve seat ring (3 or 5). With the correct
2016-12-20 - de
differential angle and proper rework, a closed, load bearing face must
form a closed load bearing surface on the outer edge of the valve seat.
7. Remove touching bow or touching up device.
Valve seat ring
Work Sequence 2 - Assessment of the valve seating surface on the valve seat ring
Starting position Cylinder head is clamped in the cylinder head turnover stand, inlet and ex-
haust valves are dismantled.
Result 1 The valve seat surface of the valve seat rings is clean, lightly lacquered or only
has slight scar formation. Uniform contact pattern all around – see Figure 4.
General, M010.060.030-04-0002 3 (5)

Figure 4: Figure for Result 1
Action
Using the grinding paste

Clean as little grinding paste as possible and then carefully clean the
valve plug and valve seat ring. Residue of grinding paste increases
wear.
Apply silicon-free grinding paste on the valve seating surfaces of the valve
seat rings (follow the manufacturer's instructions!) and clean them by hand us-
ing a touching bow or touching up device, until the lacquer is removed.
Conduct a touch test after cleaning. See Work Sequence 1.
Existing small cracks after removal of the lacquer are still permitted; they do
not affect the durability too much.
Result 2 The valve seating surface of the valve seat ring shows heavy deposit, deeper
corrosion cracks and/or distinct impact traces. Wear on valve seat ring - see
Figure 5.
2016-12-20 - de
Valve seat ring
4 (5) General, M010.060.030-04-0002

Action
Grinding and turning

Grind/turn as little as possible and then carefully clean the valve plug
and valve seat ring. Residues of grinding paste increase wear.
Machine the valve seat rings until the valve seat surfaces are clean or a new
contact pattern is achieved. See work instruction 010.060.030-05.
Conduct a touch test after cleaning. See Work Sequence 1.
Existing small cracks after grinding/turning are still permitted; they do not af-
fect the durability too much.
27021601988443147
2016-12-20 - de
Valve seat ring
General, M010.060.030-04-0002 5 (5)

27021601988443147
2016-12-20 - de
Valve seat ring
General, M010.060.030-04-0002
Valve seat ring

working/machining
Summary
Execute work on time according to the maintenance schedule, ensure correct
execution of work, restore contact pattern.
Valve seating surfaces are to be checked at regular intervals and remachined
if necessary. This is carried out using the valve seat turning machine HUNGER
Type VD4E.
The work includes:

1 Qualified Personnel 1
Tools/aids required
1 Valve seat lathe of type VD4E (277V) 113.253 Option
1 Screw driver TORX T15 113.340 Option
2 Clamping screw 113.334 Option
1 Tool holder 113.333 Option
1 Lathe with boring head 113.251-1 Option
1 Control unit 277V 113.253-2 Option
10 Indexable insert 113.251-5 Option
1 Pilot 113.251-6 Option
1 Support frame 113.251-7 Option
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1 Milling cutter 113.251-8 Option

1 Carry case 113.251-12 Option
1 Pilot nut 113.251-13 Option
Valve seat ring

1 Cutting oil - Inventory
V48/60TS, M010.060.030-05-0005 1 (11)


Removal and installation of valve seat rings 010.060.020-09
Work sequence - Machining the valve seating surface

Starting position Cylinder head is clamped disassembled in turnover stand, inlet and/or ex-
Read the operating manual from the manufacturer

Read the manufacturer’s instructions carefully before commissioning
the valve seat grinder.
Risk of injury
Work steps 1. Clean valve guide (3) and valve seating surface (A) on valve seat ring (1 or
4).
2. Chamfer the valve guide (3) on both sides. See Fig. 3.
– Insert milling cutter (113.251-8) into valve guide (3),
– rotate the milling cutter, and simultaneously press it lightly against
valve guide (3),
– mill until a tapering surface free from any adhering carbon residues
and thus a clean contact surface is created for the pilot (113.251-6) or
the pilot nut (113.251-13).
– Remove milling cutter,
– Clean valve guide (3).
2018-08-03 - de
3. Insert pilot into valve guide (3) on combustion chamber side.

4. Mount the support frame (113.251-7). See Fig. 4.
– Fit the support frame on the pilot,
Valve seat ring
– Push the support frame downwards until pins (5) are located below
the valve seat ring (1 or 4),
– Mark the position,
– Remove pilot and support frame,
– Clamp the support frame onto the pilot in the marked position.
5. Install the pilot with the support frame. See Fig. 4.
2 (11) V48/60TS, M010.060.030-05-0005

– Insert pilot with mounted support frame into valve guide (3),
– Screw a mounting nut on the guide and tighten it with moderate force,
until the guide is seated firmly in valve guide (3).
6. Apply clean lubricating oil to the shank and the front surface of the pilot.
7. Prepare the grinder (113.251-1).
– Unlock stop pin (6) to the extent possible in machining advance feeder
(7), and lock it again.
– Rotate machining feeder (7) clockwise until only 1 to 2 mm of feed
scale (8) is visible.
– Install indexable insert (113.251-5) and clamping screw (113.334) in
tool holder (113.333).
– Install the tool holder into the tool rail of boring head (9).
8. Fit the grinder onto the pilot. See Fig. 5.
Danger of damages
Do not let insert impact on the valve seat ring.
9. Adjust the indexable insert.

– Swivel out lever (12).
– Press lever (12) inwards and swivel it until the indexable insert is loc-
ated above the centre of the valve seating surface (A).
Free direction of movement of indexable insert

Check that the indexable insert can travel over the entire width of the
valve seating surface.
10.Lower the grinder to working height.

– Hold grinder from below,
– Unlock the stop pin (6).
– Lower the grinder carefully until the indexable insert is located about 2
to 3 mm above the valve seating surface (A).
– Press downwards stop pin (6) against the guide and lock it.
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Mains voltage/input voltage

Check that supply voltage matches the input voltage indicated on the
Valve seat ring
nameplate of the control unit.
11.Connect the control unit (113.251-2, 113.252-2 or 113.253-2). See Fig.

5.
– Connect the control unit to the grinder.
– Connect mains cable (11) to a suitable power supply.
V48/60TS, M010.060.030-05-0005 3 (11)

12.Advance the indexable insert.

– Check that lever (12) is latched in the rest position.
– Stop the grinder, and restart it by pressing push-button switch (13).
– Rotate machining feeder (7) counter clockwise, until the indexable in-
sert touches the valve seating surface (A).
– Rotate machining feeder (7) clockwise by 2 scale divisions to lift the
indexable insert off the valve seating surface (A).
– Switch off the grinder by releasing the push-button switch (13).
13.Set the indexable insert.
– Move boring head (9) inwards by means of lever (12), until the index-
able insert is in front of the inner edge of the valve seating surface (A),
– Latch the lever (12),
– Rotate machining feeder (7) counter clockwise by 2 scale divisions to
bring the indexable insert to the valve seating surface height.
14.Adjust the cut depth.
– Rotate machining feeder (7) counter clockwise by 6 to 8 scale divi-
sions.
15.Prepare valve seating surface (A).
– Check whether the feed control (14) is pressed down,
– Adjust rotary knob (10) on the control unit to about 180 rpm,
– Wet the valve seating surface (A) with cutting oil.
– Stop the grinder, and restart it by pressing push-button switch (13).
– Hold push-button (13) pressed until the valve seating surface (A) is
completely machined.
– Release push-button switch (13) as soon as the indexable insert has
moved away over the valve seating surface (A).
– Rotate back the machining feeder (7) clockwise by 2 scale divisions to
lift the indexable insert from the valve seat.
Unprotected valve seating surface

Repeat the process until the valve seating surface to be machined is
entirely shiny.
16.Adjust the indexable insert again, adjust the cut depth (approx. 2 to 4
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scale divisions) and machine the valve seating surface (A). See points 13
to 15.
Valve seat ring
Markings for check

Markings are for checking a uniform chip removal.
17.Apply the marks to several places on the valve seating surface (A) using a
marking pen.
4 (11) V48/60TS, M010.060.030-05-0005

18.Carry out the last boring operation as follows:

– Feed adjustment 1 scale mark,
– Adjust rotary knob (10) on the control unit to about 200 rpm.
19.Disassemble the valve seat grinder (113.251, 113.252 or 113.253) com-
pletely, clean it, and store it in the carrying case (113.251-12).
20.Carry out a touching test. See Work Instructions 010.060.030-04.
Required contact pattern cannot be produced

If you cannot obtain the required wear pattern using the valve seat
grinder, the valve seat grinder must be submitted for repair to a MAN
Service Centre.
Maximum allowable finish- The maximum allowable finishing is reached if the valve seating surface (A) is
ing finished up to surface (B). See Fig. 6.
On reaching the rework limit, replace valve seat ring (1 or 4). See Work In-
structions 010.060.020-09.
2018-08-03 - de
Valve seat ring
V48/60TS, M010.060.030-05-0005 5 (11)

2018-08-03 - de
Valve seat ring
Figure 1: Valve seat grinder type VD4E by HUNGER
6 (11) V48/60TS, M010.060.030-05-0005

1 Valve seat ring (inlet valve) 4 Valve seat ring (exhaust

valve)
2 Cylinder head A Valve seating surface
3 Valve guide
Figure 2: Inlet and exhaust valve seat ring in the cylinder head
2018-08-03 - de
Valve seat ring
V48/60TS, M010.060.030-05-0005 7 (11)

1 Valve seat ring (inlet valve) 3 Valve guide

2 Cylinder head 4 Valve seat ring (exhaust
valve)
Figure 3: Cleaning the valve guide
2018-08-03 - de
Valve seat ring
8 (11) V48/60TS, M010.060.030-05-0005

2018-08-03 - de
Valve seat ring
1 Valve seat ring (inlet valve) 4 Valve seat ring (exhaust

valve)
2 Cylinder head 5 Bolts
3 Valve guide
Figure 4: Installation of guide pilot
V48/60TS, M010.060.030-05-0005 9 (11)

2018-08-03 - de
1 Valve seat ring (inlet valve) 9 Boring head

2 Cylinder head 10 Rotary knob
4 Valve seat ring (exhaust valve) 11 Power supply cable
Valve seat ring
6 Stop pin 12 Lever

7 Machining feeder 13 Push-button
8 Feed scale 14 Feed control
Figure 5: Attaching the grinder
10 (11) V48/60TS, M010.060.030-05-0005

1 Valve seat ring (inlet valve) A Valve seating surface

2 Cylinder head B Face (Rework limit)
4 Valve seat ring (exhaust
valve)
Figure 6: Rework limit on the valve seating surfaces
27021604768694667
2018-08-03 - de
Valve seat ring
V48/60TS, M010.060.030-05-0005 11 (11)

27021604768694667
2018-08-03 - de
Valve seat ring
V48/60TS, M010.060.030-05-0005
Valve cone
inspecting
Summary
ponents for state/wear condition, assess the contact pattern /wear status.
Inlet and exhaust valve cones and seat surfaces are to be checked at regular
intervals and overhauled or replaced if necessary.
executing touching tests ,
assessing contact pattern /wear status.
Tools/aids required
1 Touching bracket for engine L,V48/60B+CR: 114.033 Standard
51/60DF
1 Touching up device for Engine 32/40, 113.224 Standard
32/44CR, 32/44K

Surface examination using penetration method 010.000.003-08
Machine the valve cone 010.060.030-07
Preliminary remark

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The overhauling intervals specified in the maintenance schedule (see Volume

010.005 Engine - operating manual 010.000.047-03) are approximate values,
Valve cone
which are independent on the operating method and the condition of the en-
gine as well as the quality of the fuels used. The most expedient overhaul in-
tervals should be defined based on the prescribed inspection.
General, M010.060.030-06-0002 1 (10)

The valve cone material is subject to fatigue as a result of frequent temperat-

ure fluctuations. The valve cones are to be replaced after the operating peri-
ods specified in the maintenance schedule (see Volume 010.005 Engine - op-
erating manual 010.000.047-03), even if the maximum allowable reworking
limits have not yet been reached.
1 Cylinder head 4 Exhaust valve cone

2 Inlet valve cone 5 Valve seat ring
3 Valve seat ring
The valve seat angle (α) of the valve cone is 120° with a positive tolerance.
The valve seat angle (β) in the valve seat ring has been engineered with a neg-
ative tolerance which produces a small differential angle (γ). This ensures that
a seal against the hot gases at the outer edge of the valve seat area is main-
tained during operation. See Fig. 2.
The wear surface appearance is tested by performing a touching test.
2016-12-20 - de
2 Inlet valve cone α Angle at valve cone γ Differential angle

3 Valve seat ring β Angle at valve seat ring
Figure 2: Relationship of geometric angle between valve seat ring and valve cone - illustration shows inlet
Valve cone
valve
2 (10) General, M010.060.030-06-0002

Check machining tools

In case of older valve seat lathes, wear could result in clearances,
changing the valve seat angle and producing incorrect contact pat-
terns. We recommend checking using a touch test with a new original
valve cone. If deviations are identified, check the valve seat lathe.
Work sequence 1 - Touching test

Starting position Cylinder head clamped in the cylinder head turnover stand, inlet and exhaust
valves dismantled.
2 Inlet valve cone

Figure 3: Touching bow or touching up device - figure shows inlet valve
Work Steps 1. Clean valve seating surfaces carefully.
Cleaning device
Do not damage valve cones by using the wrong cleaning device (e.g.
chipping hammer).
2. Fit touching bow or touching up device on valve cone (2 or 4). See Fig. 3.
2016-12-20 - de
3. Apply the thinnest possible layer of touching-test ink to the valve seating
surfaces of valve cone (2 or 4) and spread very thinly.
4. Introduce valve taper (2 or 4) in the associated valve guide in the cylinder
head (1) and move further by half a revolution with touching bow or
touching up device under pressure in vertical position.
Valve cone
5. Remove valve cone (2 or 4).

6. Check valve seating surfaces in valve seat ring (3 or 5). With the correct
differential angle and proper rework, a closed, load bearing face must
form a closed load bearing surface on the outer edge of the valve seat.
7. Remove touching bow or touching up device.
General, M010.060.030-06-0002 3 (10)

Work Sequence 2 - Assessment of the valve seating surface on the valve cone
Result 1 Valve seating surface of the valve cone is clean, lightly lacquered or only has
slight scar formation. Uniform contact pattern all around.
Action
Using the grinding paste

Clean as little grinding paste as possible and then carefully clean the
valve plug and valve seat ring. Residue of grinding paste increases
wear.
Apply silicon-free grinding paste on the valve seat surface of the valve cone
and valve seat ring (follow the manufacturer's instructions) and clean by hand
using a touching bow or touching up device until lacquer is removed. Conduct
a touch test after the cleaning (see Work Sequence 1).
Existing small cracks after removal of the lacquer are still permitted; they do
not affect the durability too much.
Result 2 Valve seating surface of the valve cone shows heavy deposit, deeper corro-
sion cracks and/or distinct impact traces. Wear on the valve cone - see Figure
4.
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Action
Valve cone
4 (10) General, M010.060.030-06-0002

Grinding and turning

Grind/turn as little as possible and then carefully clean the valve plug
and valve seat ring. Residues of grinding paste increase wear.
Machine the valve cone until valve seating surfaces are clean or a new contact
pattern is achieved (see Work Instructions 010.060.030-07). Conduct a touch
test after the cleaning (see Work Sequence 1).
Existing small cracks after grinding/turning are still permitted; they do not af-
fect the durability too much.
Result 3 Valve cone with the start of burning through or cracks in the valve seat ar-
mouring. Wear on the valve cone - see Figure 5.
Action
Replace the valve cone.
Work sequence 3 - Assessing the valve cone

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Result 4 Valve cone with the stem corrosion starting. Wear on the valve cone - see Fig-
ure 6.
Valve cone
General, M010.060.030-06-0002 5 (10)

A Stem corrosion
Action
Replace the valve cone.
Result 5 Valve cone with burn-up on the valve plate. Wear on the valve cone - see Fig-
ure 7.
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Valve cone
B Burn-up on the valve plate

6 (10) General, M010.060.030-06-0002

Figure 8: Hot corrosion
Action
Replace the valve cone if the limits indicated on the Work Sequence 4 are ex-
ceeded.
Result 6 Valve cone with tension cracks on the valve stem. Wear on the valve cone -
see Figure 9.
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Valve cone
C Tension cracks on the valve stem

Action
General, M010.060.030-06-0002 7 (10)

Replace the valve cone if tension cracks are detected on the valve stem.
Carry out a crack test as given in Work Instructions 010.000.003-08.
Work Sequence 4 - Checking the burn-up and corrosion depth
Checking the valve thickness

Work Steps 1. Clean valve cone and remove any adhering carbon residue.
2. Determine plate thickness in new condition (HN) at measuring point (C) on
a same new valve and note.
3. Mark one or more measuring points (C), depending on the state of the
valve cone to be tested, distributed on the periphery, using a felt-tip pen.
4. Measure and note the plate thickness using sliding calliper at point (C).
Dimension A = Difference between HN and the measured value must not
be greater than 10% of HN (new condition) at any point.
Regrinding on the seating surface

If regrinding is necessary on a used valve cone on the seating surface,
then the expected material reduction due to grinding should be taken
into account when assessing the determined grinding dimension A.
(The material reduction on the seating surface S further reduces the
plate thickness).
5. Measure and take note of the wear dimension (B) by placing a ruler on
the plate bottom with depth gauge or feeler gauge somewhere in the
centre of the plate. Dimension B may be maximum 3.0 mm at the deep-
est point.
Do not reduce the valve plate thickness to inadmissible values

Regrinding the valve seating surface (S) and possibly occurring hot
corrosion on the plate bottom could reduce the valve plate thickness
to inadmissible values.
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Valve cone
8 (10) General, M010.060.030-06-0002

1 Valve plate in new condi- 2 Valve plate with maximum

tion permitted wear
A Wear dimension on the B Wear dimension in the
plate edge at measuring plate centre
point C
C Measuring point at 1/6 D D Valve plate outer diameter
of the plate diameter
E Tracer arms of the sliding HN Plate thickness in the new
caliper condition at measuring
point C
S Seating surface
Figure 10: Determine wear dimension A on the valve plate
Checking for corrosion grooves on the valve plate outer diameter (D)
Work Steps
Transition from the base to the armouring material

Circumferential corrosion grooves of low depth can be produced at the
2016-12-20 - de
transition from the base to the armouring material on the valve plate
outside diameter (D). The transition point must be checked for cracks.
If there are cracks the outside diameter it must be ground down until
there are no more cracks, whilst maintaining the machining limits.
Valve cone
36028801243398027
6. Clean valve cone, do not damage surface by using the wrong cleaning
device (e.g. chipping hammer).
7. Check armouring transition by using the dye-penetrant method (Met-L-
Check) for cracks. See Work Instructions 010.000.003-08.
General, M010.060.030-06-0002 9 (10)

8. If there are cracks, regrind on valve plate outer diameter without coolant
supply until free of cracks, maintaining machining limits (see Table 1).
Valve plate outer diameter Permitted rework related to diameter

against new condition
up to 100 mm 0,2 mm
over 100 mm 0,5 mm

Table 1: Limit values for rework on valve plate outer diameter
36028801243398027
2016-12-20 - de
Valve cone
10 (10) General, M010.060.030-06-0002

Valve cone
machining
Summary
sure the work is carried out correctly, restore contact pattern.
The valve seating surfaces must be inspected at regular intervals and re-
worked if necessary.
The work includes:
Required tools/auxiliary equipment

1 Tool 113.523 Option
1 Coolant concentrate 113.323 Option
1 Dressing diamond 113.322 Option
1 Grinding wheel 113.321 Option
1 Spring element 113.299 Option

Tool models
Depending on the type of motor and supply voltage of the operation site, the
following tools are also required.
2018-11-14 - de
Valve cone
General, M010.060.030-07-0008 1 (7)

1 Spring element 4 Coolant concentrate 7 Collet for valve cone

grinder
2 Grinding disc 5 Transformer 8 Collet for valve cone
grinder
3 Dressing diamond 6 Tool
Figure 1: Valve cone grinder
Item 5 Item 5 Item 7 Item 8

480 V/400 V 690 V/400 V
32/40CD 113.524 113.257 113.247 113.395
32/40G
35/44G 113.524 113.257 113.247

35/44DF
35/44GTS
32/44CRTS
32/44CR 113.524 113.257 113.295

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32/44K
48/60B 113.524 113.257 113.307

51/60DF
51/60G
58/64CD 113.524 113.257 113.522

Valve cone
58/64RDF
2 (7) General, M010.060.030-07-0008

Preliminary remarks

The overhauling intervals entered in the maintenance schedule are approxim-

ate values, which are dependent on the operating method and the condition
of the engine as well as the quality of the fuels used. The most expedient
overhaul intervals should be defined based on the prescribed inspection.
The valve cone material is subject to fatigue as a result of frequent temperat-
ure fluctuations. The inlet and exhaust valve cones are to be replaced after the
operating periods specified in the maintenance schedule, even if the max-
imum permitted reworking limits have not yet been reached.
Additional information The valve seat angle of the valve cone is 120° with a plus tolerance. The valve
seat angle in the cylinder head is executed with a minus tolerance, so the
valve cone seating surface bears fully on the seating area of the valve seat ring
or there is a small differential angle. This ensures that there is sealing on the
outer area of the valve seating area against the hot gases during operation.
2018-11-14 - de
Figure 2: Valve cone grinder

Valve cone
General, M010.060.030-07-0008 3 (7)

Work sequence 1 - Concentricity check on run valve taper
9 Valve cone 10 Collet 11 Collar plate

Figure 3: Run-out check on the valve cone (figure shows inlet valve)
Work steps 1. Clean valve cone.

2. Tension valve cone in valve cone grinder at the back shaft diameter. See
Fig. 3.
Permitted run-out
The max. permitted run-out on the stem and seating surface of the
used valve cone is 0.08 mm. If this value is exceed, replace the valve
cone.
3. Measure run-out on front shaft diameter and seating surface of valve

cone.
4. Decide whether valve cone can be reworked or if it must be replaced.
Additional information on assessing the valve seating surface. See Work In-
structions 010.060.030-04.
Work sequence 2 - Grinding the valve taper seat

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Risk of injury
Valve cone

4 (7) General, M010.060.030-07-0008

Start-up of the valve cone grinder

Read the Operator’s Manual carefully before start-up of the valve cone
grinder.
Initial situation The valve cone is cleaned.

To set and grind the valve cone, see the manufacturer's operating instructions
and observe the following points:
Work steps
Grinding disc diameter

Due to the cutting speed the grinding disc diameter must not be smal-
ler than 150 mm.
1. Before starting the work, check the grinding disc fastening for firm seat-
ing.
2. Dress grinding disc (2) with dressing diamond (3). Move the dressing dia-
mond (3) at an angle of 15–20° to the grinding disc (2) in a pulling mo-
tion.
3. Insert collet in the spindle head.
4. Insert the valve cone in the workpiece spindle head. Clamp the valve
cone to the collar provided as short as possible (valve plate near to col-
let).
5. Tighten the collet (hand-tight using a hook spanner). To centre the collet,
knock with a plastic hammer on the valve plate floor (2 or 3 light impacts),
then retighten the collet.
6. Check run-out. See Work Sequence 1.
7. The grinding slot is fixed at the set angle by the manufacturer with a pin.
8. Before starting the cutting, set the grinding disc and valve cone so that
the centre of the valve cone seat surface = centre of the grinding disc.
See Fig. 4.
9. Advance until the valve cone seat surface starts to be ground.
Use coolant
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Always supply sufficient coolant to the taper between grinding disc

and valve cone seating surface. During the grinding process ensure
that the grinding disc does not cut into the valve cone radius (R).
The increasing grinding noise points out that the grinding disc is not
removing the material any longer. The grinding disc should then be
dressed.
Valve cone
9007232606033163
General, M010.060.030-07-0008 5 (7)

Reaching the maximum value

On reaching the maximum value (H), the valve cone may no longer be
used. See Fig. 5 and Table 1.
10.Grinding with thin coolant and oscillating (to and fro) movement of the
grinding disc by hand. Ensure that the grinding disc is always on the
valve seat. Grinding motion as low as possible (0.025 mm = 1/2 large di-
vision mark on the scale), to avoid chatter marks.
11.Dress the grinding disc again before the last grind. Set for a lower value
(< 0.02 mm) and grind out completely.
12.Lift off the valve cone seating surface away from the grinding disc.
13.Remove any burrs on the outer diameter of the valve plate with a suitable
tool (file, grindstone) or break the edge on the seat’s inner diameter using
a grindstone.
2 Grinding disc
9 Valve cone
Figure 4: Position of the grinding disc/valve cone seat surface prior to grinding
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Valve cone
6 (7) General, M010.060.030-07-0008

9 Valve cone G Valve cone seat width R Valve cone radius

(new condition)
A Radius H Max. reworking X Tangential point
Figure 5: Reworking on the valve cone
32/40 32/40G 32/44K 32/44CRT 35/44G 35/44DF 48/60B 58/64CD

32/44CR S 35/44GTS 48/60CR 58/64RDF
51/60DF
51/60G
Inlet valve cone 9.8 9.8 9.2 10.4 10.4 10.4 11.6 9.8
(G in mm)
Inlet valve cone 13.2 13.2 12.7 14.4 13.8 13.9 18.5 16.9
(H in mm)
Exhaust valve 9.8 9.8 9.2 10.4 10.4 10.4 11.6 9.8
cone (G in mm)
Exhaust valve 12 13 12.7 14.4 13.8 13.9 18.2 16.4

cone (H in mm)
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Table 1: Valve cone seat width (new condition/max. finishing)

9007232606033163
Valve cone
General, M010.060.030-07-0008 7 (7)

9007232606033163
2018-11-14 - de
Valve cone
General, M010.060.030-07-0008
Valve guide
inspecting
Summary
Impart necessary knowledge, ensure correct execution of work.
Check valve guides are to be replaced within the scope of the service and
maintenance work.
The work/ working steps include :
checking parts/components.
Work Sequence 1 - Checking valve guide

For checking the valve guide (21) a cylindrical recess (C) is provided. See Fig.
1.
Replacement criteria for valve guide:
▪ Valve cone (20) has burning marks in the area of the cylindrical recess (C) of
the valve guide (21).
▪ The circumferential wearing edge (A) on a part of the circumference or all
around the valve guide (21) can no longer be seen or felt.
2015-10-16 - de
20 Valve cone B Wearing edge worn

Valve guide
21 Valve guide C cylindrical hollowing out

A Wearing edge in new con-
dition
Figure 1: Wearing edge on the valve guide
27021601993518347
General, M010.060.030-08-0001 1 (1)

27021601993518347
2015-10-16 - de
Valve guide
General, M010.060.030-08-0001
Valve guide
Removing and installing
Summary
Ensure correct execution of work.
Valve guides are to be checked in the course of the service and maintenance
work and replaced if necessary.
Checking parts/components,
Removing components,
Fitting components.
Tools/aids required
1 Removal and fitting fixture 113.206 Standard
1 Guide piece 113.206-1 Standard
1 Plate 113.206-2 Standard
1 Clamping piece 113.206-3 Standard
1 Hollow piston cylinder 009.022 Standard

Work sequence 1 - Dismantling a valve guide

Initial situation Cylinder head clamped in the turning device (if present), inlet and exhaust
valve dismantled.
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tracted
Valve guide
Work steps 1. Insert the guide piece (113.206-1) into the valve guide (1) and screw on
hex nut (5) hand-tight.
General, M010.060.030-09-0006 1 (6)

2. Fit the clamping piece (113.206-3) and plate (113.206-2) over the guide
piece, ensuring that the clamping piece and plate are centrally aligned.
See Fig. 3/I.
tighten the hex nut (4) hand-tight. See Fig. 3/I.
4. Connect the high pressure hose (009.306) to the hollow piston cylinder
and the high pressure pump (009.342).


ceeded.
5. Activate the high-pressure pump and slowly pump up the hollow piston
6. Gradually remove the valve guide (1), releasing pressure at each stage,
push in the piston of the hollow piston cylinder and tighten the hex nut
(4). See Figs. 3/II and 3/III.
8. Disconnect the high-pressure hose from the hollow piston cylinder and
high-pressure pump and detach the tool.
9. Clean the valve guide (1), check it for wear / damage and replace it if ne-
cessary.
Work sequence 3 - Installing the valve guide

Initial situation Valve guide cleaned, checked and replaced where necessary. Hole in cylinder
head cleaned.
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tracted
Valve guide
Work Steps 1. Fit the valve guide (1) on the guide piece (113.206-1) and screw on the
hex nut (5) hand-tight. Insert the guide piece through the cylinder head
(7).
2 (6) General, M010.060.030-09-0006

2. Fit the plate (113.206-2) over the guide piece and place it on the valve
seat ring (3), ensuring that the plate and valve seat ring are centrally
aligned. See Fig. 4/I.
tighten the hex nut (4) hand-tight.
4. Connect the high pressure hose (009.306) to the hollow piston cylinder
and the high pressure pump (009.342).


ceeded.
9007206261486603
5. Activate the high-pressure pump and slowly pump up the hollow piston
6. Gradually withdraw the valve guide (1), releasing pressure at each stage,
push in the piston of the hollow piston cylinder and tighten the hex nut
(4). See Figs. 4/II and 4/III.
8. Disconnect the high-pressure hose from the hollow piston cylinder and
high-pressure pump and detach the tool.
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Valve guide
General, M010.060.030-09-0006 3 (6)

1 Valve guide
2 Cylinder head
3 Valve seat ring
Figure 1: Valve guide
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Valve guide
4 (6) General, M010.060.030-09-0006

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1 Valve guide 4 Hex nut M30 I-III Work steps

2 Cylinder head 5 Hex nut M30
Figure 2: Removing the valve guide
Valve guide
General, M010.060.030-09-0006 5 (6)

2016-11-25 - de
Valve guide
1 Valve guide 3 Valve seat ring 5 Hex nut M30

2 Cylinder head 4 Hex nut M30 I-III Work steps
Figure 3: Fitting the valve guide
9007206261486603
6 (6) General, M010.060.030-09-0006



51353862155
1 (1)

Fuel injection valve

Summary
Execute work on time according to the maintenance schedule, enable/ sup-
port economic operation, prevent operational problems/damage.
Fuel injection valves affect the fuel preparation (atomisation) in the combustion
chamber and the engine operating data (amongst other things, ignition pres-
sure, exhaust gas temperature) considerably. They are to be checked if there
are deviations in the operating data, overhauled if necessary, or replaced.
The work/work steps include :
Safety requirements
▪ Engine stopped
▪ Emergency stop activated (this reduces the high pressure in the common-
rail injection system to a low pressure level)
▪ Engine secured so that it cannot be started up: Starting air is shut off
▪ Engine fuel system isolated from plant-side fuel system
▪ Engine fuel system depressurised / emptied (corresponding drain cock
open, i.e. the supply and return in the engine fuel system are both depres-
surised)
▪ Locking the drive shaft (turning gear engaged)
Tools/aids required
1 Support plate 221.320 Standard
1 Threaded pipe 221.189-1 Standard
1 Pilot rod 221.189-2 Standard
1 Setting device 221.180 Standard
1 Removing fixture 221.179 Standard
1 Extractor sleeve 221.179-1 Standard
2019-06-11 - de
1 Threaded spindle 221.179-2 Standard

1 Deep groove thrust ball bearing 221.179-5 Standard

1 Cap 221.179-6 Standard
1 Extractor 221.128 Standard
48/60CR, M010.060.060-01-0011 1 (20)


1 Cross handle 001.891 Standard
1 Universal joint 20 001.877 Standard
1 Protection caps (set) 436.010 Standard
1 Rope - Inventory
1 Wooden spatula - Inventory
1 Lubricant Optimol Paste White T - Inventory

Work Instructions and safety regulations - Preparing the 010.000.004-02
Common-Rail engine for maintenance work
Work and safety regulations when working on fuel system 010.000.004-03
Dismantle the fuel injection valve 010.060.060-03
opening and closing indicator valve 010.060.080-02
Common-Rail components Rework sealing face (tapered)/ 010.110.060-02
Handling of high-pressure fuel pipes
Technical data
Fuel injector valve Weight 16,5 kg
2019-06-11 - de
Thrust flange Weight 7 kg

2 (20) 48/60CR, M010.060.060-01-0011

Work sequence 1 - Removing the fuel injection valve
Heavy fuel oil residues in fuel injection valves

Heavy oil residues in fuel injection valves can adversely affect test res-
ults and make cleaning more difficult. It is therefore recommended to
run the engine on diesel fuel for about an hour before removing fuel in-
jection valves. If this is not possible, and if the engine is shut down in
heavy fuel mode, the fuel injection valve must be dismantled and
cleaned before carrying out the tests described here.
Initial situation

Fuel system under pressure

Fuel escaping under very high pressure penetrates the skin and results
in painful infections and causes material damage and personal injuries
with fatal consequences.
• Engine must be isolated from the fuel system on the plant side
• The entire fuel system must be depressurised
Danger of explosion / fire

Fuel is highly flammable and causes very severe personal injuries with
fatal consequences.
• Do not use open flame
2019-06-11 - de
• Smoking is strictly prohibited

Casing of the injection system removed. Cooling water for fuel injection valve
cooling system drained completely. Cylinder head cover and indicator valve
are open. See Work Instructions 010.060.080-02.
48/60CR, M010.060.060-01-0011 3 (20)

Pressure in the combustion chamber

After an engine stop or turning the running gear, a high pressure will
build up in the combustion chamber if the intake and exhaust valves
are closed. In this condition, any work on the cylinder head or on the
engine components situated within the cylinder head may result in ac-
cidents with severe or fatal personal injuries.
• Carry out any work only 20 minutes after engine has stopped
• Carry out any work only 1 minute after stopping the turning operation
Work steps 1. Unscrew pipeline (25) for cooling water supply from cylinder head (6);
drain the cooling holes of the fuel injection valve (9) by blowing with com-
pressed air. Screw the pipe line on again. See Fig. 11
2. Push the support plate (221.320) over the hexagon socket bolt (14), and
fasten it to the rocker arm bracket (16) with the hex bolt (15). See Fig. 2
3. Unscrew and remove the hex nut on the exhaust side (1). See Fig. 2
4. Unscrew the hex bolt (15) and remove the support plate (221.320). Store
the hex bolt (15) by screwing it into the threaded hole on the support
plate (221.320).
5. Unscrew and remove the hex nut on the control side (1). See Fig. 3
6. Remove the fuel injection line. See Work Instructions 010.110.052-01.
7. Undo threaded piece (7), then unscrew and remove it from the cylinder
head (6). See Fig. 4
8. Screw the extractor device (221.128) into thrust flange (3). See Fig. 5/I.
Removing thrust flange correctly

When removing the last third of the thrust flange, turn it slightly and
hold it at an angle to allow sufficient access to rocker arm (13).
When removing the pressure flange, avoid damaging stud bolts (2).
9. Remove the thrust flange (3) and set it aside. See Fig. 5/II.
Note on removal of fuel injection valve

Only undo the fuel injection valve using the removal device (221.179)
2019-06-11 - de
and only remove or install using the suspension device (221.189).

10.Screw threaded spindle (221.179-2) onto fuel injection valve (9) until it
abuts. See Fig. 6/I.
Fitting extractor sleeve correctly

Fit the extractor sleeve such that it is fixed by stud bolt (2) on the con-
trol side. See Fig. 6/I.
4 (20) 48/60CR, M010.060.060-01-0011

11.Fit the extractor sleeve (221.179-1) on bush (5).
Properly attaching deep groove thrust ball bearing

Ensure correct installation of the deep groove thrust ball bearing. See
Fig. 6.
12.Push the deep groove thrust ball bearing (221.179-5) over the threaded
spindle and insert it into the extraction sleeve.
13.Place cap (221.179-6) on extraction sleeve.
14.Screw the hex nut (19) onto the threaded spindle.
15.Detach the fuel injection valve (9) by turning the hex nut (19). See Fig. 6/II.
16.Remove the removal device (221.179).
17.Screw the threaded pipe (221.189-1) onto the fuel injection valve (9) until
it abuts. See Fig. 7
18.Fasten the cable (20) to the threaded pipe using a shackle (002.454) and
Avoiding any damage

In order to ensure sufficient access to rocker arm (13) when dismant-
ling the fuel injection valve, rotate fuel injection valve slightly in the last
one third of dismantling and hold it at an angle.
When dismantling, see that sealing ring (8) is also dismantled and
studs (2) are not damaged.
19.Slightly lift the fuel injection valve (9) and screw the pilot rod (221.189-2)
into the threaded pipe. See Fig. 7
20.Carefully remove the fuel injection valve (9) from the cylinder head (6) and
set it aside on the workbench.
No foreign matter in the combustion chamber

During cleaning, make sure that no foreign matter falls into the com-
bustion chamber.
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21.Clean the locating hole with the cleaning tool (055.133). See Fig. 8
22.Check the valve seat surfaces (B) and grind in if necessary. See Fig. 1
and Work Instructions 010.060.020-05.
23.Cover opening in cylinder head (6).
24.Detach suspension device (221.189).
25.Remove sealing ring (8) and O-rings (4, 11 and 21).
48/60CR, M010.060.060-01-0011 5 (20)

Cleaning the fuel injection valve

Scrape the fuel injection nozzle only with a wooden spatula, so as not
to damage the nozzle apertures.
Remove any adherent carbon residue from the nozzle body using a
wire brush. Proceed with particular care when cleaning the cylindrical
shoulder of the injector body.
26.Clean fuel injection valve (9) externally; dismantle it if necessary. See

27.Clean threaded piece (7).
28.Check the sealing surface of threaded piece (7) for damage; replace the
threaded piece as required.
Work sequence 2 - Installing the fuel injection valve

Starting position The fuel injection valve, in particular the cylindrical shoulder of the nozzle
body, has been carefully cleaned. Opening pressure, leakage and nozzle
bores are checked.
Fuel injection valve from reserve stock or spare parts supply

Fuel injection valve from reserve stock or spares supply cleaned and
checked externally.
Locating hole in the cylinder head and valve seating surface in the insert
cleaned.

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Work steps
Fitting sealing ring on nozzle body

Observe whether sealing ring fits tightly on the nozzle body.
1. Mount new sealing ring (8) on the fuel injection valve (9).
6 (20) 48/60CR, M010.060.060-01-0011

Installing O-rings correctly

Strictly ensure that the O-rings are installed in the correct ring grooves.
Consequences
Ring groove I – IV sealing ring item 11 / green colour
Ring groove V sealing ring item 21 / black colour
2. Insert new O-rings (11, green) oiled with clean lubricating oil into the ring
grooves (I to IV), making sure that they are equally tensioned around the
entire circumference and are not twisted. See Fig. 9
3. Insert a new O-ring (21, black) oiled with clean lubricating oil into the ring
groove (V), making sure it is equally tensioned around the entire circum-
ference and is not twisted. See Fig. 9
4. Screw the threaded pipe (221.189-1) onto the fuel injection valve (9) until
it abuts. See Fig. 7/I.
5. Fasten the cable (20) to the threaded pipe using a shackle (002.454) and
6. Lift up the fuel injection valve (9).
7. Screw the pilot rod (221.189-2) into the threaded pipe.
8. In case of a vertically suspended fuel injection valve (9), fill the interior
(spring) chamber with clean fuel through the hole for the threaded piece
(7).
Damping of the compression spring

This is important for damping the compression spring during commis-
sioning.
9. Remove the cover from the locating hole in the cylinder head (6).
10.Move the fuel injection valve (9) over the cylinder head (6), and install it
carefully in the locating hole, guiding the fuel injection valve with a pilot
rod. See Fig. 7/II.
11.Push in fuel injection valve (9) until it abuts.
12.Detach the tools.
13.Apply “Optimol Paste White T” lubricant to the thread and sealing seat of
the threaded piece (7).
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14.Fit adjusting device (221.180) onto fuel injection valve (9), paying attention
to fixing bore in adjusting device and parallel pin (12) on fuel injection
valve. See Fig. 10
15.Align fuel injection valve (9) by turning it using the adjusting device, simul-
taneously inserting threaded piece (7) into cylinder head (6) and screwing
it into the fuel injection valve. See Fig. 10
16.Tighten threaded piece (7) up to the specified torque. See Fig. 4 and
17.Remove the adjusting device (221.180).
18.Fit fuel injection pipe. See Work Instructions 010.110.052-01.
48/60CR, M010.060.060-01-0011 7 (20)

19.Insert a new O-ring (4) oiled with clean lubricating oil into the ring groove
of the thrust flange (3), making sure it is equally tensioned around the en-
tire circumference and is not twisted.
20.Screw the extractor device (221.128) into thrust flange (3). See Fig. 5/II.
Installation of the thrust flange

When installing the thrust flange, turn it slightly during the first third of
the installation and hold it at an angle to allow sufficient access to
rocker arm (13).
Make sure the stud bolts (2) are not damaged during installation.
21.Install the thrust flange (3). See Fig. 5/I.

22.Detach the tool.
23.Apply MoS2 lubricant to thread and contact surface of hex nuts (1) and
screw onto the stud bolts (2), then tighten by hand.
Installing the fuel injection valve in a cylinder head at operating

temperature
If the fuel injection valve is installed in a cylinder head at the operating
temperature, initially tighten the hexagon nuts only hand-tight (item
23), then allow for temperature equalisation before tightening with the
specified torque (items 24 to 26).
24.Tighten the control-side hex nut (1) to the prescribed torque. See Fig. 3
and Work Instructions 010.000.003-05.
25.Push the support plate (221.320) over the hexagon socket bolt (14), and
fasten it to the rocker arm bracket (16) with the hex bolt (15). See Fig. 2
26.Tighten hex nut on exhaust side (1) to specified torque. See Fig. 2 and
27.Unscrew the hex bolt (15) and remove the support plate (221.320). Store
the hex bolt (15) by screwing it into the threaded hole on the support
plate (221.320).
28.Close the indicator valve.
29.Fill cooling water into fuel injection valve cooling system.
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30.Close the cylinder head cover.

Resetting the exhaust gas
balancer
Resetting exhaust gas balancer

After replacing some components of the fuel injection system, the ex-
haust gas balancer has to be reset. For this, refer to work instructions
010.285.000-49 in the folder 010.285 SaCoSone Vol. 02.
8 (20) 48/60CR, M010.060.060-01-0011

31.Reset the exhaust gas balancer. Refer to work instructions

Work sequence 3 - Installing the studs (2)

Starting position Fuel injection valve has been removed and cleaned; studs have been removed
and threaded holes cleaned.
Work steps 1. Install the fuel injection valve (9). See Work Sequence 2, Steps 1 to 17.
2. Fit fuel injection pipe. See Work Instructions 010.110.052-01.
3. Prepare the thrust flange (3) for installation. See Work Sequence 2, Steps
19 and 20.
4. Apply “Loctite 638” securing compound to the threads of the stud bolts
(2) and screw them in until the specified bolt projection
(A = 188 ±0.2 mm) is reached. See fig. 1.
Rapid installation
Carry out items 5 and 6 rapidly! The hexagon nuts (1) should be
tightened to the specified torque before the Loctite 638 securing com-
pound on the screwed-in stud bolts (2) has hardened (approx. 10
minutes).
45036014334161035
5. Install the thrust flange (3). See Work Sequence 2, Steps 21 and 22.
6. Coat the thread and contact surface of the hex nut (1) with MoS2 lubric-
ant, screw onto the stud bolts (2), and tighten to the specified torque.
See Work Sequence 2, Steps 23 to 27.
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48/60CR, M010.060.060-01-0011 9 (20)

1 Hex nut 6 Cylinder head 11 O-ring

2 Stud bolt 7 Threaded piece 12 Parallel pin
3 Thrust flange 8 Sealing ring 21 O-ring
4 O-ring 9 Fuel injection valve A Bolt projection
5 Liner 10 Insert B Valve seating surface
Figure 1: Fuel injection valve and threaded piece (the shape of the threaded piece may differ from the fig-
ure)
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10 (20) 48/60CR, M010.060.060-01-0011

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1 Hex nut 13 Rocker arm 16 Rocker arm bracket

2 Stud bolt 14 Hexagon socket bolt
3 Thrust flange 15 Hex bolt M16x30
Figure 2: Releasing/tightening the hex nut on the exhaust side – The illustration shows hex nut being
tightened
48/60CR, M010.060.060-01-0011 11 (20)

1 Hex nut 3 Thrust flange

2 Stud bolt 13 Rocker arm
Figure 3: Releasing/tightening the hex nut on the control side – The illustration shows the hex nut being
tightened
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12 (20) 48/60CR, M010.060.060-01-0011

6 Cylinder head 9 Fuel injection valve

7 Threaded piece
Figure 4: Releasing/tightening the threaded piece – The illustration shows the threaded piece being
tightened
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48/60CR, M010.060.060-01-0011 13 (20)

2 Stud bolt 9 Fuel injection valve

3 Thrust flange 12 Parallel pin
4 O-ring I-II Work steps
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6 Cylinder head
Figure 5: Removal/installation of the thrust flange
14 (20) 48/60CR, M010.060.060-01-0011

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2 Stud bolt 19 Hex nut M24

8 Sealing ring 21 O-ring
9 Fuel injection valve PC Control side
Figure 6: Detaching the fuel injection valve
48/60CR, M010.060.060-01-0011 15 (20)

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6 Cylinder head 11 O-ring I-II Work steps

8 Sealing ring 20 Cable
9 Fuel injection valve 21 O-ring
Figure 7: Removal/installation of the fuel injection valve
16 (20) 48/60CR, M010.060.060-01-0011

5 Liner
6 Cylinder head
10 Insert
Figure 8: Cleaning the locating hole in the cylinder head
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48/60CR, M010.060.060-01-0011 17 (20)

9 Fuel injection valve

11 O-ring
21 O-ring
I-V Ring groove
Figure 9: O-ring / ring groove
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18 (20) 48/60CR, M010.060.060-01-0011

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6 Cylinder head 9 Fuel injection valve 12 Parallel pin

7 Threaded piece
Figure 10: Aligning the fuel injection valve/installing the threaded piece
48/60CR, M010.060.060-01-0011 19 (20)

6 Cylinder head 25 Pipeline for cooling wa- 26 Pipeline for cooling wa-
ter supply ter drainage
Figure 11: Pipelines for injection valve cooling
45036014334161035
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20 (20) 48/60CR, M010.060.060-01-0011


check
Summary
Check components for state/wear condition, ensure/ restore operational
safety. Fuel injection valves affect the fuel preparation (atomisation) in the
combustion chamber and the engine operating data (amongst other things,
ignition pressure and exhaust gas temperature) considerably. They are to be
checked if there are deviations in the operating data, overhauled if necessary,
or replaced.
The work includes: Checking parts /components.
Tools/aids required
1 Connecting piece 221.272 Standard
1 Nozzle tester 221.322 Standard
1 Cleaning wire 0.55 221.305 Standard
1 Chuck 002.701 Standard
1 Receptacle for slushing oil - Inventory
1 Compressed air, max. 15 bar - Inventory
Observation
The tool numbers for the individual nozzle tester components are listed in the
spare parts catalogue.

Dismantle the fuel injection valve 010.060.060-03
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Preliminary remark
The functional performance and setting of the fuel injection valve affect the
combustion process, the operating data and the loading of the fuel injection
system. If there are changes in the operational values (ignition pressure, ex-
haust gas temperature), check the opening pressure and tightness of the rel-
evant fuel injection valves. The basis of the nozzle tester is a hydropneumatic
high-pressure pump which allows work to be conveniently carried out under
reproducible conditions.
48/60CR, M010.060.060-02-0011 1 (9)

Note
Atomisation is no longer a test criterion used in the testing of fuel injection
valves of modern 4-stroke engines, because the behaviour of the fuel injection
nozzle in engine operation cannot be verified.
An inferior spray pattern does not provide any indication of the functioning of
the fuel injection nozzle in the engine. It is fully functional if it fulfils the criteria
for opening pressure, tightness and free nozzle apertures.
Additional information on nozzle tester

Read the operating manual Carefully read the entire instruction manual provided by the manufacturer be-
from the manufacturer fore commissioning the nozzle tester. Also refer to the manufacturer’s instruc-
tion manual in Volume 015 Tools and spares (PDS 015.010.010 Standard
tools for inspection of engine)
Individual nozzle tester In some cases, actual individual nozzle tester components may be different in
components shape and size to what is depicted in the manual.
Layout and design of the nozzle tester
4a Filter pressure controller 10 High pressure hose

4b Air tap 12 High-pressure pump
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4c Pressure limiting valve 14 Compressed air coupling

5 Nozzle jet collection re- 19 Pressure relief valve
ceptacle
8 Pressure gauge
Figure 1: Diagram of the nozzle tester
2 (9) 48/60CR, M010.060.060-02-0011

2 Nozzle holder 14 Compressed air coup- 33 Washer

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ling
4a Filter pressure control- 15 Fastening rod 34 Eye bolt M12x110

ler
4b Air tap 19 Pressure relief valve 35 Drain
5 Nozzle jet collection re- 20 Oil sight glass 36 Wing screw M10x50
ceptacle
6 Insert, top 23 Yoke, top 37 Oil filler neck
7 Insert, bottom 24 Yoke, bottom 38 Hexagon head bolt
M20x45
8 Pressure gauge 30 Fuel injection valve 39 Washer
10 High pressure hose 32 Hexagon nut M12
Figure 2: Nozzle tester
48/60CR, M010.060.060-02-0011 3 (9)

Work sequence 1 - Preparing the inspection
Heavy fuel oil residues in fuel injection valves

Heavy oil residues in fuel injection valves can adversely affect test res-
ults and make cleaning more difficult. It is therefore recommended to
run the engine on diesel fuel for about an hour before removing fuel in-
jection valves. If this is not possible, and if the engine is shut down in
heavy fuel mode, the fuel injection valve must be dismantled and
cleaned before carrying out the tests described here.
Danger of explosion / fire

Fuel is highly flammable and causes very severe personal injuries with
fatal consequences.
• Do not use open flame
Initial situation Fuel injection valve has been removed and cleaned externally.
Inspecting the fuel injection valves

Use slushing oil when inspecting the fuel injection valves, since this
also acts as a preservation treatment. Only absolutely clean slushing
oil may be used in the nozzle tester, as otherwise faults could develop
in the pump or fuel injection valve being tested. Monitor the fill level of
the oil tank at the oil level indicator (20).
Work steps 1. Place the inserts (6 and 7) in the nozzle holder (2).
2. Insert fuel injection valve (30) into the nozzle holder (2) and clamp uni-
formly with yoke (23 and 24).
3. Place nozzle jet receptacle (5) under the injection nozzle, and push it up
to the point where the jets strike the inside of the outer walls of the nozzle
jet receptacle.
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Fuel jets under pressure

Fuel jets escaping under very high-pressure can penetrate the skin and
cause painful infections, or material damage and personal injuries with
fatal consequences.
• The fuel injection valve must always spray into the nozzle jet receptacle,
and never into the open air.
• Do not touch the fuel jets
4. Fuel injection valves (30) can be tested and adjusted as follows:
4 (9) 48/60CR, M010.060.060-02-0011

– Check nozzle bores for free passage

– Adjust new and used injection nozzles,
– Check tightness
– Checking opening pressure
Work Sequence 2 - Check nozzle bores for free passage

Work steps 1. Rotate filter pressure controller (4a) completely to the left (minus - ), open
pressure relief valve (19) and proceed as follows. See Figure 1.
2. Release hexagon nut (44) and turn back setting screw (45) until valve
spring (49) is released. Also see Fig. 5. For positioning details see Work
3. Close pressure relief valve (19). Start up the high-pressure pump (12) with
the knob on the filter pressure controller (4a) and set the opening pres-
sure to 30 bar using the adjusting screw (45). See Figure 1 and Figure 5.
Decision Are all nozzle bores opened, or is the quantity from all nozzle bores delivered
uniformly? See Figure 3.
Yes continue to the next Work Sequence

No - Clean nozzle bores according to Work Instructions 010.060.060-03
Figure 3: Assessment of the nozzle bores. Left - open, right - partly blocked
Partly blocked nozzle bores

Partly blocked nozzle bores are not detectable with this method. Use
cleaning wire (221.305) for detection. For detection of partly or com-
pletely blocked nozzle bores, dismantle and clean the injection nozzle.
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4. Dismantle the fuel injection valve according to Work Instructions

010.060.060-03.
5. Check internal parts for visible damage and replace worn components.
Work Sequence 3 - Adjustment of new and used injection nozzles

Work steps 1. Assemble fuel injection valve (30) according to Work Instructions
010.060.060-03.
2. Slowly screw setting screw (45) by hand into holder (46) up to contact
with thrust piece (48).
48/60CR, M010.060.060-02-0011 5 (9)

3. Mark the setting screw (45) in 6 hour = 0° - position. See Fig. 4.
Figure 4: Mark on setting screw (45) at 6 hour = 0° - position.
4. Screw-in setting screw (45) by a defined number of turns. For number of

turns, see 010.005 Engine operating manual 010.000.035-02.
5. Lock setting screw (45) in position using hexagon nut (44). In the pro-
cess, make sure that setting screw (45) is not twisted when tightening
hexagon nut (44). See Fig. 5.
Particles on sealing face

It is possible that during the setting procedure, particles can ingress
between sealing face at injection nozzle and nozzle needle through the
testing instrument. As a result, no pressure can be built up. The injec-
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tion nozzle may seem to be untight because fuel is flowing out of

nozzle bores.
Remedy:
In this case, setting screw (45) must be screwed out until unloading is
obtained, and the injection nozzle must be flushed with nozzle tester
within ca. 30 sec. Then fuel injection valve (30) may be tested and set
again starting with Work Sequence 3/Work Step 2.
If this symptom appears often, checking or cleaning the tester is re-
commended.
6 (9) 48/60CR, M010.060.060-02-0011

Work Sequence 4 - Checking for leaks

Initial situation Nozzle area is clean and dry.
Work steps 1. To check for leaks, set the pressure to 250 bar by using the knob on the
filter pressure controller (4a) and leave it there. The injection nozzle is
considered tight if no drops fall within 5 seconds.
Leakage bore
Make sure that no fuel escapes from the leakage bore, flowing down
on the fuel injection valve, and thus making the of leakage check res-
ults invalid. See Fig. 5.
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44 Hex nut 48 Thrust piece

45 Adjusting bolt 49 Compression spring

46 Holder L Leakage bore
Figure 5: Leakage bore (L) on the fuel injection valve (figure shows engine type
32/44CR)
Decision Yes The fuel injection valve can be made available for use
No - Install a new injection nozzle into the fuel injection valve
48/60CR, M010.060.060-02-0011 7 (9)

Work sequence 5 - Checking opening pressure

Work steps 1. Rotate the knob on filter pressure controller (4a) completely to the left
(minus -) and set the air tap (4b) to “On”.
2. Close pressure relief valve (19).
Do not exceed the maximum pressure

Used fuel injection valves may be stuck, thus resulting in eventually in-
creased opening pressure. To prevent damage to fuel injection valves,
do not exceed the maximum pressure. For maximum pressure, see
010.005 Engine - Operating manual, 010.000.035.-02.
3. Turn the knob on filter pressure controller (4a) to the right (plus +) to ac-
tivate high-pressure pump (12) and raise the pressure slowly until the fuel
injection valve opens. Let the nozzle tester run for at least 20 seconds,
thereby flushing the fuel injection valve.
Opening pressure
The hydraulic pressure must be taken slowly past the opening pres-
sure, since there are otherwise errors when reading the opening pres-
sure. Do not exceed the maximum pressure. In new injection nozzles,
the nozzle needle may stick during the initial spray test due to the pre-
servation treatment and must be released by intensive flushing. If the
injection nozzles are already in service, collect the slushing oil contam-
inated with fuel and do not reuse it in the nozzle tester.
In case of new injection nozzles, there may be a significant drop in the
opening pressure after just a few operating hours. This pressure drop
does not imply any malfunction and is characteristic of all fuel injection
valves. As the running time increases, the opening pressure may drop
by over 100 bars with regard to the setting pressure in a new condition.
Target value for opening pressure and maximum pressure; see 010.005
Engine - Operating manual, 010.000.035-02.
4. Turn the knob on filter pressure controller (4a) completely to the left.
Open and close again pressure relief valve (19).
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Opening performance of used injection nozzles

For used injection nozzles (used = longer than 10 hours in operation),
the opening performance is other than for new injection nozzles. For
used injection nozzles, a distinct spray pattern is not essential for
definition of the opening pressure. For used injection nozzles, the
opening pressure is defined as soon as the smallest quantities are es-
caping (dripping off) from the injection nozzle.
8 (9) 48/60CR, M010.060.060-02-0011

5. Turn the knob on filter pressure controller (4a) to the right (plus +) to ac-
tivate high-pressure pump (12) and raise the pressure slowly until the fuel
injection valve opens. Compare the opening pressure with the nominal
value range. For nominal value, see 010.005 Engine – Operating Manual,
010.000.035-02.
Figure 6: Assessment of the tightness. Left - tight, right - drips
Decision A result evaluation is required. In this case check, whether the opening pres-
sure indicated on the testing instrument is within the prescribed control range.
010.005 Engine - operating manual 010.000.035-02.
Opening pressure drop within the prescribed ▪ Injection valve may be installed in the engine. Readjustment of the
control range - setting screw outside the prescribed number of turns to achieve
the control range is not permitted. See 010.005 Engine - operat-
ing manual, 010.000.035-02.
Opening pressure drop outside the pre- ▪ Replace the injection nozzle and repeat the adjustment process
scribed control range - according to Work Sequence 3.
38609476363
Readjustment of the setting screw is not permitted

Readjustment of the setting screw outside the prescribed number of
turns to achieve the control range is not permitted. Readjustment of
the setting screw may result in damages to parts (e.g. fracture of com-
pression spring).
38609476363
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48/60CR, M010.060.060-02-0011 9 (9)

38609476363
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48/60CR, M010.060.060-02-0011

dismantling and assembling
Summary
Check quality/wear condition of components, prevent operating problems/
damage.
Fuel injection valves influence the loading of the injection system and the op-
erating parameters of the engine. They are to be checked if there are devi-
ations in the operating data, overhauled if necessary, or replaced.
checking parts/components,
1 Nozzle tester 221.322 Standard
1 Chuck 002.701 Standard
1 Eye bolt 001.412 Standard
1 Tank with fuel - Inventory
1 Wooden spatula - Inventory
1 Paper towels - Inventory
1 Plastic hammer - Inventory
1 Cleaning medium (wool) - Inventory
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Inspecting the fuel injection valve 010.060.060-02
48/60CR, M010.060.060-03-0011 1 (9)

Preliminary remark
Dismantling the fuel injection valves

Dismantle the fuel injection valves if errors are detected during the
tests specified in Work Instructions 010.060.060-02, or if the fuel injec-
tion nozzle has reached the end of its service life and needs to be re-
placed.
Dismantling is performed at the nozzle test bed.
Work sequence 1 - Dismantling of a fuel injection valve

Initial situation
Cleaning the fuel injection valve

Scrape the fuel injection nozzle only with a wooden spatula, so as not
to damage the nozzle apertures.
Remove any adherent carbon residue from the nozzle body using a
wire brush. Proceed with particular care when cleaning the cylindrical
shoulder of the injector body.
Fuel injection valve removed and cleaned on the outside.

Work steps 1. Clean the fuel injection valve in diesel oil and remove any adherent car-
bon residue using a wire brush.
2. Swivel nozzle jet receptacle (5) to one side. See Fig. 3.
3. Place upper insert (6) and lower insert (7) in nozzle holder (2).
4. Insert the fuel injection valve, with the injection nozzle facing down, in
nozzle holder (2) and tighten it uniformly.
5. Loosen hexagon nut (44) and turn back adjusting screw (45) until com-
pression spring (49) is released.
6. Unscrew hexagon head bolts (38), rotate nozzle holder (2) with the fuel in-
jection valve through 180°, and screw the hexagon head bolts with wash-
ers (39) back in. See Fig. 2.
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Prevent damage to sealing faces

When releasing the nozzle clamping nut, press the injection nozzle on
the holder sealing face with a plastic hammer so as to prevent damage
to the sealing face by the rotating parallel pin.
7. Release nozzle clamping nut (52) carefully.
2 (9) 48/60CR, M010.060.060-03-0011

Releasing the nozzle clamping nut

If there is heavy resistance when releasing the nozzle clamping nut, try
releasing the threads again by soaking them in diesel oil and rotating
them to and fro. Do not release the nozzle clamping nut with force, as
this may cause the threads to seize, rendering parts unusable.
8. Unscrew nozzle clamping nut (52) and remove nozzle body (42), ensuring
that nozzle needle (43) does not fall out.
9. Extract nozzle needle (43) from nozzle body (42) and place it in diesel oil
for cleaning.
Nozzle needle
Never interchange nozzle needles from one nozzle body to another.
They are manufactured in pairs.
10.Unscrew hexagon bolts (38), turn back nozzle holder (2) with fuel injection
valve through 180° and screw the hexagon bolts with washers (39) back
in.
11.Remove fuel injection valve from nozzle holder (2) and place on work-
bench.
12.Unscrew the adjusting bolt (45).
Jammed part
In the event of jammed parts inside the fuel injection valve, the com-
pression spring may be still tensioned, and, as a result, the thrust
piece can be ejected upwards when releasing.
• Do not stand in the area of the extended axis of compression spring
13.If internal parts are not loose, screw eye bolt (001.412) into pressure shim
(48) and extract the pressure shim, then remove the compression spring
(49) and spring plate (50).
14.Place all parts for cleaning in diesel oil and wash them, then blow them
off with compressed air.
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15.Blow injection nozzle out from outside with compressed air.

Work Sequence 2 - Checking components

The inspection of the components includes:
▪ free passage of the nozzle bores,
▪ quality of fitting surfaces,
▪ mobility of the nozzle needle,
▪ corrosion traces on the nozzle clamping nut and nozzle body,
▪ nozzle specification.
48/60CR, M010.060.060-03-0011 3 (9)

Pay attention to sources of faults

Pay particular attention to the fault sources that have led to unsatis-
factory results in the inspection of the fuel injection valve.
Work steps 1. To clean the nozzle bores, clamp a suitable cleaning wire (221.305) into
the chuck (002.701) and push it through the nozzle bores, then blow
them out with compressed air. See Figure 4.
2. Examine all components, especially sealing faces, for damage/traces of
wear.
No rework on the seating and fitting surfaces

Seat and fitting surfaces should not be machined manually or mechan-
ically, as the required accuracies cannot be achieved by either means.
3. Check if nozzle needle (43) can be moved in nozzle body (42) easily and
without perceivable resistance. See Figure 5.
4. Examine nozzle bodies (42) for traces of corrosion. Visual check for dam-
ages or seizure points. These may be maximally 2.5 mm deep. In case of
corrosion, check the nozzle cooling water outlet temperature; increase it
to a maximum of 90 °C if necessary.
5. Read off the nozzle specifications on the collar of nozzle body (42), and
compare with the reference specifications. See Fig. 6.
Original specification - see acceptance test record of the engine.
6. Replace damaged parts, replacing nozzle needle (43) and nozzle body
(42) as combination.
Work Sequence 3 - Assembly of a fuel injection valve
Specification of the injection nozzle

Before the assembly, check whether the specification of the fuel injec-
tion nozzle matches the reference specification. The original specifica-
tion can be obtained from the acceptance test record (number, number
of nozzle bores, bore diameter, spraying angle).
2020-05-06 - de
Initial situation Fuel injection valve dismantled, all individual parts cleaned carefully, damaged
parts replaced. Insert the holder (46) into the nozzle holder (2) with the sealing
surface facing up.
Work steps 1. Place the upper insert (6) and the lower insert (7) into the nozzle holder
(2).
2. Insert the thrust piece including valve spring (49) and valve spring retainer
(50), taking into account the position of the opening for the threaded
piece. See fig. 1. Checking the correct position of the thrust piece (48).
3. Screw in the adjusting screw (45), but do not tighten the valve spring (49)
yet.
4 (9) 48/60CR, M010.060.060-03-0011

4. Dip the nozzle needle (43) in clean fuel and guide it into the nozzle body
(42). Check the nozzle needle for mobility.
5. Check nozzle needle stroke between upper nozzle body edge (42) and
stepped part of nozzle needle (43) kontrollieren. See 010.005 Engine –
Operating instructions 010.000.035-04 for nozzle needle stroke setpoint
value.
6. Check impaction on the stroke magnitude of holder (42). See 010.005
Engine – Operating instructions 010.000.035-04 for setpoints.
Sealing face is free of fat, clean and dry

During the installation, the sealing face between holder (46) and nozzle
body (42) must be absolutely dry, clean and free of fat. For cleaning
these surfaces, clean paper towel and fast-acting cleaner Loctite 7061
must be used.
7. Wipe the sealing faces with clean paper towel and fast-acting cleaner
Loctite 7061 to remove any fat; clean and dry them.
8. Check that the sealing face on the holder (46) and the nozzle body (42) is
perfectly clean (no lint, etc.).
9. Insert the nozzle body (42) with nozzle needle (43) on the holder (46),
paying attention to the position of the two parallel pins (51).
Do not damage nozzle needle

During the installation, make sure that the nozzle needle does not slip
out from the nozzle body and is not damaged.
10.Coat the pressure shoulder (D) at the nozzle body (42) with “Optimol
Paste White T” lubricant. See Figure 1.
11.Coat the threads on the holder (46) and the nozzle clamping nut (52) as
well as the thrust shoulder (D) on the nozzle clamping nut with Optimol
Paste White T lubricant. See Figure 1.
12.Screw nozzle clamping nut (52) onto holder (46) until hand-tight.
13.Tighten the nozzle clamping nut (52) to the specified torque. See Work
14.Undo and remove hex screws (38), unscrew nozzle holder (2) with holder
2020-05-06 - de
(46) by 180° and screw hex screws with washers (39) back in. See Fig-
ure 3.
15.Screw the hex nut (44) loosely onto adjustment screw (45) and do not
tighten it until the injection valve has been set. See Work Instructions
010.060.060-02.
48/60CR, M010.060.060-03-0011 5 (9)

42 Nozzle body 50 Spring plate

43 Nozzle needle 51 Parallel pin
44 Hex nut 52 Nozzle clamping nut
45 Adjustment screw 53 Sealing ring
46 Holder 55 Parallel pin
48 Thrust piece D Pressure shoulder
49 Valve spring
Figure 1: Fuel injection valve
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6 (9) 48/60CR, M010.060.060-03-0011

2 Nozzle holder 32 Hexagon nut M12 42 Nozzle body

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5 Tank 33 Washer 46 Holder

6 Insert, top 34 Eye bolt M12x110 52 Nozzle clamping nut
23 Yoke, top 38 Hexagon head bolt

M20x45
24 Yoke, bottom 39 Washer
Figure 2: Fuel injection valve - Unscrewing the nozzle clamping nut / removing the fuel injection nozzle
48/60CR, M010.060.060-03-0011 7 (9)

2 Nozzle holder 24 Yoke, bottom 39 Washer

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5 Tank 32 Hexagon nut M12 44 Hexagon nut

6 Insert, top 33 Washer 45 Adjusting screw
7 Insert, bottom 34 Eye bolt M12x110 46 Holder

23 Yoke, top 38 Hexagon head bolt
M20x45
Figure 3: Fuel injection valve - releasing the compression spring
38609479563
8 (9) 48/60CR, M010.060.060-03-0011

42 Nozzle body
Figure 4: Cleaning the nozzle bores
42 Nozzle body
43 Nozzle needle
Figure 5: Checking the mobility of the nozzle needle
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Figure 6: Example of nozzle element with nozzle specification

38609479563
48/60CR, M010.060.060-03-0011 9 (9)

38609479563
2020-05-06 - de
48/60CR, M010.060.060-03-0011

51353866379
1 (1)

Starting valve
Summary
Execute work on time according to the maintenance schedule, ensure/ re-
store operational safety.
Starting valves are to be checked at regular intervals and overhauled, if neces-
sary.
checking for leakages,
Safety requirements
l Engine stopped
Tools/aids required
1 Threaded pipe 221.189-1 Standard
1 Pilot rod 221.189-2 Standard
1 Extractor sleeve 221.179-1 Standard
1 Intermediate piece 161.022 Standard
1 Extension 161.020 Standard
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Starting valve

General, M010.060.070-01-0002 1 (11)


1 Rope - Inventory

Dismantling and assembly of the starting valve 010.060.070-02
Technical data
Thrust flange Weight 12,5 kg
Starting valve Weight 6,5 kg
Preliminary remark
If the starting air line becomes hot during the operation, shut off the engine
immediately and replace the defective starting valve.
Make all air pipes pressureless before work on the starting valve. Close the
shut-off valve on the compressed air tank.
Work sequence 1 - Checking for leakage

Work steps 1. Seal control air line upstream of distributing line to the starting air pilot
valves (after removal of pipe section) using cap nut and sealing plugs. In
this way it is impossible to expose a starting valve to control air pressure.
2. Open the indicator valve on the cylinder head.
3. Turn the running gear until the piston is at ignition TDC (inlet and exhaust
valves closed).
4. Vent start air line. Leaks in the starting valves can be detected by leaking
air on the indicator valve.
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Leaking starting valves

If leaking starting valves are not overhauled immediately, the valve seat
may be destroyed.
Starting valve
Work sequence 2 - removing the starting valve

Initial situation Cylinder head cover and indicator valve are open.
2 (11) General, M010.060.070-01-0002


Work steps 1. Undo and unscrew hex nuts (1).

2. Screw the lifting eye bolt (000.142) into thrust flange (2).
3. Fasten cable (8) to lifting eye bolt using a shackle (002.452) and suspend
it from the lifting tackle. See Fig. 2/I.
4. Remove the thrust flange (2) and set it aside. See Fig. 2/II.
5. Detach the tools.
6. Screw on the extension (161.020) until it is seated on starting valve (5).
See Fig. 3/I.
7. Screw on threaded spindle (221.179-2) until it abuts on extension.
8. Place the intermediate piece (161.022) on cylinder head (6).
9. Place extractor sleeve (221.179-1) on the connecting piece. In doing so,
make sure that the extractor sleeve is fixed by a stud bolt (7). See Fig. 3/I.
10.Screw the hex nut (9) onto the threaded spindle.
11.By turning hex nut (9), release the starting valve (5) and carefully lift it out.
See Fig. 3/II.
12.Detach the tool, extension (161.020) remains screwed onto starting valve
(5).
13.Screw on the threaded pipe (221.189-1) until it is seated on the exten-
sion. See Fig. 4/I.
14.Fasten cable (8) to lifting eye bolt (10) using shackle (002.454) and sus-
pend it from lifting tackle.
15.Screw the pilot rod (221.189-2) into the threaded pipe.
16.Remove starting valve (5) and place it down on the workbench. See Fig.
4/II.
17.Clean the locating hole in the cylinder head (6) with the cleaning tool
(055.133). In doing so, make sure that no foreign matter is allowed to
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drop into the combustion chamber. See Fig. 5

18.Check the valve seating surface in cylinder head (6), and grind in if neces-
sary. See Work Instructions 010.060.020-05.
19.Cover the opening in cylinder head (6).
Starting valve
20.Detach the suspension device (221.189) and the extension.

21.Remove O-rings (3 and 4).
22.Clean starting valve (5) externally and dismantle if necessary. See Work
General, M010.060.070-01-0002 3 (11)

Work sequence 3 - installing the starting valve

Initial situation All individual parts cleaned, inspected and replaced where necessary.

Work steps 1. Insert new O-ring (4), lubricated with clean lubricating oil, in ring groove.
In doing so, make sure that the O-ring is tensioned evenly around its en-
tire circumference and is not twisted.
2. Screw on the extension (161.020) until it is seated on starting valve (5).
See Fig. 6/I.
3. Screw on the threaded pipe (221.189-1) until it is seated on the exten-
sion.
4. Fasten cable (8) to lifting eye bolt (10) using shackle (002.454) and sus-
pend it from lifting tackle.
5. Screw the pilot rod (221.189-2) into the threaded pipe.
6. Lift up starting valve (5) and move it over cylinder head (6).
7. Remove the cover for the locating hole.
8. Insert starting valve (5) in the locating hole. See Fig. 6/I.
9. Install starting valve (5) until it makes contact. See Fig. 6/II.
11.Insert new O-rings (3) lubricated with clean lubricating oil into the ring
grooves. In doing so, make sure that O-rings are tensioned evenly around
their entire circumference and are not twisted.
12.Screw the lifting eye bolt (000.142) into thrust flange (2).
13.Fasten cable (8) to lifting eye bolt using a shackle (002.452) and suspend
it from the lifting tackle. Lift up thrust flange (2).
14.Move thrust flange (2) over cylinder head (6), and insert it into the locating
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hole. See Fig. 2/II.

15.Install the thrust flange (2) until it makes contact. See Fig. 2/I.
Starting valve
17.Apply MoS2 lubricant to the thread and contact surfaces of the hex nuts
(1), screw on, and tighten them alternately to the specified torque. See
18.After installing the starting valve, check for leaks. See Work Sequence 1.
4 (11) General, M010.060.070-01-0002

Work Sequence 4 - Installing the stud bolts

Initial situation Starting valve has been removed and cleaned. Stud bolts unscrewed and re-
moved; threaded holes cleaned.
Work steps 1. Prepare starting valve (5) and thrust flange (2) for installation.
Hardening of the securing compound

Carry out installation and tightening quickly. The hex nuts should be
tightened to the specified torque before the securing compound on the
screwed-in stud bolts has hardened. See manufacturer's instructions.
2. Apply “Loctite 638” securing compound to the male threads of stud bolts
(7), and screw them in until the specified protrusion (A) is reached. See
Fig. 1
3. Install starting valve (5) and thrust flange (2). See Work Sequence 3.
4. Apply MoS2 lubricant to the thread and contact surfaces of the hex nuts
(1), screw on, and tighten them alternately to the specified torque. See
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Starting valve
General, M010.060.070-01-0002 5 (11)

1 Hex nut
2 Thrust flange
3 O-ring
4 O-ring
5 Starting valve
6 Cylinder head
7 Stud bolt
A Bolt projection
Figure 1: Starting valve in the cylinder head
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Starting valve
6 (11) General, M010.060.070-01-0002

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2 Thrust flange 7 Stud bolt

3 O-ring 8 Cable
Starting valve
5 Starting valve I-II Work steps

6 Cylinder head
Figure 2: Removal/installation of the thrust flange
General, M010.060.070-01-0002 7 (11)

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Starting valve
4 O-ring seal 6 Cylinder head 9 Hex nut M24

5 Starting valve 7 Stud bolt I-II Work steps
Figure 3: Removing the starting valve
27021604772754827
8 (11) General, M010.060.070-01-0002

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Starting valve
4 O-ring 6 Cylinder head 10 Lifting eye bolt

5 Starting valve 8 Cable I-II Work steps
Figure 4: Removing the starting valve
General, M010.060.070-01-0002 9 (11)

6 Cylinder head
Figure 5: Cleaning the locating hole in the cylinder head
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Starting valve
10 (11) General, M010.060.070-01-0002

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Starting valve
4 O-ring 6 Cylinder head 10 Lifting eye bolt

5 Starting valve 8 Cable I-II Work steps
Figure 6: Installing the starting valve
27021604772754827
General, M010.060.070-01-0002 11 (11)

27021604772754827
2019-06-11 - de
Starting valve
General, M010.060.070-01-0002
Starting valve
Summary
Execute work on time according to the maintenance schedule, ensure/ re-
Starting valves are to be checked at regular intervals and overhauled, if neces-
sary.
disassembly of components,
replacement of sealing rings/sealing elements,
assembly of components.
Tools/aids required
1 Socket spanner insert 24x12.5L 001.768 Standard

Work sequence 1 - Dismantling the starting valve

Initial situation Starting valve is removed.
Work steps 1. Clamp starting valve in a vice using two surfaces of the valve cone (10).
2. Unscrew hexagon nut (1), thus releasing compression spring (2).
2016-11-28 - de
3. Remove piston (14) from valve taper (10).

4. Remove casing (3) with compression spring (2).
5. Remove sealing rings (4 and 7) from piston (14).
Starting valve
6. Clean all individual parts, check for attrition and damage.

7. Check valve seat with touching test.
Grinding the valve seat If grinding in is necessary, carefully clamp casing (3) in vice without damaging
any sealing faces. Apply grinding paste on valve seat. Install valve taper (10)
with piston (14) without compression spring and sealing rings (4 and 7) in the
casing. Rotate valve taper to and fro. Raise valve cone in the meanwhile, so
General, M010.060.070-02-0002 1 (3)

that grinding paste can be redistributed. Remove as little material as possible

and grind only until a uniform matt grey ring face has appeared (check with
touching test). After grinding in, carefully clean valve taper, casing and piston.
Work sequence 2 - Assembling the starting valves

Initial situation All individual parts cleaned, inspected and replaced where necessary.
Work steps Assembly of the starting valve is basically carried out in reverse order to re-
moval. The following must be observed when doing so:
▪ Install new sealing rings (4 and 7) in piston (14) (see Work Sequence 3).
▪ Coat the thread and contact faces of hex nut (1) with MoS2 lubricant,
screw on and tighten them to the specified torque. See Work Instructions
010.000.003-05.
Work sequence 3 - Mounting of the sealing rings (4 and 7)

Work steps 1. Insert new O-rings (5 and 8) oiled with clean lube oil into the correspond-
ing sealing ring groove. In doing so, make sure that O-rings are tensioned
evenly along their entire circumference and are not twisted.
Burns by hot oil

Placing and removing the PTFE rings in/from the hot oil bath may res-
ult in burns.
• use suitable additional means for placing and removing
9007206263561227
2. Heat up the PTFE rings (6 and 9) in oil to 80°-100°.

3. Pull PTFE rings over piston (14) into the respective sealing ring groove.
4. Reshape the expanded PTFE rings (6 or 9) by placing the piston (14) into
the oiled casing (3).
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Starting valve
2 (3) General, M010.060.070-02-0002

1 Hexagon nut (self-locking)

3 Casing
4 Sealing ring
7 Sealing ring
10 Valve cone
14 Piston
Figure 1: Starting valve
4 Sealing ring
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5 O-ring
6 PTFE ring
7 Sealing ring
8 O-ring
9 PTFE ring
Starting valve
14 Piston
Figure 2: Piston with sealing rings
9007206263561227
General, M010.060.070-02-0002 3 (3)

9007206263561227
2016-11-28 - de
Starting valve
General, M010.060.070-02-0002

51353870603
1 (1)

Ignition pressures
determine
Summary
Record and assess operational data, detect problems on (influencing) sub-as-
semblies /systems.
Ignition pressures are important measures for the mechanical loading of the
engine. They are closely connected to important operating values and allow
conclusions as to the condition of components and systems to be drawn.
Recording pressures,
Collating operational data and
Assessing results.
Tools/aids required
1 Ignition pressure measuring device EPM-XP/ 419.058 Option
MAN
1 Ear defenders - Inventory
Preliminary remarks
Ignition pressures are an important benchmark for the mechanical loading of
the engine. They are closely connected to important operating values and al-
low conclusions as to the condition of components and systems to be drawn.
They must be determined with an ignition pressure meter at regular intervals,
in accordance with the maintenance schedule. When evaluating, both the ab-
solute values and the differences from cylinder to cylinder are important.
The calibration interval for the ignition pressure measuring device should be
one year.
Work sequence 1 - Recording pressures

Preliminary remark Before using the ignition pressure measuring device IW-1550 (419.058), care-
2020-03-31 - de
fully read the manufacturer's operating instructions. See manufacturer's oper-

ating manual in Volume 015.010. Tools and spare parts – 015.010.110 Elec-
tronic ignition pressure measuring device.
Ignition pressures
Initial situation Engine running at required output in stable operation. Steady state of operat-
ing data is achieved.
Work steps
General, M010.060.080-01-0007 1 (2)

Danger of injury/danger of burning through fire jet

A fire jet escaping from indicator valve and explosive gases can cause
severe injuries and burnings.
• Ignition pressure measurements may only be taken by trained person-
nel.
• When opening the indicator valve do not stand directly in its longitudinal
axis.
• Do not step in front of the fire jet.
• Do not place any flammable/ignitable objects in the vicinity of the indic-
ator valve.
• Wear personal protective equipment.
1. Before indicating, open the indicator valve and keep it open for 2–3 igni-
tion strokes to remove carbon or combustion residues that have built up
in the indicator pipe.
2. Close the indicator valve.
3. Screw the pressure sensor of the measuring device onto the indicator
valve.
4. Record the ignition pressures according to the Operating Manual for the
relevant ignition pressure measuring device.
Work sequence 2 - Evaluation/Assessment

The ignition pressure of the engine depends on the current operating point
(output/speed), the ambient conditions, and the type of fuel used.
MAN Energy Solutions recommends performing the measurement at the time
intervals specified in the maintenance schedule.
The following operating values must be recorded for the measurement:
▪ Engine output
▪ Speed
▪ Fuel type
▪ Environmental conditions
A fault analysis is required if:
▪ individual cylinders deviate from the mean value by >±10 bar.
▪ the mean value deviates >±10 bar from previous measurements.
2020-03-31 - de
For fault analysis, the trend of the measured ignition pressures with the recor-
ded operating values of the engine is used. If there are abnormalities, consult
Ignition pressures
with MAN PrimeServ.

42909242635
2 (2) General, M010.060.080-01-0007

Indicator valve
opening and closing
Summary
Ensure correct execution of work. Open and close the indicator valve by using
a tool for determining the ignition and compression pressure.
The work includes: Opening the indicator valve, Collect performance data and
Closing the indicator valve.
Tools/aids required

Determining ignition pressure 010.060.080-01
Work sequence - Open/close indicator valve

Starting position Engine at desired performance level in stable operation. Steady state condi-
tion of operational values is reached.
Work steps 1. Unscrew the hand wheel and remove the protective cover (2). See Fig. 2.
2. Fit the socket wrench (419.011) on the indicator valve (6). See Fig. 3.
Danger of injury/danger of burning through fire jet

A fire jet escaping from indicator valve and explosive gases can cause
severe injuries and burnings.
• Ignition pressure measurements may only be taken by trained person-
nel.
• When opening the indicator valve do not stand directly in its longitudinal
axis.
• Do not step in front of the fire jet.
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• Do not place any flammable/ignitable objects in the vicinity of the indic-

ator valve.
• Wear personal protective equipment.
Indicator valve
9007206336821515
3. Open the indicator valve (6) with the socket wrench and hold it open for
two or three ignition impacts in order to remove soot or combustion com-
ponents that have accumulated in the indicator pipe (4).
4. Close the indicator valve (6) with the socket wrench.
L48/60CR, M010.060.080-02-0001 1 (4)

5. Screw the pressure sensor of the ignition pressure measuring device

(419.019 or 419.015) onto the indicator valve (6), open the indicator valve
and carry out the measurement. See Work Instructions 010.060.080-01.
6. Close the indicator valve (6) after the measurement is complete and un-
screw the pressure sensor.
7. Remove the box spanner.
8. Fit the protective cover (2) and screw the handwheel onto the indicator
valve (6). See Fig. 1.
1 Cylinder head cover 4 Indicator pipe

2 Protective cover 5 Cylinder head
3 Casing
Figure 1: Indicator valve with attached protective cover
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Indicator valve
2 (4) L48/60CR, M010.060.080-02-0001

1 Cylinder head cover 3 Casing

2 Protective cover 6 Indicator valve
Figure 2: Removal and installation of the protective cover
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Indicator valve
L48/60CR, M010.060.080-02-0001 3 (4)

3 Casing 6 Indicator valve

Figure 3: Indicator valve with mounted socket wrench
9007206336821515
2016-11-28 - de
Indicator valve
4 (4) L48/60CR, M010.060.080-02-0001


010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas 010.090 Camshaft and control drive
51353874827
1 (1)


51353883275
1 (1)

Camshaft
inspection
Summary
The running surfaces of the cams and bearing points must be checked at reg-
ular intervals.
The work includes:
Safety requirements
l Engine stopped
Tools/aids required

Loosening and tightening the camshaft bearing bolts 010.090.030-02
Work sequence - Inspection

Initial situation
Damage to the cam/camshaft

Replacement or re-adjustment of the cam/camshaft may only be car-
ried out by an MAN Energy Solutions service outlet or MAN Energy
Solutions personnel.
2018-09-18 - de
Work steps 1. Unscrew hex nuts (12) and detach cover (8) with washers (11) from cam-
shaft covering.
Danger of crushing due to moving parts

During operation or work on the engine, moving parts may cause acci-
Camshaft
dents involving severe injuries.

• Do not reach into/touch rotating parts
• If possible, secure or cover moving parts.
48/60CR, M010.090.020-01-0005 1 (3)

Checking the cams

Rotate the running gear with turning gear all the way round, checking
each of the individual cams.
2. Inspect running surfaces of the exhaust cams (1), triple cams (3) and inlet
cams (4) for damage.
3. Smoothen small areas of roughness with grindstone.
4. Inspect camshaft bearing bolts (2) and hex bolts (5) for correct tightening
and firm fit. See work instructions 010.090.030-02.
5. Check whether all bearing positions are supplied with adequate oil.
Using correct tightening torque

For the camshaft covering with attached impulse sensors for VVT
scanning, the fastening elements for the cover must be tightened to
the standard torque. Otherwise, it spacing of the impulse transmitter
may no longer be correct. See work instructions 010.000.003-07.
6. Attach cover of the camshaft covering correctly.

7. Check the remaining cams in the same way (see Steps 1 to 6).
Hot surfaces
Contact with hot surfaces can lead to serious burns.
• Engine operation is only permitted with the properly mounted insula-
tion / casing
• Maintain a safety area around the engine
18014416685493515
2018-09-18 - de
Camshaft
2 (3) 48/60CR, M010.090.020-01-0005

1 Exhaust cam 5 Hex bolt

2018-09-18 - de
2 Camshaft bearing bolt 8 Cover

3 Triple cam 11 Washer
4 Inlet cam 12 Hex nut
Figure 1: Cover and camshaft covering, camshaft with cams
18014416685493515
Camshaft
48/60CR, M010.090.020-01-0005 3 (3)

18014416685493515
2018-09-18 - de
Camshaft
48/60CR, M010.090.020-01-0005
Camshaft
Checking the cam setting
Summary
Checking the cam setting using the valve stroke.
The work includes:
Checking values against the setting scheme and recording them in the ma-
chine diary.
Safety requirements
l Engine stopped

2 Dial gauge (with long measuring needle) - Inventory
Work sequence – Checking the cam setting

Initial condition Pistons of the relevant cylinder in the ignition TDC (all valves closed). Valve
clearance checked and adjusted if necessary.
Work Steps 1. Move magnet holder to a suitable position on the rocker arm casing (1) or
cylinder head (6).
2. Fix the dial gauges in place in the magnet holder.
3. Place the measuring needles on the an thrust bearing (3) or valve rotator
(5).
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4. Set the dial gauges to zero.
Note engine sense of rotation

Only turn the crankshaft in the respective sense of rotation of the en-
gine.
Camshaft
General, M010.090.020-02-0001 1 (4)

Correction during turning

If a turn exceeds the 10mm valve stroke, turn the crankshaft back to
5mm before the valve stroke. Then, turn the crankshaft back to the
10mm valve stroke.
5. Turn the engine until the outlet valve (2) opens and a 10mm stroke is
reached.
– Read off the degree value on the flywheel. Note down the value in the
machine diary and compare it with the setting scheme.
6. Turn the engine further until the inlet valve (4) opens and a 10mm stroke
is reached.
7. Turn the engine further until the outlet valve (2) closes and has again
reached a stroke of 10mm.
8. Turn the engine further until the inlet valve (4) closes and has again
reached a stroke of 10mm.
9. Detach the tool.
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Camshaft
2 (4) General, M010.090.020-02-0001

1 Rocker arm casing 4 Inlet valve

2 Exhaust valve 5 Valve rotator
3 Thrust bearing
Figure 1: Checking the cam setting - figure shows 51/60DF
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Camshaft
General, M010.090.020-02-0001 3 (4)

2 Exhaust valve 5 Valve rotator

3 Thrust bearing 6 Cylinder head
4 Inlet valve
Figure 2: Checking the cam setting - figure shows 32/40
20748453003
2016-10-10 - de
Camshaft
4 (4) General, M010.090.020-02-0001


51353887499
1 (1)

Camshaft bearing screws

Check
Summary
Camshaft bearing screws must be checked at regular intervals using hydraulic
tensioners.
Safety requirements
▪ Engine stopped
surised)
▪ Voltage supply / voltage generation interrupted
Tools/aids required

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1 Single-ended open-jaw spanner 50 000.569 Option

Pertinent work instructions

L48/60CR, M010.090.030-01-0016 1 (8)

Dismantle and install high pressure pump 010.110.050-01

Work sequence – checking the camshaft bearing screws

served.
Initial situation The cover of the camshaft casing has been removed.
Casing on the exhaust counter side removed.
Work steps 1. Check the hex bolt (9) with the specified torque. Tighten to the specified
torque if necessary. See Work Instructions 010.000.003-05. See Fig. 1
and Fig. 2.
2. Remove two fuel lines (13). See Work Instructions 010.110.050-01.
3. Unscrew the union nuts on the fuel line (11) and remove the fuel line. See
Fig. 1.
4. Remove all pipelines and component parts obstructing the installation of
the hydraulic tensioners (009.664).
6. Clean the threads of camshaft bearing screws (4).

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7. Fit the thrust pieces (101.222) over the hex nuts (2). See Figs. 3, 4 and 5.
8. Check that the tensioning nut (030.539) is firmly attached to the piston of
the hydraulic tensioner, using an open-ended spanner (000.569). If the
tensioning nut is loose, retighten it with torque. See Work Instructions
015.000.030-02.
9. Screw the hydraulic tensioners onto the camshaft bearing screws (4). In
draulic tensioners.
structions 010.000.003-05.
2 (8) L48/60CR, M010.090.030-01-0016


structions 015.000.002-01.
sioners.
48189014155
13.Pump up the hydraulic tensioners until the hex nuts (2) can be released.
pressure. The release pressure must not be more than 7% below or
more than 5% above the tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.001-01.
15.Tighten the hex nuts (2) hand-tight using a tommy bar (009.068) through
the cut-out in the thrust pieces.
19.Fit the protective caps (1) on the camshaft bearing screws (4).
20.Attach the fuel lines (13). See Work Instructions 010.110.050-01.
21.Attach the fuel line (11).
22.Refit all pipelines and component parts previously removed for the install-
ation of the hydraulic tensioners.

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L48/60CR, M010.090.030-01-0016 3 (8)

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1 Protective cap 6 Bearing cover 11 Fuel line

2 Hex nut 7 Hex nut 12 Threaded socket
3 Crankcase 8 Camshaft casing 15 Fuel line
4 Camshaft bearing 9 Hex bolt 19 High-pressure fuel pipe
screw
5 Bearing body 10 Bearing bracket
Figure 1: Camshaft bearing and cam follower bearing
4 (8) L48/60CR, M010.090.030-01-0016


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1 Protective cap 5 Bearing body 9 Hex bolt

2 Hex nut 6 Bearing cover 10 Bearing bracket
3 Crankcase 7 Hex nut 13 Fuel line
4 Camshaft bearing 8 Camshaft casing 16 High-pressure pump
screw
L48/60CR, M010.090.030-01-0016 5 (8)

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4 Camshaft bearing 7 Hex nut 9 Hex bolt

screw
16 High-pressure pump
Figure 3: Camshaft bearing screws with attached hydraulic tensioners – high-pressure pump area
6 (8) L48/60CR, M010.090.030-01-0016


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screw
17 Rail bracket
Figure 4: Camshaft bearing screws with attached hydraulic tensioners – rail bracket area
L48/60CR, M010.090.030-01-0016 7 (8)

2 Hex nut 14 Hexagonal insert

3 Crankcase
4 Camshaft bearing screw A Bolt projection
Figure 5: Camshaft bearing screw with attached hydraulic tensioner
48189014155
2020-09-24 - de
8 (8) L48/60CR, M010.090.030-01-0016


Summary
For maintenance work, camshaft bearing bolts must be released and ten-
sioned using hydraulic tensioners.
Safety requirements
▪ Engine stopped
surised)
Required tools and auxiliary equipment


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1 Single-ended open-jaw spanner 50 000.569 Option

Pertinent work instructions

L48/60CR, M010.090.030-02-0016 1 (10)


Technical data
Warning messages
Danger of deflagration, explosions and fires as a result of

highly flammable media
Highly flammable media can cause deflagration, explosions and fires.
These may in turn lead to serious or even life-threatening injuries.
• Use personal protective equipment
• Ensure sufficient ventilation in the work area
• Remove escaped media immediately
• Open flames and sparks are prohibited
Serious, life-threatening injury as a result of media being ejec-

ted suddenly and under high pressure
Pressurised media can penetrate the skin and cause serious and even
life-threatening injuries.
• Block off the media system at the plant
• Depressurise the media system

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served.
2 (10) L48/60CR, M010.090.030-02-0016

Work sequence 1 – releasing the camshaft bearing screws

Initial situation The cover of the camshaft casing has been removed.
Casing on the exhaust counter side removed.
Work steps
Damage to the camshaft due to simultaneous release of two

adjacent camshaft bearings
When two adjacent camshaft bearings are released simultaneously,
the support of the camshaft is lost. This may result in material damage.
• When releasing the camshaft bearing screws, every other camshaft
bearing must remain tightened. The camshaft must remain supported.
Removing component parts 1. Remove two fuel lines (13). See Work Instructions 010.110.050-01.
2. Unscrew the union nuts on the fuel line (11) and remove the fuel line. See
Fig. 1.
3. Remove all pipelines and component parts obstructing the installation of
the hydraulic tensioners (009.664).
5. Clean the threads of camshaft bearing screws (4).
015.000.030-02.
8. Screw the hydraulic tensioners onto the camshaft bearing screws (4). In
draulic tensioners.
structions 010.000.003-05.
2020-09-24 - de

structions 015.000.002-01.
sioners.
L48/60CR, M010.090.030-02-0016 3 (10)

12.Pump up the hydraulic tensioners until the hex nuts (2) can be released.
pressure. The release pressure must not be more than 7% below or
more than 5% above the tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.001-01.
13.Using a tommy bar (009.068), turn the hex nuts (2) back by the turning-
back angle through the cut-out in the thrust pieces. See Work Instruc-
tions 010.000.003-05.
17.Unscrew and remove the hex bolt (9). See Fig. 1.
Work sequence 2 – Tensioning the camshaft bearing screws

Initial situation Hex nuts are bolted and tightened hand-tight; camshaft bearing screw
threads are cleaned. Fuel lines and plug-in fuel pipes are removed.
the bearing cover (6) and the bearing body (5), and between the bearing
body and the crankcase (3) is closed on both sides (measures less than
0.05 mm).
2. Coat the threads and contact surface of the hex screw (9) with lubricant.
3. Screw in the hex bolt (9) and tighten to the specified torque. See Work In-
structions 010.000.003-05. See Fig. 1.
4. Check the bolt protrusion (A) of the camshaft bearing screws (4). See
Technical Data. See Fig. 5.
015.000.030-02.
7. Screw the hydraulic tensioners (009.664) onto the camshaft bearing

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screws (4). In doing so, ensure that the thrust pieces are centrally aligned
structions 015.000.002-01.
sioners.
48189068555
9. Start up the high-pressure pump and tension the camshaft bearing

screws (4) with the specified tensioning pressure. See Work Instructions
010.000.003-05 and 015.000.003-01.
4 (10) L48/60CR, M010.090.030-02-0016

10.Tighten the hex nuts (2) hand-tight using a tommy bar (009.068) through
the cut-out in the thrust pieces.
14.Fit the protective caps (1) on the camshaft bearing screws (4).
15.Attach the fuel lines (13). See Work Instructions 010.110.050-01.
16.Attach the fuel line (11).
17.Refit all pipelines and component parts previously removed for the install-
ation of the hydraulic tensioners.
18.Attach the cover of the camshaft casing (8). When fitting a cover with at-
tached impulse sensors for VVT scanning, the fastening elements for the
cover must be tightened with the standard torque. See Work Instructions
010.000.003-07.
19.Attach the covering on the exhaust counter side.

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L48/60CR, M010.090.030-02-0016 5 (10)

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1 Protective cap 6 Bearing cover 11 Fuel line

2 Hex nut 7 Hex nut 12 Threaded socket
3 Crankcase 8 Camshaft casing 15 Fuel line
4 Camshaft bearing 9 Hex bolt 19 High-pressure fuel pipe
screw
5 Bearing body 10 Bearing bracket
6 (10) L48/60CR, M010.090.030-02-0016


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1 Protective cap 5 Bearing body 9 Hex bolt

2 Hex nut 6 Bearing cover 10 Bearing bracket
3 Crankcase 7 Hex nut 13 Fuel line
4 Camshaft bearing 8 Camshaft casing 16 High-pressure pump
screw
L48/60CR, M010.090.030-02-0016 7 (10)

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screw
16 High-pressure pump
Figure 3: Camshaft bearing screws with attached hydraulic tensioners – high-pressure pump area
8 (10) L48/60CR, M010.090.030-02-0016


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screw
17 Rail bracket
Figure 4: Camshaft bearing screws with attached hydraulic tensioners – rail bracket area
L48/60CR, M010.090.030-02-0016 9 (10)

2 Hex nut 14 Hexagonal insert

3 Crankcase
4 Camshaft bearing screw A Bolt projection
Figure 5: Camshaft bearing screw with attached hydraulic tensioner – sec-
tional view
48189068555
2020-09-24 - de
10 (10) L48/60CR, M010.090.030-02-0016

Camshaft (thrust bearing)

inspecting
Summary
Check camshaft thrust bearings for condition/degree of wear to ensure
trouble-free operation of the engine. The axial clearance must be determined.
Removal of the camshaft thrust bearing
Check of the camshaft thrust bearing
Installation of the camshaft thrust bearing
Safety requirements
l Engine stopped
2 Assembly bolts 102.001 Standard

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1 Socket spanner insert 17x12.5L 001.754 Option

1 Set of feeler plates 000.454 Standard
1 Sealant (Rhodorsil silicone) - Option
1 Nylon rope - Inventory
1 Hammer - Inventory
L51/60DF, M010.090.030-03-0007 1 (12)


1 Medium-strength screw locking agent (Loctite - Option
243)

Impulse transmitter 010.290.010-01
Technical data
Bearing body Weight 110 kg
Casing Weight 90 kg
Thrust washer Weight 30 kg
Warning messages

Work sequence 1 – Removal of the camshaft thrust bearing

Initial situation Cylinder 1 is at ignition TDC. Cover on the camshaft casing is removed in the
area of the control drive.

Work steps 1. Remove all component parts that hinder the removal of the camshaft
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thrust bearing (e.g. cable guides and piping).

2. Remove the plate (4). Remove all impulse transmitters (24). See Work In-
structions 010.290.010-01.
3. Remove the oil drain line (17). See Fig. 3.
4. Mark the position of the cover (5) on the casing (20) with a needle pin.
5. Unscrew hex bolts (7) and remove cover (5). See Fig. 3.
6. Mark the front face of the sensor disc (10) using a marker pin.
7. Unscrew the hex bolts (26) with washers (25). Press out the sensor disc
(10) using suitable means. Remove sensor disc.
2 (12) L51/60DF, M010.090.030-03-0007

8. Remove dowel pin (8).

9. Unscrew two horizontally opposite hex bolts (14) with washers (15).
Screw the fitting pins (102.001) into the crankcase (3). Coat the fitting
pins with oil. See Figs. 4/I and 4/II.
10.Unscrew the remaining hex bolts (14) with washers (15).
11.Carefully pull out the casing (20) along the fitting pins. Make sure that the
parallel pins (27) do not fall out. See Figs. 4/III and 4/IV.
12.Suspend the casing (20) with a nylon rope from the hoist. Tension the
nylon rope slightly.
13.Remove casing (20) and place it on wooden support.
14.Remove nylon rope from casing (20).
15.Clean contact surfaces on casing (20) and thrust ring (13).
16.Measure and note the projection (C) between casing and thrust ring
(20/13) at several points. See Figure 7/I.
17.Clean contact surfaces on bearing body (16) and thrust washer (11).
18.Measure and note the projection (D) of the bearing body contact washer
(16/11) at several points. See Figure 7/II
19.Unscrew the hexagon socket screws (6). See Fig. 5/I.
20.Loop nylon rope around thrust washer (11). Attach nylon rope to hoist
and tension nylon rope slightly.
21.Remove the thrust washer (11). Make sure that the parallel pin (27) does
not fall out.
22.Remove nylon rope from thrust washer (11).
23.Clean contact areas on camshaft (21) and thrust ring (18).
24.Measure and note the protrusion (E) between camshaft and thrust ring
(21/18) at several points. See Figure 7/ III.
25.Calculate the axial clearance from the measurements in work steps 16,
18 and 24 and compare with the permissible clearance. See Volume
010.005 Engine – Operating Instructions 010.000.035-04.
26.Carefully pull bearing body (16) from the fitting pins, paying attention to
clamping sleeve (29). See Fig. 5/II
27.Suspend the bearing body (16) with a nylon rope from the hoist. Tension
the nylon rope slightly.

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28.Remove bearing body (16) and place it on wooden support surface.
29.Remove nylon rope from bearing body (16).
30.Remove the O-rings (22 and 23). See Fig. 6/I.
31.Clean all the components and check for damage. Replace if necessary.
32.If new thrust rings (13 or 18) are to be fitted, coat the thread of the
hexagon socket screws (12 or 19) with thread lock.
33.If new thrust rings (13 or 18) are to be fitted, screw hexagon socket
screws (12 or 19) into thrust rings and tighten them.
L51/60DF, M010.090.030-03-0007 3 (12)

Work sequence 2 – Check of the camshaft thrust bearing
Damage to the camshaft due to dirty bearing sleeve

If a dirty bearing sleeve is used, this can damage the camshaft.
• Machining of the bearing sleeve is generally prohibited.
• Damaged bearing sleeves must be replaced. It is recommended that
the bearing sleeve only be replaced by anMAN Energy Solutions ser-
vice outlet or by MAN Energy Solutions service personnel because the
bearing sleeve is pressed into the bearing body.
• After replacement of the bearing sleeve, check the camshaft and polish
it with a suitable abrasive material (grain less than 15 µm) if necessary.
Work steps 1. Clean the running surface of the bearing sleeve carefully, taking care not
to damage it.
2. Check the condition of the running surface. See Work Instructions
010.000.003-03.
Work sequence 3 – Installation of the camshaft thrust bearing

Initial situation Cylinder 1 is at ignition TDC. All individual parts are cleaned and checked.
Two fitting pins (102.001) are screwed into the crankcase. Fitting pins are lub-
ricated. Bearing sleeve checked and replaced if necessary.
Work steps 1. Insert new O-ring (22) into ring groove of the bearing body (16). See Fig.
6/I.
2. Suspend the bearing body (16) with a nylon rope from the hoist. Raise
bearing body.
3. Coat the contact area (H) on the bearing body (16) with sealant. See Fig.
8.
4. Align the bearing body (16) to the correct fitting position (clamping
sleeve (29)/bore) and push it onto the fitting pins (102.001). See Fig. 5/II.
5. Remove nylon rope from bearing body (16).
6. Oil the running surface of the bearing sleeve (9) liberally.
7. Carefully push the bearing body (16) into the crankcase (3), ensuring that
it is fixed in position by means of the clamping sleeve (29). See Fig. 5/II.
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8. Determine bearing sleeve clearance using thickness gauge (000.454) and

record in the operation notes. For maximum permissible clearance see
volume 010.005 Engine – Operating Instructions, 010.000.035-04.
9. Oil the running surface of thrust ring (18) liberally.
10.Oil the thrust washer (11) liberally in the area of the thrust rings (13 and
18).
11.Attach the thrust washer (11) to the hoist using nylon rope, lift the thrust
washer.
4 (12) L51/60DF, M010.090.030-03-0007

12.Place the thrust washer (11) on the camshaft (21). Ensure it is fixed in
place with the parallel pin (28). See Fig. 5/II
13.Coat the thread of the hexagon socket screws (6) with thread lock.
14.Screw the hexagon socket screws (6) into the camshaft (21) and tighten
them to the prescribed torque. See Work Instructions 010.000.003-05.
15.Remove nylon rope from thrust washer (11).
16.Coat the contact area (G) on the bearing body (16) with sealant. Ensure
that the area around the oil bore remains free. See Fig. 8.
17.Insert new O-ring (23) into bore of the bearing body (16). See Fig. 6/I.
18.Suspend the casing (20) with a nylon rope from the hoist. Lift casing.
19.Oil the running surface of the thrust ring (13) liberally.
20.Align the casing (20) to the correct fitting position (parallel pins (27)/bores,
asymmetric drilling pattern) and push it onto the fitting pins. See Figure 4/
IV.
21.Remove nylon rope from casing (20).
22.Slide the casing (20) into place through the fitting pins until it contacts the
bearing body (16), ensuring it is fixed in place with parallel pins (27). See
Fig. 4/III.
23.Apply lubricant to the thread and contact surface of all hex bolts (14).
24.Screw in the hex bolts (14) with washers (15) and tighten them to the pre-
scribed torque. See Work Instructions 010.000.003-05.
25.Unscrew fitting pins.
26.Screw in the two remaining hex bolts (14) with washers (15) and tighten
them to the prescribed torque. See Work Instructions 010.000.003-05.
See Fig. 4.
27.Place sensor disc (10) on top of the butting disc (11). In doing so, pay at-
tention to the marking indicating the front side, and make sure the bores
for the dowel pin (8) are in the same position. See work sequence 1, step
6. See figure 3.
28.Insert new dowel pin (8).
29.Apply lubricant to the thread and contact surfaces of the hex bolts (26).
30.Screw the hex bolts (26) with washers (25) into sensor disc (10) and
tighten them to the prescribed torque. See Work Instructions
010.000.003-05.
31.Coat the contact area (F) on the casing (20) with sealant.
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32.Place cover (5) on casing (20), paying attention to the marks on cover/
casing. See work sequence 1 - work step 4.
33.Apply lubricant to the thread and contact surfaces of the hex bolts (7).
34.Screw the hex bolts (7) into the cover (5) and tighten them to the pre-
35.Attach the oil return line (17).
36.Fit all impulse transmitters (24). Attach the plate (4). See Work Instruc-
tions 010.290.010-01.
37.Attach all detached component parts (wiring ducts, pipes, etc.). See work
sequence 1 - work step 1.
L51/60DF, M010.090.030-03-0007 5 (12)

1 Camshaft thrust bearing 3 Crankcase

2 Cover
Figure 1: Camshaft thrust bearing
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6 (12) L51/60DF, M010.090.030-03-0007

2 Cover 14 Hex bolt

3 Crankcase 15 Washer
4 Plate 16 Bearing body
5 Cover 17 Oil return line
6 Hexagon socket bolt 18 Thrust ring

7 Hex bolt 19 Hexagon socket bolt
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8 Dowel pin 20 Casing

9 Bearing sleeve 21 Camshaft
10 Sensor disc 22 O-ring
11 Thrust washer 23 O-ring
12 Hexagon socket bolt 24 Impulse transmitter
13 Thrust ring
Figure 2: Camshaft thrust bearing
L51/60DF, M010.090.030-03-0007 7 (12)

4 Plate 17 Oil return line

5 Cover 20 Casing
7 Hex bolt 24 Impulse transmitter
8 Dowel pin 25 Washer
10 Sensor disc 26 Hex bolt
11 Butting disc F Contact area
Figure 3: Camshaft thrust bearing – Removal/fitting
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8 (12) L51/60DF, M010.090.030-03-0007

3 Crankcase 16 Bearing body I-IV Work steps

14 Hex bolt 20 Casing
15 Washer 27 Parallel pin

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L51/60DF, M010.090.030-03-0007 9 (12)

3 Crankcase 21 Camshaft
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6 Hexagon socket bolt 28 Parallel pin

11 Thrust washer 29 Clamping sleeve
16 Bearing body I-II Work steps
10 (12) L51/60DF, M010.090.030-03-0007

12 Hexagon socket bolt 20 Casing

13 Butting ring 22 O-ring
16 Bearing body 23 O-ring
18 Butting ring I-II Work Steps

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L51/60DF, M010.090.030-03-0007 11 (12)

3 Crankcase 16 Bearing body C Projection

9 Bearing sleeve 18 Thrust ring D Projection
11 Thrust washer 20 Casing E Projection
13 Thrust ring 21 Camshaft I-III Work steps
Figure 7: Camshaft thrust bearing – Measuring the protrusions to determine the axial clearance
2020-08-06 - de
16 Bearing body H Contact area

G Contact area
Figure 8: Bearing body
18014421044546443
12 (12) L51/60DF, M010.090.030-03-0007

Camshaft bearing shells

inspecting
Summary
Bearing shells must be checked at regular intervals. The wear condition and
running profile will give a clue to the load ratios, lubricating oil care etc.
Checking bearing shell and
Assembling components.
Safety requirements
l Engine stopped
Tools/aids required

Loosening and tightening the camshaft bearing bolts 010.090.030-02

2016-11-28 - de
Technical data
Camshaft bearing bolt Weight 6 kg
Bearing cover Weight 16,8 kg
L48/60CR, M010.090.030-04-0003 1 (6)

Work sequence 1 - Dismantle and inspection of the camshaft bearing shell

Initial situation Cover of the camshaft casing removed.
Inspection of camshaft bearing shells

Never check two directly adjacent camshaft bearing shells at the same
time. Every other camshaft bearing must remain installed (the camshaft
must be supported at all times).
Work steps 1. Detach the lubricating oil pipe (12). See Fig. 1.
2. Release the camshaft bearing bolts (1). See Work Instructions
010.090.030-02.
3. Release and unscrew the hex bolt (13). See Figs. 1 and 2.
4. Support the bearing cover (8) using a wooden support (16). See Fig. 2.
5. Unscrew the hex nuts (9), remove the camshaft bearing bolts (1) from
above. See Fig. 2.
6. Take away the wooden support (16), take off the bearing cover (8) and
remove. See Fig. 3.
7. Remove the bearing shell (10) and place it on a clean surface.
8. Twist the bearing shell (4) out, ensuring it does not become damaged,
and place it on a clean surface.
Observe the direction of rotation of the bearing shells

When unscrewing the bearing shell (4), observe the direction of rota-
tion (position of the lug for affixing bearing shells). See Fig. 3.
9. Carefully clean the running surface of the bearing shells (4 and 10)
without damaging them.
10.Check the condition of the running surfaces. See Work Instructions
010.000.003-03.
Do not perform any rework on bearing shells

Do not perform any rework on bearing shells.

2016-11-28 - de

Replace bearing shells that are damaged or that have severe score
marks!
If there are score marks on the bearing shells, the camshaft must be
inspected and re-polished if necessary (polishing cloth with grain size
< 15 μm).
2 (6) L48/60CR, M010.090.030-04-0003

Work sequence 2 - Installing the camshaft bearing shells
New bearing shells

worked or otherwise machined in any way.
Initial situation Bearing shells and camshaft bearing bolts cleaned.

Work steps 1. Clean the contact face between the bearing cover (8) and bearing body
(5).
2. Thoroughly oil the running surface of the bearing shell (4) (the reverse side
of the bearing shell remains dry).
Pay attention when affixing bearing shells

Observe the correct position of the lug for affixing the bearing shells.
3. Twist in the bearing shell (4).

4. Thoroughly oil the running surface of the bearing shell (10) (the reverse
side of the bearing shell remains dry).
5. Place the bearing shell (10) into the bearing cover (8).
Installing the bearing cover correctly

Ensure correct installation of the bearing cover. The connection for the
lubricating oil pipe (12) must face the control side (CS).
When joining the bearing cover to the bearing body, take into account
the parallel pins (7). See Figs. 1 and 2.
18172056075
6. Place the bearing cover (8) into the cylinder crankcase (3) and raise it up
until it comes into contact with the bearing body (5). Support the bearing
cover using a wooden support (16). See Figs. 2 and 3.
7. Screw the hex nuts (2) onto the camshaft bearing bolts (1).
8. Insert the camshaft bearing bolts (1), screw on the hex nuts (9). See Fig.
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2.
9. Adjust the bolt projection (A). See Fig. 1.
10.Tighten the hex nuts (9) hand-tight.
11.Remove the wooden support (16).
12.Apply MoS2-lubricant to the threads and contact surfaces of hex bolts (2),
screw them in with washer (14), and tighten them with the specified
torque. See Fig. 1 and Work Instructions 010.000.003-05.
13.Tension the camshaft bearing bolts (1) see Work Instructions
010.090.030-02.
L48/60CR, M010.090.030-04-0003 3 (6)

14.Connect the lubricating oil pipe (12). See Fig. 1.
1 Camshaft bearing bolt 10 Bearing shell, bottom

2 Hex nut 11 Camshaft casing
3 Cylinder crankcase 12 Lubricating oil line
4 Bearing shell, top 13 Hex bolt
5 Bearing body 14 Washer
6 Camshaft 15 Bearing bracket
7 Parallel pin
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8 Bearing cover A Bolt projection

9 Hex nut ST Control side
Figure 1: Camshaft bearing and rocker arm bearing (Figure shows L48/60B)
4 (6) L48/60CR, M010.090.030-04-0003

1 Camshaft bearing bolt 13 Hex bolt

2 Hex nut 14 Washer
3 Cylinder crankcase 15 Bearing bracket
5 Bearing body 16 Wooden support
8 Bearing cover
9 Hex nut ST Control side
Figure 2: Camshaft bearing – Removal and installation of the camshaft bear-
ing bolts (Figure shows L48/60B)

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L48/60CR, M010.090.030-04-0003 5 (6)

3 Cylinder crankcase 7 Parallel pin

4 Bearing shell, top 8 Bearing cover
5 Bearing body 10 Bearing shell, bottom
6 Camshaft ST Control side
Figure 3: Camshaft bearing – Removal and installation of the bearing cover
(Figure shows L48/60B)
18172056075
2016-11-28 - de
6 (6) L48/60CR, M010.090.030-04-0003


51353891723
1 (1)

Control drive
inspecting
Summary
The camshaft drive must be checked at regular intervals for changes, the con-
tact pattern must be determined in order to detect malfunction causes early
and rectify them.
The work includes:
Safety requirements
l Engine stopped
Tools/aids required
1 Thickness gauges 0.05-1 000.451 Standard

Checking the bolts of the crankshaft gear wheel 010.030.010-06
Work sequence 1 - Checking the camshaft drive

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Initial situation Casing cap on control drive removed.

Work steps 1. Carry out a visual inspection of all gear wheels (1, 6 and 7).
2. Measure the rotating shoulder clearances with feeler gauges (000.451),
note them down, and compare with the prescribed nominal values. See
Volume 010.005 Engine - Operating Manual 010.000.035-04.
Control drive
3. Measure the bearing and axial clearances of the double spur wheel (6),
note down and compare with the specified target values. See Volume
010.005 Engine - Operating Manual 010.000.035-04.
4. Check the hex bolts (3 and 5) for secure fit with the specified torque. See
5. Check all the spray nozzles for perfect operation.
L51/60DF;L48/60B, M010.090.060-01-0004 1 (4)

6. Check the tightness of all bolted connections. Blow compressed air

through blocked spray nozzles.
Work sequence 2 - Overhaul work on the camshaft drive
Recommendation
We recommend having the control drive overhaul carried out at a cus-
tomer service support point, or by MAN Energy Solutions personnel.
Overhaul work on the control drive

During overhaul work requiring the interruption of the control drive
from the crankshaft to the camshaft drive, turn running gear only when
all push rods of the inlet and exhaust valves were removed.
Crankshaft gear wheel Check the crankshaft gear wheel (7). See Work Instructions 010.030.010-06.
2018-09-19 - de
Control drive
2 (4) L51/60DF;L48/60B, M010.090.060-01-0004

2018-09-19 - de
Control drive
1 Camshaft gear wheel 5 Hex bolt

2 Camshaft 6 Double spur wheel
3 Hex bolt 7 Crankshaft gear wheel
4 Axle 8 Crankshaft
Figure 1: Control drive
L51/60DF;L48/60B, M010.090.060-01-0004 3 (4)

18014405471619083
2018-09-19 - de
Control drive
4 (4) L51/60DF;L48/60B, M010.090.060-01-0004


010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas
010.100 Valve drive
51353900555
1 (1)

010.100 Valve drive


51353904779
1 (1)

Rocker arm casing with control levers

Summary
Impart necessary knowledge, Ensure correct execution of work.
Rocker arm casings are to be checked in the course of the service and main-
tenance work and replaced if necessary.
fitting components.
Safety requirements
l Engine stopped
Tools/aids required
1 Fixing screw M16 111.132 Standard
1 Carrier 111.130 Standard
1 Closing cover 055.143 Standard

1 Suspension link 002.481 Standard
1 Adapter 12.5x20 001.927 Option
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1 Screwdriver bit 22x25 001.861 Standard
1 Rubber mallet - Inventory
V48/60CR, M010.100.020-01-0001 1 (9)


1 Adhesive tape - Inventory
1 Screwdriver insert 19x12.5 - Inventory
1 Screwdriver insert 10x12.5 - Inventory
1 Anti-seize agent - Inventory
1 High temperature HSC plus lubricant - Inventory

Inspection and adjustment of valve clearance 010.100.020-02
Technical data
Rocker arm casing with rocker arms Weight 715 kg
Work sequence 1 - Inspection

Starting position Running gear of relevant cylinder has been turned to the ignition TDC position
(inlet and exhaust valves are closed).
Work steps ▪ Check valve clearance, threaded connections and rocker arm lubrication
at the intervals specified in the service schedule.
▪ Check the individual parts for wear every time they are removed and dur-
ing overhauling activities.
▪ Blow compressed air through oil bores in the rocker arms.
▪ Turn the engine with turning gear, checking whether inlet and exhaust
valves always follow the movements of the rocker arm or whether they re-
main fixed.
Work sequence 2 - Removing the rocker arm casing

Starting position Running gear of relevant cylinder has been turned to the ignition TDC position
(inlet and exhaust valves are closed).
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2 (9) V48/60CR, M010.100.020-01-0001

Work steps 1. Place the receptacle under charge air pipe section (3), unscrew locking
bolt (5) and drain condensed water from charge air pipe section. See Fig.
1.
2. Screw in locking bolt (5) including seal (4) , remove receptacle.
Removal of pipe coupling

Move the pipe coupling, depending on the space conditions, to the
charge air pipe section of the adjacent cylinder or on the charge air
pipe section of the rocker arm casing to be attached.
3. Release hexagon socket bolts (1 or 20) and push pipe couplings (2 or 21)
to the side. See Fig. 1.
4. Detach lube oil supply pipe from rocker arm casing (13) and secure it
against penetration of dirt.
5. Remove the fastening for indicator valve of the rocker arm casing (13)
(only on in-line engine).
6. Open cylinder head cover (14).
7. Insert fixing screw (111.131) through bearing block (9) and screw into the
inlet rocker arm (12) and tighten hand-tight. While doing so, slightly lift the
inlet rocker arm. See Fig. 4 and 5.
8. Insert fixing screw (111.132) through bearing block (9) and screw into the
outlet rocker arm (7) and tighten hand-tight. While doing so, slightly lift
the outlet rocker arm. See Fig. 4 and 5.
9. Place suspension device (111.130) onto rocker arm casing (13) and
fasten it with hexagon bolts (15 and 16). See Fig. 4 and 5.


structions
2016-11-07 - de
10.Fasten suspension link (002.481) with shackle (002.455) on carrier and

suspend lifting tackle from suspension element.
11.Screw the pilot rod (034.006) into the carrier.
12.Release and unscrew hexagon socket bolts (6 and 8). See Fig. 5.
13.Lift rocker arm casing (13) carefully, guiding with pilot rod.
14.Remove pipe couplings (2 or 21).
15.Detach rocker arm casing (13) and place it on a clean support surface.
V48/60CR, M010.100.020-01-0001 3 (9)

16.Block air entry into cylinder head (10) with closing cover (055.143), so
that no foreign matter can fall into the intake duct.
17.Detach carrier (111.130).
18.Clean rocker arm casing (13) and rocker (7 and 12) as well as charge air
pipe section (3).
19.Clean the sealing lips on pipe couplings (2 or 21) and check for damage,
renew pipe couplings if necessary.
Work sequence 3 - Attaching the rocker arm casing

Initial situation Rocker arm casing and rocker arms and the charge air pipe section are
cleaned, rocker arms are fixed in position with fixing screws. Sealing lips of
pipe couplings cleaned.

Work steps 1. Clean the resting surface on cylinder head (10).

2. Insert new O-rings (17, 18, and 19), lubricated with clean lubricating oil,
into ring grooves, ensuring that they are not twisted. See Fig. 6.
3. Place suspension device (111.130) onto rocker arm casing (13) and
fasten it with hexagon bolts (15 and 16). See Fig. 4 and 5.

structions
2016-11-07 - de

4. Fasten suspension link (002.481) with shackle (002.455) on carrier and

suspend lifting tackle from suspension element.
5. Screw the pilot rod (034.006) into the carrier.
6. Raise rocker arm casing (13) and drive it over cylinder head (10).
7. Attach pipe couplings (2 or 21). See Fig. 1.
8. Remove closing cover (055.143).
4 (9) V48/60CR, M010.100.020-01-0001

Fitting the rocker arm casing

Ensure proper fixing by two parallel pins (11) in the cylinder head when
assembling the rocker arm casing. See Fig. 6.
Moreover, ensure that the thrust pieces at the rocker arms engage in
the thrust cups of push rods.
9007206238219915
9. Lower rocker arm casing (13) carefully on cylinder head (10), guiding with
the pilot rod.
10.Coat the thread and contact surface of hexagon socket bolts (8) with
MoS2 lubricant, screw in and tighten them with the specified torque. See
11.Coat the thread and contact area of hexagon socket bolt (6) with MoS2
lubricant, screw in and tighten them to the specified torque. See Work In-
structions 010.000.003-05.
12.Detach carrier (111.130).
13.Adjust the valve clearance on inlet- and exhaust valves. See Work In-
structions 010.100.020-02.
14.Unscrew and remove fixing screws (111.131 and 111.132) after setting
the valve clearance.
15.Close cylinder head cover (14).
16.Attach lube oil supply pipe to rocker arm casing (13).
17.Mount indicator valve to rocker arm casing (13) (only on in-line engine).
18.Slide the pipe couplings (2 or 21) over the parting lines and align them
centrally. See Fig. 2.
19.Coat the thread and contact faces of the hexagon socket bolts (1 or 20)
with MoS2 lubricant and tighten them to the specified torque. See Work

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V48/60CR, M010.100.020-01-0001 5 (9)

1 Hexagon socket bolt 5 Screw plug

2 Pipe coupling 20 Hexagon socket bolt
3 Charge air pipe section 21 Pipe coupling
4 Seal 22 Casing on the charge air
cooler
Figure 1: Charge air pipe – charge air pipe section with pipe couplings (illus-
tration shows V-type engine – view top: tube couplings attached/view bot-
tom: pipe couplings moved)
2 Pipe coupling
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3 Charge air pipe section

Figure 2: Pipe coupling between the charge air pipe sections (sectional draw-
ing)
6 (9) V48/60CR, M010.100.020-01-0001

6 Hexagon socket bolt 11 Parallel pin

7 Outlet rocker arm 12 Inlet rocker arm
8 Hexagon socket bolt 13 Rocker arm casing
9 Bearing bracket 14 Cylinder head cover
10 Cylinder head
Figure 3: Rocker arm casing with rockers and charge air pipe section

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7 Outlet rocker arm 15 Hexagon screw M20x300

12 Inlet rocker arm 16 Hexagon screw M20x180
13 Rocker arm casing
Figure 4: Rocker arm casing with rocker arms and charge air pipe section -
Tools for assembly/ disassembly
V48/60CR, M010.100.020-01-0001 7 (9)

6 Hexagon socket bolt 10 Cylinder head

8 Hexagon socket bolt 13 Rocker arm casing
Figure 5: Rocker arm casing with rocker arms and charge air pipe section -
Deinstallation/ installation of the hexagon socket bolts
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8 (9) V48/60CR, M010.100.020-01-0001

10 Cylinder head 19 O-ring

11 Parallel pin
13 Rocker arm casing A Illustration for suspension
point for V-engine
17 O-ring B Illustration for suspension
point for in-line engine
(with cylinder head cover)

18 O-ring C Illustration for suspension
point for in-line engine
(without cylinder head
cover)
Figure 6: Attaching/detaching the rocker arm casing - Illustration "A" shows
suspension point for V-engine /Illustration "B" shows suspension point for in-
line engine (rocker arm casing with cylinder head cover)/Illustration "C" shows
suspension point for in-line engine (rocker arm casing without cylinder head
2016-11-07 - de
cover)
9007206238219915
V48/60CR, M010.100.020-01-0001 9 (9)

9007206238219915
2016-11-07 - de
V48/60CR, M010.100.020-01-0001
Valve clearance
checking and adjusting
Summary
Carry out the work in accordance with the maintenance plan in good time, en-
able/support economic working, prevent operational problems/damage.
Check the valve clearance at regular intervals and correct if required.
The work includes:
Checking /adjusting valve clearance.
Safety requirements
l Engine stopped
l Drive shaft secured to prevent it from rotating

1 Assistant Personnel 0,2
Tools/aids required
2 Setting gauge (exhaust valve) 0.9 113.139 Standard
2 Setting gauge (inlet valve) 0.4 113.324 Standard
1 Setting device 111.150 Standard
1 Socket wrench SW17 111.150-1 Standard
1 Socket wrench SW36 111.150-2 Standard
2018-02-12 - de

Valve clearance


48/60CR, M010.100.020-02-0009 1 (9)

Preliminary remark
If necessary, carry out an inspection and adjustment of the valve clearance,
when commissioning, if new parts are installed or the rocker arm casing is re-
fitted after maintenance.
Work Sequence 1 - Checking the valve clearance

Initial situation ▪ Engine cold (same temperature of all engine components), or
▪ Engine at operating temperature (temperature of all engine components
equalized).
Incorrectly adjusted valve clearance

With the engine at the operating temperature, an inspection/adjust-
ment of the valve clearance may be carried out at least 0.5 hours after
stopping. An inspection/adjustment of the valve clearance with engine
preheated is possible, however a new inspection/adjustment of the
valve clearance is absolutely imperative once the temperature of all en-
gine components is equalized. For this purpose the engine must be
operated minimum 0.5 hours. Incorrectly adjusted valve clearances
may cause reduced service life of the components within the valve
drive, as well as severe damage to the engine in case of a valve stem
break.
VVT in part-load position

If a VVT drive is fitted on the engine, it must be in the part-load position
when checking and adjusting the valve clearance.
Running gear of the cylinder concerned in ignition TDC position. Inlet and ex-
haust valves closed.
Work steps 1. Open cylinder head cover (5).
2. Insert fixing bolt (111.131) through bearing block (2) and screw into the
inlet rocker arm (3). While doing so, slightly lift the inlet rocker arm. See
Fig. 2 and 3.
outlet rocker arm (1). While doing so, slightly lift the outlet rocker arm.
2018-02-12 - de
See Fig. 2 and 3.

Valve clearance
Torque-tightening the fixing bolts

Tightening the fixing bolts to a particular torque is required so that the
inlet and outlet rocker arms can contact the push rods without any
clearance.
4. Tighten both fixing bolts to a torque of 40 Nm.
2 (9) 48/60CR, M010.100.020-02-0009

5. Measure and note down the valve clearance (A) of the inlet and exhaust
valves (8 and 9) between valve stem (11 and 12) and ball cup (10) with
thickness gauge (000.451). For specified nominal values, see Volume
010.005 Engine – Operating Manual 010.000.035-04.
6. If necessary, adjust the valve clearance. See Work Sequence 2.
7. Unscrew and remove both fixing bolts.
8. Close cylinder head cover (5).
Work Sequence 2 - Setting the valve clearance

Initial situation ▪ Engine cold (same temperature of all engine components), or
▪ Engine at operating temperature (temperature of all engine components
equalized).
Incorrectly adjusted valve clearance

With the engine at the operating temperature, an inspection/adjust-
ment of the valve clearance may be carried out at least 0.5 hours after
stopping. An inspection/adjustment of the valve clearance with engine
preheated is possible, however a new inspection/adjustment of the
valve clearance is absolutely imperative once the temperature of all en-
gine components is equalized. For this purpose the engine must be
operated minimum 0.5 hours. Incorrectly adjusted valve clearances
may cause reduced service life of the components within the valve
drive, as well as severe damage to the engine in case of a valve stem
break.
VVT in part-load position

If a VVT drive is fitted on the engine, it must be in the part-load position
when checking and adjusting the valve clearance.
Running gear of relevant cylinder turned to the ignition TDC position (inlet and
exhaust valves closed).
Work steps 1. Open cylinder head cover (5).
inlet rocker arm (3). While doing so, slightly lift the inlet rocker arm. See
Fig. 2 and 3.
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outlet rocker arm (1). While doing so, slightly lift the outlet rocker arm.
See Fig. 2 and 3.
Valve clearance
Torque-tightening the fixing bolts

Tightening the fixing bolts to a particular torque is required so that the
inlet and outlet rocker arms can contact the push rods without any
clearance.
9007217276919307
48/60CR, M010.100.020-02-0009 3 (9)

4. Tighten both fixing bolts to a torque of 40 Nm.

5. Adjust the valve clearance (A) at inlet valves (8) (see Fig. 5/I):
– Fit the box spanner (111.150-2) on hexagon nut (6).
– Insert another socket wrench (111.150-1) through the socket wrench
(111.150-2) and place it on valve adjusting screw (7).
– Fit the tool holder (008.180) onto the socket wrench (111.150-2).
– Loosen hexagon nut (6) by using the socket wrench (111.150-2),
while holding valve adjusting screw (7) with socket wrench
(111.150-1).
– Turn back valve adjusting screw (7).
– Remove the adjusting device (111.150).
– Loosen valve adjusting screw (7) at second inlet valve (8) in the same
manner.
– Push the adjusting gauges (113.324) parallel to both inlet valves (8)
between valve stem (11) and ball cup (10).
– Fit the socket wrench (111.150-2) on hex nut (6).
– Screw in valve adjusting screw (7) until ball cup (10) is resting without
clearance on the adjusting gauge.
– Fit the torque wrench (008.183) onto the socket wrench (111.150-2).
– With the adjusting gauge inserted, tighten the hexagon nut (6) to the
specified torque; while doing so, hold the valve adjusting screw (7) in
place with the socket wrench (111.150-1). See Work Instructions
010.000.003-05.
– Remove the adjusting device (111.150); the adjusting gauge (113.324)
remains inserted.
– Adjust the valve clearance (A) at the second inlet valve (8) in the same
manner.
– After adjustment of the valve clearance (A) at inlet valves (8), carefully
remove both adjusting gauges.
6. Adjust the valve clearance (A) at the exhaust valves (9) (see Fig. 5/II):
– Fit the tool holder (008.180) onto the socket wrench (111.150-2).
2018-02-12 - de
– Loosen the hex nut (6) using the socket wrench (111.150-2), while
holding valve adjusting screw (7) in place with another socket wrench
(111.150-1).
Valve clearance
– Turn back valve adjusting screw (7).

– Remove the adjusting device (111.150).
– Loosen valve adjusting screw (7) at second exhaust valve (9) in the
same manner.
– Push the adjusting gauges (113.139) parallel to both exhaust valves
(9) between valve stem (12) and ball cup (10).
4 (9) 48/60CR, M010.100.020-02-0009


– Screw in valve adjusting screw (7) until ball cup (10) is resting without
clearance on the adjusting gauge.
– Fit the torque wrench (008.183) onto the socket wrench (111.150-2).
– With the adjusting gauge inserted, tighten the hexagon nut (6) to the
specified torque; while doing so, hold the valve adjusting screw (7) in
place with the socket wrench (111.150-1). See Work Instructions
010.000.003-05.
– Remove the adjusting device (111.150); the adjusting gauge (113.139)
remains inserted.
– Adjust the valve clearance (A) at second exhaust valve (9) in the same
manner.
– After adjustment of the valve clearance (A) at the exhaust valves (9),
carefully remove both adjusting gauges.
7. Unscrew both fixing bolts (111.131 and 111.132) and remove.
8. Close cylinder head cover (5).
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1 Outlet rocker arm 5 Cylinder head cover

2 Bearing bracket 6 Hex nut
3 Inlet rocker arm 7 Valve adjusting screw
Valve clearance
4 Rocker arm casing

Figure 1: Rocker arm casing with rocker arms
48/60CR, M010.100.020-02-0009 5 (9)

1 Outlet rocker arm 8 Inlet valve

2 Bearing bracket 9 Exhaust valve
3 Inlet rocker arm
Figure 2: Rocker arm casing with rocker arms – adjusting tools
2018-02-12 - de
Valve clearance
6 (9) 48/60CR, M010.100.020-02-0009

1 Outlet rocker arm 3 Inlet rocker arm

Figure 3: Rocker arm casing with rocker arms – lifting the inlet and outlet
rocker arms
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Valve clearance
48/60CR, M010.100.020-02-0009 7 (9)

1 Outlet rocker arm

9 Exhaust valve A Valve clearance
Figure 4: Rocker arm casing with rocker arms - Adjusting the valve clearance
(Illustration shows the setting device fitted on the outlet rocker arm)
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Valve clearance
8 (9) 48/60CR, M010.100.020-02-0009

2018-02-12 - de
Valve clearance
1 Outlet rocker arm 11 Valve stem (inlet valve)

3 Inlet rocker arm 12 Valve stem (exhaust valve)
6 Hex nut
7 Valve adjusting screw I Illustration shows adjustment at inlet valve
10 Ball cup II Illustration shows adjustment at exhaust
valve
Figure 5: Adjusting the valve clearance
9007217276919307
48/60CR, M010.100.020-02-0009 9 (9)

9007217276919307
2018-02-12 - de
Valve clearance
48/60CR, M010.100.020-02-0009

51353909387
1 (1)

Push rods
Summary
Check components for quality/wear status, ensure /restore operating safety.
push rods are to be disassembled and assessed within the scope of mainten-
ance and repair work.
Checking parts/ components,
Safety requirements
l Engine stopped
Tools/aids required
1 Ratchet 12.5 008.200 Standard

Removing and installing the rocker arm casing with control 010.100.020-01
2016-11-07 - de
levers
Technical data
Push rod Weight 20,5 kg
Push rods
Work Sequence 1 - Disassembly of the push rod

Initial situation Cover of camshaft casing and rocker arm casing detached.
48/60CR, M010.100.030-03-0006 1 (5)


Work steps 1. Clean ring groove at the upper end of push rods (6).
2. Remove shackle (002.452) from clamping pieces (12 and 14).
3. Unscrew hexagon socket bolts (11) from suspension device (112.063).
4. Clean joint faces and contact areas on clamping pieces (12 and 14).
5. Fit clamping pieces (12 and 14) around push rod (6) and screw in hexagon
socket bolts (11). See Fig. 2.
6. Tighten hexagon socket bolts (11) with a torque of 15 Nm.
Joint faces of clamping pieces

After tightening the hexagon socket bolts, joint faces of clamping
pieces must rest one on the other without clearance.
7. Attach ropes (15) with shackle (002.452) to lifting eye bolts (16) and hook
ropes onto the lifting tackle.
8. Pull out push rod (6) carefully upwards, guiding the push rod by hand.
Make sure that the push rod and neighbouring engine components are not
damaged.
9. Remove push rod (6) completely and set down on clean support surface.
10. Detach suspension device (112.063).
11. Dismantle second push rod (6) in the same manner.
12. Clean push rods (6) and check the thrust cups.
Work sequence 2 - Installing the push rod

Initial situation Push rods cleaned.
2016-11-07 - de

Push rods

2 (5) 48/60CR, M010.100.030-03-0006

Work steps 1. Remove shackle (002.452) from clamping pieces (12 and 14).
2. Unscrew hexagon socket bolts (11) from suspension device (112.063).
3. Clean joint faces and contact areas on clamping pieces (12 and 14).
4. Fit clamping pieces (12 and 14) around push rod (6) and screw in
hexagon socket bolt (11). See Fig. 2.
5. Tighten hexagon socket bolts (11) with torque 15 Nm.
Joint faces of clamping pieces

After tightening the hexagon socket bolts, joint faces of clamping
pieces must rest one on the other without clearance.
6. Attach ropes (15) with shackles to lifting eye bolts (16) and hook them
onto the lifting tackle.
7. Oil the thrust cups of push rod (6).
8. Lift push rod (6) carefully and move over cylinder.
9. Insert push rod (6) carefully into push rod covering (5), guiding the push
rod by hand. Make sure that the push rod and neighbouring engine com-
ponents are not damaged.
10.Fit push rod (6) onto thrust piece (18) of cam follower (3).
12.Install second push rod (6) in the same manner.
13.Attach rocker arm casing, fitting thrust piece (18) of rocker arms (9) on
thrust cups of push rods (6). See Work Instructions 010.100.020-01.
14.Attach cover of the camshaft casing.
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Push rods
48/60CR, M010.100.030-03-0006 3 (5)

1 Cam 5 Push rods - casing 18 Thrust piece

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3 Cam follower 6 Push rod

4 Cylinder crankcase 9 Rocker arm
Figure 1: Push rods fitted
Push rods
4 (5) 48/60CR, M010.100.030-03-0006

6 Push rod 13 Parallel pin 16 Lifting eye bolt

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11 Hexagon socket bolt 14 Clamping piece I-III Work steps

M10x40
12 Clamping piece 15 Rope
Figure 2: Push rod - Removal/installation of the suspension device
18022186379
Push rods
48/60CR, M010.100.030-03-0006 5 (5)

18022186379
2016-11-07 - de
Push rods
48/60CR, M010.100.030-03-0006
Cam follower assembly with adaptor device at turning device

adaptor plate
Brief description
Various tasks must be performed on cam followers at regular intervals. For
this purpose, an adaptor device in connection with a turnover device is used.
The work includes:
Fitting the components.

1 Adaptor device 112.043 Option
2 Holder for butting disc 112.014 Standard
1 Mounting pin 112.029 Standard

Inspecting the rocker arms 010.110.020-01
Technical data
Cam follower assembly with adaptor device at turning device

Inlet and outlet rocker arm with bearings 243 kg
Weight
(rocker arm block with three rocker arms)
Inlet and outlet rocker arm with bearings and Weight 203 kg
lever
Inlet and outlet rocker arm with bearings, 197 kg
Weight
without lever
Work Sequence - Fitting the cam follower assembly

Initial situation Have an assembly and turnover device (055.130) ready. Cam follower as-
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sembly (5) removed and hanging on lifting tackle with installation and removal
device (112…). Holder (112.014) and mounting pin (112.029) fitted to the cam
follower assembly. See Work Instructions 010.110.020-01.
48/60CR, M010.100.030-06-0001 1 (7)


Work steps
Installation of adaptor
device

turnover device (055.130).
1. By turning the handwheel (12) on the shuttle gearbox (3), place the ad-
apter head (4) onto the assembly and turnover device (055.130) in such a
way that the bore for the locking latch (10) is horizontal. Fix adaptor head
(4) in this position with locking lever (7).
2. Open support bracket (11) and pull out locking latch (10).
3. Insert adaptor device (112.043) into the turnover device.
4. Slide locking latch (10) in the hole on the adapter head until it is engaged.
In addition, secure the locking latch with a cotter against falling out.
5. Close and clamp fixing bracket (11). See Fig. 1.
Fitting the cam follower as- 6. Disengage locking lever (7) from adapter head (4).
sembly 7. Turn adaptor device (112.043) using handwheel (12) by 90°, so that the
adaptor device is positioned horizontally. See Fig. 2.
8. Fix locking lever (7) in adapter head (4).
Before fitting cam follower assembly (5), ensure that the fol-
lowing prerequisites are fulfilled:
2016-11-07 - de
• Adaptor device (112.043) in horizontal position.

• Locking latch (10) is engaged and secured with a cotter pin.
• Fixing bracket (11) is clamped.
• Adapter head (4) is secured with locking lever (7).
adaptor plate
9. Carefully insert cam follower assembly (5) into the adaptor device using a
lifting tackle. During this process, ensure that the cam follower and rollers
of the cam follower assembly do not collide with the adaptor device and
therefore are not damaged. See Fig. 3.
2 (7) 48/60CR, M010.100.030-06-0001

10.Fix the cam follower assembly using hexagon head bolts (30) and
hexagon nuts (31). Tighten hexagon nuts (31).
11.Remove suspension device (112…) from the cam follower assembly.
12.By turning the handwheel, the cam follower assembly can be brought
into any desired position, but only if the locking lever (7) is flipped up-
wards, Locking positions every 45°.
Removing the cam follower 13.Disengage locking lever (7) from adapter head (4).
assembly from the adaptor 14.Position the adaptor device with assembly and turnover device (055.130)
device by turning handwheel (12), so that cam follower assembly (5) is vertical.
Fix adaptor head (4) in this position with locking lever (7). The adaptor
device position see in Fig. 4.
15.Sling the cam follower assembly with a rope (ideally at two points
between the bearing bracket and cam follower, so that during transport
the cam follower assembly is hanging horizontally), hang the rope on the
lifting tackle, and tension it lightly.
16.Unscrew hexagon nuts (31) and pull hexagon bolts (30) out of the cam
follower assembly.
17.Next, carefully lift the cam follower assembly out of the adaptor device
and place it on a suitable base.
2016-11-07 - de
adaptor plate
48/60CR, M010.100.030-06-0001 3 (7)

3 Shuttle gearbox 10 Locking latch 13 Collecting pan

4 Adapter head 11 Support bracket
7 Locking lever 12 Hand wheel
Figure 1: Turnover device with a fitted adaptor device
2016-11-07 - de
adaptor plate
4 (7) 48/60CR, M010.100.030-06-0001

3 Shuttle gearbox 10 Locking latch 13 Collecting pan

4 Adapter head 11 Support bracket
7 Locking lever 12 Hand wheel
Figure 2: Turnover device with a fitted adaptor device (adaptor device turned)
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adaptor plate
48/60CR, M010.100.030-06-0001 5 (7)

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3 Shuttle gearbox 11 Support bracket 31 Hex nut M20

4 Adapter head 12 Hand wheel
adaptor plate
5 Cam follower assembly 13 Collecting pan

7 Locking lever 30 Stud bolt M20x240
Figure 3: Turnover device with a fitted adaptor device (installation/removal of the cam follower assembly)
6 (7) 48/60CR, M010.100.030-06-0001

3 Shuttle gearbox 11 Support bracket 31 Hex nut M20

2016-11-07 - de
4 Adapter head 12 Hand wheel

5 Cam follower assembly 13 Collecting pan
7 Locking lever 30 Stud bolt M20x240
Figure 4: Turnover device with a fitted adaptor device (adaptor device in a vertical position)
18022609547
adaptor plate
48/60CR, M010.100.030-06-0001 7 (7)

18022609547
2016-11-07 - de
adaptor plate
48/60CR, M010.100.030-06-0001

51353913611
1 (1)

VVT drive
Summary
Insert/replace the components, process and install them professionally. Ex-
ecute work on time according to the maintenance schedule. Ensure correct
execution of work. Check components for quality/wear condition.
The work/working steps include: Removal of components, Dismantling and
Assembly, Attachment of components.
Safety requirements
l Engine stopped
Tools/aids required
1 Suspension gear 140.006 Standard
1 Ring spanner 60x345 000.838 Standard
1 Extension tube 000.864 Standard
1 Ring spanner SW55 008.809 Standard
1 Offset screwdriver (Torx 25) 000.430 Standard
1 Socket spanner insert (set) - Inventory
2016-06-29 - de


VVT drive

48/60CR, M010.100.050-01-0003 1 (11)

Technical data
Hydraulic cylinder Weight 17,6 kg
Valve block with bracket Weight 14,5 kg
Work Sequence 1 - Removal of the VVT drive
Starting position Power supply to hydraulic pump is disconnected (Hydraulic pump is switched
off via motor circuit breaker). Oil control system (hydraulic oil pipes and hy-
draulic hoses) for hydraulic cylinders (10) are depressurised. Hydraulic cylinder
must be in its extended position.
Work Steps 1. Unscrew hex nuts (4) from the cover (1) in front of the hydraulic cylinder
Removing the cover on (10) and valve block (22) and remove them with washers (3). See Fig. 1.
camshaft covering 2. Remove cap (1).
Depressurising pressure
accumulator (30)
Risk of injury. Risk of scalding.

Despite pressureless hydraulic oil pipes (5, 6), pressures of 60 bar are
enclosed in the pressure accumulators (30) of the valve block (22). If
these pressures are not removed, there is a risk of severe scalding and
injuries resulting in death. These pressures can be released using
manual valve actuation. See following points.
• Personal protective equipment (protective goggles, gloves) must be
worn
• Depressurise pressure accumulator
3. Slightly open bleed screws (23, 24) on the hydraulic cylinder (10).
4. Manually operate switching valves until the residual hydraulic pressure
has completely escaped from the pressure accumulators (30).
Removing the VVT drive
Risk of injury. Risk of scalding.

2016-06-29 - de
Pressurised hydraulic oil (approx. 60 bar) can cause serious injuries

resulting in death. The entire oil control system for the hydraulic cylin-
der must be depressurised before components are removed.
• Depressurise the entire oil control system for the hydraulic cylinder.
worn
VVT drive
5. Unscrew union nuts from the hydraulic oil pipes (5, 6), between bolt block
(9) and valve block (22) and remove hydraulic oil pipes.
2 (11) 48/60CR, M010.100.050-01-0003

6. Open ends must be closed with protection caps to prevent ingress of

dirt.
Mark hydraulic hoses!

Mark the allocation of hydraulic hoses prior to their removal, to ensure
that they can re-installed correctly and are not mixed up inadvertently.
7. Remove hydraulic hoses (7, 8). See Fig. 2.

8. Detach locking rings (13) from the axle (11) and remove axle from the
lever (12). See Fig. 3.
9. Unscrew two pressure sensors (28) from the bolt block (9) and place
them to one side in the camshaft chamber.
10.Unscrew hex bolts (16) of bearing brackets (19, 20) and remove plate
(17) with bolt block (9).
11.Remove lube oil pipes (29) with threaded socket.
12.Suspend hydraulic cylinder (10) through the swivel eye using suspension
gear (140.006), and fasten the suspension gear to the crane hook. Ten-
sion the suspension gear lightly.
13.Unscrew hex bolts (15) from camshaft bearing bracket (18) and remove
them with sleeves (14).
14.Pull out and remove bearing bracket (19) from the side of the bearing
journal of the hydraulic cylinder (10).
Avoid any damage!

During removing and installing the VVT drive, make sure that it does
not collide with anything, thus damaging parts.
15.Pull out hydraulic cylinder (10) from the side of the bearing bracket (20)
and lift out of the camshaft covering (2) with lifting gear and suspension
gear (140.006).
16.Unscrew hex bolts (15) from second camshaft bearing bracket (18) and
remove them with sleeves (14) and bearing bracket (20).
Work Sequence 2 - Refitting the VVT drive

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Initial situation Power supply to hydraulic pump is disconnected (Hydraulic pump is switched
off via motor circuit breaker). Hydraulic cylinder must be in its extended posi-
tion!
Work steps
VVT drive
Installing the VVT drive
48/60CR, M010.100.050-01-0003 3 (11)

Preventing any damage

During removal and fitting of the VVT drive, make sure it does not hit
any surface, resulting in damage to components.
1. Bolt the bearing bracket (20) to camshaft bearing bracket (18) using hex
bolts (15) and sleeves (14). Tighten the hexagon bolts (15) to the spe-
cified torque. See Work Instructions 010.000.003-05.
2. Suspend hydraulic cylinder (10) to the swivel eye using suspension gear
(140.006), and fasten the suspension gear to the lifting gear.
3. Lift hydraulic cylinder (10) and insert into the side of the bearing bracket
(20).
4. Push bearing bracket (19) on the side of bearing journal of the hydraulic
cylinder (10) and screw on to camshaft bearing bracket (18) using hex
bolts (15) and sleeves (14).
5. Remove suspension gear (140.006) from hydraulic cylinder (10).
6. Bolt block (9) and plate (17) to bearing brackets (19, 20) using hex bolts
(16).
7. Attach lube oil pipes (29) with threaded socket.
8. Attach hydraulic oil pipes (5, 6) between bolt block (9) and valve unit (22).
Tighten union nuts.
9. Attach hydraulic hoses (7, 8) between bolt block (9) and hydraulic cylinder
(10), ensuring that the proper connections are made. When removing,
pay attention to the marks that have been applied.
10.Install pressure sensors (28) in bolt block (9).
11.Ensure power supply to the hydraulic pump.
Bleeding the hydraulic cyl-
inder
Danger of crushing due to VVT movement

There is a danger that persons may reach into the hazardous area dur-
ing the VVT movement, and their limbs will be crushed.
• The VVT may be moved only by hand when it is ensured that there is
no one in the hazardous area.
• For V engines, a second person will always have to secure the hazard-
ous area.
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Risk of injury
When bleeding the hydraulic cylinder, forcefully escaping and splash-
ing hydraulic oil can cause injuries.
VVT drive

worn.
4 (11) 48/60CR, M010.100.050-01-0003

Preventing collisions during bleeding

When bleeding the hydraulic cylinder, collisions may occur when oper-
ating the hydraulic cylinder piston rod with the lever (12); damage may
result. This can be prevented by:
• Aligning the swivel eye of the hydraulic cylinder parallel to the groove of
the lever (12)
• Preventing collision
Loosening and tightening bleed screws

The bleed screws (23, 24) can be loosened and tightened by using the
offset screwdriver (000.430).
12.Slightly open both bleed screws (23, 24) with the offset screwdriver
(000.430).
13.Connect electrical connections to the hydraulic pump and start both end
positions of the hydraulic cylinder one at a time via engine control. See
relevant instructions on this in Volume 010.285 SaCoSone.
14.When the hydraulic cylinder (10) has reached the second end position,
the bleed screw on the depressurised side of the hydraulic cylinder must
be tightened.
15.Bring the piston of the hydraulic cylinder to its alternate end position via
the engine control. With the piston in this end position, tighten the
second bleed screw. See relevant instructions on this in Volume 010.285
SaCoSone.
16.Open both bleed screws again slightly.
17.Slightly retract the piston of hydraulic cylinder via the engine control again
to eliminate any remaining air pockets. Upon reaching the end position,
tighten the bleed screw (24). See relevant instructions on this in Volume
010.285 SaCoSone.
18.Slightly move the piston of hydraulic cylinder out via the engine control
again to eliminate any remaining air pockets. Upon reaching the end pos-
ition, tighten the bleed screw (23). See relevant instructions on this in
Volume 010.285 SaCoSone.
Fitting the axle (11)
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Turning facility for the eccentric shaft

Turning facilities for eccentric shaft are provided on the ends of the ec-
centric shaft line in the form of hexagon (25). See Fig. 5.
18022219147
VVT drive
19.Slightly (approx. 5-10 mm) retract the hydraulic cylinder (10) via the en-
gine control again, so that the axle (11) can be pushed into the bore of
lever (12). See relevant instructions on this in Volume 010.285 SaCo-
Sone.
48/60CR, M010.100.050-01-0003 5 (11)

20.Push in axle (11) in bore on lever (12) and swivel eye and secure with
locking rings (13). If necessary, turn the eccentric shaft at hexagon (25)
using ring spanner (000.838 for L48/60CR; 008.809 for V48/60CR), until
axle (11) can be pushed in. See Fig. 4 and 5.
21.Check the system for tightness and leakages.
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VVT drive
6 (11) 48/60CR, M010.100.050-01-0003

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1 Cover 4 Hex nut 22 Valve unit

2 Camshaft covering 5 Hydraulic oil pipe 30 Pressure accumulator
3 Washer 6 Hydraulic oil pipe
VVT drive
Figure 1: Fitting/removing the covers of camshaft covering
48/60CR, M010.100.050-01-0003 7 (11)

7 Hydraulic hose 10 Hydraulic cylinder 28 Pressure sensor

8 Hydraulic hose 23 Bleed screw
9 Bolt block 24 Bleed screw
Figure 2: Detaching/attaching the hydraulic hoses
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VVT drive
8 (11) 48/60CR, M010.100.050-01-0003

9 Bolt block 11 Axle 13 Locking ring

10 Hydraulic cylinder 12 Lever 29 Lubricating oil pipe
Figure 3: Detaching/attaching the axle
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VVT drive
48/60CR, M010.100.050-01-0003 9 (11)

9 Bolt block 15 Hex bolt 19 Bearing bracket

10 Hydraulic cylinder 16 Hex bolt 20 Bearing bracket
12 Lever 17 Plate
14 Sleeve 18 Camshaft bearing
bracket
Figure 4: Removing/fitting the hydraulic cylinder 2016-06-29 - de
VVT drive
10 (11) 48/60CR, M010.100.050-01-0003

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1 Cover 25 Hexagon
2 Camshaft covering 26 Hydraulic pump
VVT drive
Figure 5: Hexagon at the eccentric shaft line ends (illustration shows engine type L48/60CR)
18022219147
48/60CR, M010.100.050-01-0003 11 (11)

18022219147
2016-06-29 - de
VVT drive
48/60CR, M010.100.050-01-0003
Pulse pick-ups for VVT scanning

Summary
Do the work on time according to the maintenance schedule, clean the com-
ponents free of dirt/residues, ensure / restore operational safety.
Check impulse transmitters at regular intervals and replace if necessary. Prop-
erly functioning impulse transmitters need not be replaced.
Installing components.
Safety requirements
l Engine stopped
Tools/aids required
1 Claw wrench 19x200 001.675 Standard
1 Torch - Inventory

Work Sequence 1 - Removing the impulse transmitter
Initial situation Engine cooled down to room temperature. VVT actuator de-energized. VVT-
scanning-systems in each case on the first and the last cylinder per cylinder
bank.
Work steps 1. Unscrew hex nuts (4) and detach cover (1) with washers (3). See Fig. 1.
2019-10-23 - de
Removal of cover
Removal of the 1st impulse 2. Loosen and unscrew right hex nut (21) on impulse transmitter (11). See
transmitter Fig. 3.
3. Pull impulse transmitter out of sensor holder (13) towards the left. Ensure
that washers (19, 20) do not fall into the camshaft covering (5) or into the
crankcase.
4. Remove left hex nut (18) with washer (19) from the impulse transmitter.
5. Unscrew hexagon socket bolts on cable clamps in camshaft covering
and crankcase.
48/60CR, M010.100.050-02-0004 1 (6)

Mark the plug. Observe markings.

Do not mix up plugs (6) and impulse transmitters (11) when installing
them!
Otherwise the correct function of the VVT-scanning-system is no
longer provided.
Therefore, the plugs must be marked before removal so that they are
refitted in the same position from which they were removed.
Observe the markings (FL = Full Load, PL = Part Load) on crankcase
and sensor holder and ensure that they match!
6. Unscrew hexagon socket bolts (7) from the camshaft covering, and re-
move cable (12) and impulse transmitter through the bore in the camshaft
covering.
Removal of the 2nd impulse 7. Remove the second impulse transmitter in the same way. See points 1 to
transmitter 5.
Condition check 8. Check the condition of the cable, plug and impulse transmitter; replace
them if necessary.
Work Sequence 2 - Installing the impulse transmitter

Initial situation Impulse transmitters are removed. Cables, plugs and impulse transmitters
checked, and replaced if necessary. Measuring pin (22) positioned so that it is
on the impulse transmitter to be fitted.
Work steps Installation is essentially carried out in reverse order to removal.
Positions of plugs and impulse transmitters

With reference to the cable lengths and correct function of the VVT-
scanning-systems, it is required that both the plug and the impulse
transmitter are refitted in the same positions as they were removed.
For this purpose, observe the markings (FL, PL) on the crankcase and
sensor holder.
Installation of impulse 1. Insert impulse transmitter (11) through the bore in camshaft covering (5)
transmitter and carefully pull cable (12) through the bore.
2. Screw plug (6) with hexagon socket bolts (7) in the camshaft covering.
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Tighten hexagon socket bolts.

3. Screw left hex nut (18) onto the impulse transmitter. Push washer (19)
onto the impulse transmitter. See Fig. 3.
4. Push impulse transmitter with hex nut and washer into sensor holder (13).
5. Push second washer (20) onto the impulse transmitter from the right and
screw right hex nut (21) onto the impulse transmitter without tightening.
Screw hex nut (21) onto the impulse transmitter only until the contact sur-
face on the impulse transmitter coincides with the contact surface of hex
nut (21).
2 (6) 48/60CR, M010.100.050-02-0004

Spacing adjustment 6. Carefully slide the impulse transmitter forward up to measuring pin (22),
hold it in this position and screw it on left hex nut (18) up to the sensor
holder.
7. Press the left hex nut against the sensor holder, hold it, and simultan-
eously turn the impulse transmitter by 1.25 turns.
8. Screw on right hex nut (21) and washer (20) up to the sensor holder and
tighten. At the same time, hold left hex nut (18) so that the impulse trans-
mitter does not twist when tightening.
The required spacing (A) must be observed

The required spacing (A) between the impulse transmitter and the stop
is defined by the thread pitch of the impulse transmitter and the num-
ber of turns by which the impulse transmitter is to be turned back. The
spacing (A) must be between 1 mm and 1.5 mm.
9. Measure spacing between impulse transmitter and stop. If the spacing

does not correspond to the setpoint, it must be reset.
Radial alignment of impulse 10.Slightly loosen right hex nut (21) so that the impulse transmitter can be
transmitter moved radially.
11.Unscrew hex nut with collar (14) and align impulse transmitter with cent-
ring diameter on hex nut with collar (14). See Fig. 3.
12.Tighten the right hex nut (21), at the same time hold the left hex nut (18)
so that the impulse transmitter does not twist when tightening.
13.Screw hex nut with collar (14) on measuring pin (22) and tighten.
Installation of the 2nd im-
pulse transmitter
Positioning the measuring pin at the impulse transmitter to be

fitted
Before fitting the second impulse transmitter, move the measuring pin
to its position. Pulse pick-ups for VVT scanning
9007217276967307
14.Fit and adjust the second impulse transmitter in the same way.
Fixing the cable 15.Coat the thread of the hexagon socket bolts for cable clamps in the
crankcase and in the camshaft covering (5) with Loctite 243 and affix the
2019-10-23 - de
cable clamps in the crankcase and in the camshaft covering using

hexagon socket bolts.
16.Fasten loose cables with cable ties so that they cannot be touched and
frayed by moving components.
Installation of cover 17.Attach cover (1) to camshaft covering (5) using washers (3) and hex nuts
(4). Also make sure that the seal in the cover is clean, placed in the
groove and seals correctly.
48/60CR, M010.100.050-02-0004 3 (6)

1 Cover 4 Hex nut 7 Hexagon socket bolt

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2 Stud bolt 5 Camshaft covering

3 Washer 6 Plug
Figure 1: Detaching and attaching the cover and connector
4 (6) 48/60CR, M010.100.050-02-0004

5 Camshaft covering 13 Sensor holder 26 Bearing bracket

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6 Plug 14 Hex nut with collar FL Full Load

7 Hexagon socket bolt 15 Lever for measuring PL Part Load
head holder
11 Impulse transmitter 22 Measuring pin CW Clockwise
12 Cable 25 Measuring head holder CCW Counter Clockwise
Figure 2: Detaching and attaching the impulse transmitter
48/60CR, M010.100.050-02-0004 5 (6)

11 Impulse transmitter 15 Lever for measuring 21 Right hex nut

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head holder
12 Cable 18 Left hex nut 22 Measuring pin
13 Sensor holder 19 Washer 25 Measuring head holder
14 Hex nut with collar 20 Washer A Spacing
Figure 3: Installation and adjustment of the impulse transmitter
9007217276967307
6 (6) 48/60CR, M010.100.050-02-0004

VVT
block
Summary
Ensure correct execution of work. Enable emergency engine operation in
VVT-full-load position.
By means of the holder, the eccentric shaft of the VVT-system can be main-
tained in full-load position, when the drive is failed or removed.
proper assembly
and if necessary
disassembly.
Safety requirements
l Engine stopped
Tools/aids required
1 Holder long 112.034 Standard
1 Holder short 112.033 Standard
1 Axle 112.033-2 Standard
1 Cover 112.022-4 Standard
1 Ring spanner SW55 008.809 Standard
2016-06-29 - de


VVT
48/60CR, M010.100.050-03-0003 1 (6)


removal and installation of the VVT drive 010.100.050-01
Technical data
Holder long (112.034) Weight 14,1 kg
Holder short (112.033) Weight 11,4 kg
Preliminary remark
In advance The VVT must always be blocked with the holder in full-load position.
On V-engines, the holders must always be installed on both cylinder rows.
Use of holders In order to achieve this, the following allocation must be observed:
For in-line engines, the fol- The short holder (112.033) must be used for clockwise-rotating engines
lowing applies The long holder (112.034) must be used for anticlockwise-rotating engines
On V-engines, the following clockwise-rotating engines

applies for The short holder (112.033) must be used for cylinder bank A.
The long holder (112.034) must be used for cylinder bank B.
Anticlockwise-rotating engines
The long holder (112.034) must be used for cylinder bank A.
The short holder (112.033) must be used for cylinder bank B.
Fitting/removing the holders As there are two types of holder (short/long), they must be differentiated.
Mounting locations for the Cylinder 3 for 6- and 7-cylinder engine

holders for in-line engines Cylinder 5 for 8- and 9-cylinder engine
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Mounting locations for the Holders mounting locations

holders for V-engines
Cylinder bank A Cylinder bank B
Mounting location on cylinder
12-cylinder engine 3 4
VVT
2 (6) 48/60CR, M010.100.050-03-0003

Work Sequence 1 - Locking VVT in the full-load position (with a long / short holder)
Initial situation Hydraulic pump power supply is interrupted. Hydraulic cylinder removed.
Keep axle (13) and locking rings (14) from removal of hydraulic cylinder avail-
able for installing the holder. See Work Instructions 010.100.050-01.
Work steps 1. Remove all pipes preventing the holder from being attached and close
the open ends to prevent contamination.
2. Disconnect cabling for pressure sensors (28). Remove pressure sensors
(28) from the camshaft chamber. Illustration of the pressure sensors (28),
see Work Instructions 010.100.050-01.
Conditions for emergency operation with blocked VVT

In order for the emergency VVT operation to be detected via control
system SaCoS, the following conditions must be met:
• Pressure sensors (28) must be disconnected.
• As soon as the pressure sensors (28) are disconnected, the corres-
ponding sensor failures are displayed in the alarm list on the SaCoS
display.
Attaching the long holder 3. Insert axle (112.003-02) through bearing brackets (3, 4) and long holder
(112.034) (112.034), insert washers (7) on axle and secure axle with splint (8). See
Fig. 1.
4. Attach long holder (112.034) and bearing brackets together with hex
bolts (6) and sleeves (5) to bearing bracket (10). Tighten hex bolts (6). See
Fig. 1 and 2.
5. Push axle (13) into bore on lever (12) and holder. If necessary, turn the
eccentric shafts at hexagon using ring spanner (000.838 for L48/60CR;
008.809 for V48/60CR), until axle (13) can be pushed in.
6. Secure axle (13) with locking rings (14).
Attaching the short holder 7. Push axle (13) in bore on lever (12) and short holder (112.033) and secure
(112.033) with locking rings (14).
8. Then, turn the eccentric shafts at hexagon using ring spanner (000.838
for L48/60CR; 008.809 for V48/60CR), until bearing brackets (3, 4) can
be bolted to camshaft bearing bracket (10).
9. Attach short holder (112.033) and bearing brackets (3, 4) together with
hex bolts (6) and sleeves (5) to camshaft bearing bracket (10). Tighten
2016-06-29 - de
hex bolts (6). See Fig. 1 and 2.

Fitting the cover on cam- 10.Fit cover (1) to the camshaft covering (2), and screw it on with hex nuts
shaft covering and washers.
Start problems with emergency VVT operation

With blocked VVT in full-load position (= emergency VVT operation),
start problems may occur.
• If necessary, the engine can be started manually using the emergency-
VVT
start button.
48/60CR, M010.100.050-03-0003 3 (6)

Work Sequence 2 - Disabling the VVT locking (with holder long / short)
Initial situation Holder is fitted. Cover (1) of camshaft covering (2) attached. Hydraulic pump
power supply is interrupted. Hydraulic control system (hydraulic oil pipes for
hydraulic hoses) for hydraulic cylinders are depressurised.
Work steps 1. Unscrew the hex nuts and remove them complete with washers.
Removing the cover from 2. Remove the cover (1) of the camshaft covering (2).
camshaft covering
Attaching the long holder 3. Remove locking rings (14) from axle (13).
4. Remove axle (13) from lever (12) and long holder (112.033). Keep axle
(12) and locking ring (14) available for installation of the hydraulic cylinder.
5. Remove splints (8) and washers (7) from axle (112.033-2).
6. Remove hex bolts (6) and sleeves (5) from first bearing bracket and re-
move bearing bracket.
7. Remove holder from second bearing bracket and store together with axle
(112.033-2), washers (7) and splints (8). Keep removed bearing bracket
available for installation of the hydraulic cylinder.
Attaching the short holder 8. Remove splints (8) and washers (7) from axle (112.033-2) and push out
axle (112.033-2) from bearing brackets and short holder (112.034).
9. Unscrew the hex bolts (6) and washers (5) from bearing brackets (3, 4)
and detach bearing brackets (3, 4).
10.Turn the eccentric shafts at hexagon using ring spanner (000.838 for
L48/60CR; 008.809 for V48/60CR), until axle (13) can be removed from
lever (12).
11.Remove locking rings (14) from axle (13).
12.Push out axle (13) from lever (12) and short holder (112.033) and remove
short holder (112.033) and axle (12). Keep axle (12) and locking ring (14)
available for installation of the hydraulic cylinder.
Installing the hydraulic cyl- 13.Install and bleed hydraulic cylinder. See Work Instructions
inder 010.100.050-01.
14.Connect cabling for pressure sensors (28). Make sure that the cabling is
correctly connected.
Fitting the cover on cam- 15.Attach cover (1) of the camshaft covering (2) with hex nuts and washers.
shaft covering
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VVT
4 (6) 48/60CR, M010.100.050-03-0003

1 Cover 4 Bearing bracket 7 Washer

2 Camshaft covering 5 Sleeve 8 Cotter pin
3 Bearing bracket 6 Hex bolt 10 Bearing bracket for
cam follower
Figure 1: Attaching/removing the holder
2016-06-29 - de
VVT
48/60CR, M010.100.050-03-0003 5 (6)

1 Cover 4 Bearing bracket 14 Locking ring

2 Camshaft covering 12 Lever
3 Bearing bracket 13 Axle, top
Figure 2: Fitting / removing the axle on the lever
18022387083
2016-06-29 - de
VVT
6 (6) 48/60CR, M010.100.050-03-0003


010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas

51353917835
1 (1)


010.110.054 Common-Rail accumulator unit with fitted
components
51353922059
1 (1)

Cam follower
Removal and installation/inspection
Summary
Cam followers must be checked and/or replaced during maintenance.
Safety requirements
l Engine stopped
Tools/aids required
1 Assembly bolts 201.023 Standard
1 Holder for butting disc 112.014 Standard
1 Lever for inlet cam follower 112.087-3 Standard
1 Lever for high-pressure pump cam follower 112.087-4 Standard
1 Lever for outlet cam follower 112.087-5 Standard
1 Adjusting screws 112.087-13 Standard
3 Mounting pin 112.029 Standard
1 Tightening device 112.025 Standard
1 Spanner with head 112.026 Standard
1 Spanner with head 112.027 Standard
1 Head for hexagon socket bolt 001.867 Standard
2021-03-04 - de

Cam follower
2 Endless lifting sling 021.419 Standard

48/60CR, M010.110.020-01-0011 1 (23)


levers
Removal and installation of push rods 010.100.030-03
removal and installation of the VVT drive 010.100.050-01
Removing and installing the pulse pick-up for VVT-scanning 010.100.050-02
Technical data
Inlet and outlet rocker arm with bearings 243 kg
Weight
(rocker arm block with three rocker arms)
Inlet and outlet rocker arm with bearings and Weight 203 kg
lever
Inlet and outlet rocker arm with bearings, 197 kg
Weight
without lever
Warning messages

Risk of crushing due to unsecured high-pressure pump drive

There is a danger that people’s limbs may be crushed during assembly
work if the high-pressure pump drive, which is pre-tensioned by high
2021-03-04 - de
spring force, springs down.

• Secure the high-pressure pump drive with mounting bolts (201.023).
See the described work steps.
• Do not reach into the area directly beneath the high-pressure pump
Cam follower
drive
2 (23) 48/60CR, M010.110.020-01-0011

Leaks caused by escaping media

When opening pipelines, flanges, bolt connections etc., media may es-
cape and cause leakages. These may contaminate/damage compon-
ents.
• Close openings from which media could escape with suitable means
• Immediately dispose of escaping media and leakages
• Clean contaminated components
• Replace damaged components
Work sequence 1 – Removing the inlet and exhaust cam followers

Initial situation Rocker arm casings of respective cylinders removed. If removing the cam fol-
lowers located behind the oil control system for VVT, make sure that it is com-
pletely depressurised for removing its components. See Work Instructions
010.100.020-01 and 010.100.050-01.
Work steps 1. Remove all obstructing piping.
2. Unscrew the hex nut (4) on the camshaft casing cover (6) of the relevant
and adjacent cylinders and remove the cover (6), including the seal (7).
See Fig. 1.
Securing the high-pressure Risk of crushing due to unsecured high-pressure pump drive
pump drive with mounting 3. Turn the engine with turning gear to move the roller of the high-pressure
bolts (201.023) pump cam follower on the relevant cylinder to the point of cam lift of the
triple cam. See Fig. 2/I.
4. Screw in the mounting bolts (201.023), thereby securing the high-pres-
sure pump drive (9) in this position.
5. Turn the engine again until the roller (14) of the high-pressure pump cam
follower is on the cam base circle of the triple cam. See Fig. 2/II.
Decoupling the VVT drive When removing the cam follower assembly near the VVT drive, the connection
to the VVT drive must be disconnected and the VVT drive removed. It may be
necessary to remove the hydraulic control system for the VVT drive. Also see
6. Remove the locking ring (48) from both ends of the shaft (47) and remove
the shaft (47). To do this, the hydraulic cylinder must be in its extended
position. See Fig. 5.
7. Unscrew the four hex bolts (51) and remove them.
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8. Remove the VVT drive with hydraulic oil pipes (5) and place it on a clean
surface. See Fig. 5 and Work Instructions 010.000.050-01.
Removing the eccentric 9. Set the eccentric shafts to the full-load position (for engines with clock-
shafts (27) with mounting wise camshaft rotation) or to the part-load position (for engines with anti-
Cam follower
pins (112.029) clockwise camshaft rotation). Position of the eccentric shafts and bore (N)
for mounting pin (112.029), see Fig. 4.
10.Remove the push rods (16). See Work Instructions 010.100.030-03 and
Fig. 3.
11.Fix the eccentric shafts (27) to the cam follower assembly to be removed
and to the adjacent cam follower assembly using mounting pins
(112.029). In order to be able to insert the mounting pins (112.029) com-
48/60CR, M010.110.020-01-0011 3 (23)

pletely into the bore (N), the eccentric shafts (27) must be in the position
as shown in Fig. 4. To achieve this, the eccentric shafts can be turned
using a ring spanner. See Work Instructions 010.100.050-01.
Removing the coupling, in- 12.Unscrew the four cap screws (20) and remove the coupling (21). See Fig.
stalling the holder 6.
(112.014) 13.Unscrew the cap screws (25) (inlet cam follower side) with the spanner
(112.026 and 112.027) and remove the intermediate shaft (22). See Fig.
7.
14.Unscrew the cap screws (25) (exhaust cam follower side) with the span-
ner (112.026 and 112.027) and remove the intermediate shaft (22). See
Fig. 8.
15.Secure the exhaust cam follower (18) and the thrust ring (39) with the
holder (112.014) and hex bolts (26). See Fig. 9.
16.Loosen the two lower hex bolts (29) of the bearing bracket, and remove
them together with the washers (30) and the plate (28). See Fig. 9.
Remove VVT-scanning If the cam follower assembly with installed VVT-scanning system must be re-
moved, first remove the component parts (pulse pick-up, probe holder and
sensor holder) of the VVT-scanning system, which are installed on the cam
follower assembly. Also see Work Instructions 010.100.050-02.
Suspending the cam fol- 17.Check whether markings A-A and B-B on the suspension device
lower assembly (112.087) are arranged correctly in relation to each other. Only then will
the suspension device be assembled correctly. See Fig. 13/A-A and B-B.
18.Attach the endless belt strap (021.419) with shackle (002.453) to the cor-
rect suspension point (suspension point “3” (AV) for V engine or suspen-
sion point “5” (AL) for L engine) on the suspension device (112.087). See
Fig. 10.
19.Attach endless sling to hoist.
20.Lift the suspension device, position it and mount it to the bearing bracket
(11) using hex bolts (42). See Fig. 10 and Fig. 13.
21.Lift the inlet and exhaust cam followers and high-pressure pump cam fol-
lower (if present) from the cam using adjusting screws (112.087-13). See
Fig. 10.
22.Loosen the remaining hex bolts (32), and remove them together with the
washers (30). See Fig. 11.
Removing the cam follower DANGER Standing and driving under suspended loads is prohibited.
assembly 23.Move the inlet and exhaust cam followers using the suspension device
(112.087) horizontally until the parallel pins (33 and 34) of the bearing
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bracket (11) are released from the locating bores in the crankcase (8),
then move the inlet and exhaust cam followers carefully out through the
camshaft casing opening, guiding with the pilot rod (034.006). See Fig.
12.
Cam follower
24.Place the complete assembly on a clean workbench.

25.Remove the suspension device (112.087).
4 (23) 48/60CR, M010.110.020-01-0011

Work sequence 2 – checking inlet and exhaust cam followers

Work steps 1. Measure the axial clearance of the inlet and exhaust cam followers using
the feeler gauge (000.451); record and compare with the specified clear-
ance. See Volume 010.005 Engine – Operating Instructions
010.000.035-04.
2. Dismantle the inlet and exhaust cam followers. See Fig. 14.
3. Clean all individual parts.
4. Clean the oil bores using compressed air.
5. Check the running surfaces of the rollers for damage, and smooth them
with an oilstone if necessary.
6. Check the radial and axial clearance of the rollers. See Volume 010.005
Engine – Operating Instructions 010.000.035-04.
7. Measure the bores of the bearing sleeves in the cam followers (10, 17
and 18) and eccentric shaft (27), and calculate the clearances. If the
clearance has exceeded the permissible value, replace the bearing
sleeve. It is advisable to replace bearing sleeves at a MAN Energy Solu-
tions service outlet or have replacement performed by MAN Energy Solu-
tions service personnel.
Work sequence 3 – installing inlet and exhaust cam followers

Initial situation Eccentric shaft, running surface and contact faces of all individual parts com-
pletely clean. Oil bores free of dirt.
Work steps 1. Fit the left contact washer (36) with countersunk bolts (35) to eccentric
Assembling the cam fol- shaft (27). See Fig. 14.
lower assembly 2. Lubricate the eccentric shaft (27) and the locating bore for the eccentric
shaft in the bearing bracket (11) with clean lubricating oil.
3. Oil the new O-rings (38) with lubricating oil.
4. Insert the new O-rings (38), lubricated with lubricating oil, into the ring
grooves.
5. Insert the eccentric shaft (27) into the bore in the bearing bracket (11); in
doing so, mount the lever (41 or 44, if present) or the high-pressure cam
follower (10) (if present) with two thrust washers (39) onto the eccentric
shaft. Install the high-pressure pump cam follower as shown in Fig. 14
(with flat area, position U, facing upwards).
6. Mount the inlet cam follower (17) onto the eccentric shaft, and fix it with
butting discs (36) using the countersunk bolts (35).
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7. Align the lever (41 or 44) (if present) with the parallel pin (45) on the ec-
centric shaft (27), securing the parallel pin with the centre punch.
8. Apply MoS2 lubricant to the threads of the cap screws (40 or 46).
9. Screw the cap screws (40) into the lever (41), or screw the cap screws
Cam follower
(46) into the lever (44) and tighten them with the specified torque. See
48/60CR, M010.110.020-01-0011 5 (23)

10.Check the reference dimensions G=26 mm and H=154.9 mm, and cor-
rect them if necessary. Then brace the hex bolts (43) using hex nuts (42);
in doing so, coat the threaded surfaces of the hex bolts (43) with MoS2
lubricant, and tighten the hex nuts (42) with the prescribed torque. See
11.Mount the butting discs (39) and the exhaust cam follower (18) on the ec-
centric shaft (27) and secure with the holder (112.014).
Removing the eccentric 12.Check whether all eccentric shaft sections are in the same position. For
shafts (27) with mounting the position of the eccentric shaft and of the bore (N) for the mounting pin
pins (112.029) (112.029), see Fig. 4. If the positions do not match, the eccentric shaft
may be twisted. See Work Instructions 010.100.050-01.
13.Set the eccentric shaft (27) to the full-load position (for engines with
clockwise camshaft rotation) or to the part-load position (for engines with
anticlockwise camshaft rotation) and fix the eccentric shaft (27) with the
mounting pin (112.029). See Fig. 4.
Attach the suspension 14.Attach the endless belt strap (021.419) with shackle (002.453) to the cor-
device (112.087). rect suspension point (suspension point “3” (AV) for V engine or suspen-
sion point “5” (AL) for L engine) on the suspension device (112.087). See
Fig. 10.
15.Attach the endless belt strap (021.419) to the hoist.
16.Screw the guide rod (034.006) into the suspension device (112.087).
17.Fasten the suspension device (112.087) with the hoist and secure to
bearing bracket (11) using hex bolts (42). Guide the suspension device
with the pilot rod (034.006).
18.Lift the inlet and exhaust cam followers and the high-pressure pump cam
follower (if present) using the adjusting screws (112.087-13) so far that
mounting through the camshaft casing opening is possible.
Installing the cam follower DANGER Standing and driving under suspended loads is prohibited.
assembly 19.Lift the complete cam follower assembly.
20.Carefully move the complete assembly into the engine, guiding with the
pilot rod (034.006) until the parallel pins (33 and 34) of the bearing
bracket coincide with the locating bores in the crankcase (8). Mount the
complete assembly and bring it into contact with the crankcase.
21.Apply MoS2 lubricant to threads and contact faces of hex bolts (32).
22.Push the hex bolts (32) with washers (30) through the bores on the bear-
ing bracket, screw them into the crankcase (8) and tighten until hand-
tight. See Fig. 11.
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23.Lower the inlet and exhaust cam followers and the high-pressure pump
cam follower (if present) onto the cam contour carefully, using adjusting
screws (112.087-13).
Cam follower
24.Use the hoist to remove the suspension device (112.087).

25.Apply MoS2 lubricant to the threads and contact surface of the hex bolts
(29).
26.Screw in the hex bolts (29) with washers (30) through the bores on the
bearing bracket into the crankcase (8).
6 (23) 48/60CR, M010.110.020-01-0011

27.Tighten all hex bolts (29 and 32) to the specified torque. See Work In-
structions 010.000.003-05.
28.Detach the holder (112.014).
29.Apply MoS2 lubricant on the threads of the cap screws (25).
Damage caused by incorrect torque

If the spanner (112.026, 112.027) is used to tighten the cap screws (25),
then the specified value for the tightening torque taken from the Work
Instructions 010.000.003-05 must be multiplied by a factor of 0.73. If an
incorrect tightening torque is used, this may cause damage.
• Multiply the specified tightening torque by a factor of 0.73.
50547286283
30.Install the short intermediate shafts (22, 23) onto the eccentric shaft (on
inlet and exhaust cam follower side) using cap screws (25). See Fig. 7
and Fig. 8.
31.Tighten the cap screws (25) with the specified torque (see Work Instruc-
tions 010.000.003-05 x factor 0.73) using the spanner (112.026 and
112.027). See Fig. 7.
Attaching the coupling (21) 32.Check whether the coupling shell (19), the coupling (21) and the crank
journals of the intermediate shaft (22) are free of oil and grease. Clean if
necessary. These component parts must be completely free of oil and
grease during assembly.
33.Check whether the threads and contact surfaces of the new cap screws
(20) are grease-free. Clean if necessary. The new cap screws must be
completely free of grease during assembly. Use new cap screws be-
cause the cap screws must only be used once. See Fig. 16.
34.Fit the coupling (21) without the coupling shells (19) on the two short in-
termediate shafts so that the two coupling shells can be bolted with two
cap screws (20) each from the underside (the coupling must still be rotat-
able on the short intermediate shafts). The markings on coupling shells
must match those on couplings. Thus every coupling shell has its clearly
identified mounting location.
35.Turn the coupling so that the cap screw heads of the right coupling shell
are pointing vertically downwards. Only tighten the cap screws (20) in this
position, otherwise removal of the coupling with the camshaft casing fit-
ted is not possible. See Fig. 15.
36.Tighten all cap screws (20) hand tight.
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37.Check whether the edge distance A between the front surfaces of the
rollers and the cams is more than A=1 mm. The inlet and exhaust cam
followers of the adjacent assemblies must be positioned centrally on the
cam. See Fig. 6.
Cam follower
38.Check whether the gap between the coupling shells (19) and the coup-
ling (21) is equal at all points.
39.As described below, the cap screws (20) must be tightened gradually
with the torque wrench (008.185) (see also technical documentation from
the manufacturer in volume 010.010 … 010.190 engine components –
010.100.030 push rod and tappet):
– Tighten cap screws C and E with 330 Nm. See Fig. 15 and Fig. 16.
48/60CR, M010.110.020-01-0011 7 (23)

– Tighten cap screws D and F with 500 Nm. See Fig. 15 and Fig. 16.
– Tighten cap screws C and E with 500 Nm. See Fig. 15 and Fig. 16.
40.Check whether the edge distance A between the front surfaces of the
rollers and the cams is still more than A=1 mm. The inlet and exhaust
cam followers of the adjacent assemblies must be positioned centrally on
the cam. See Fig. 6.
41.Check whether the gap between the coupling shells (19) and the coup-
ling (21) is equal at all points.
42.Remove the mounting pins (112.029).
Installing the VVT 43.If the VVT drive or the oil control system for the VVT drive has been re-
moved, then reinstall it correctly. See Work Instructions 010.100.050-01.
44.When installing the cam follower near the VVT drive, the connection to
the VVT drive must be restored. To do this, the following work steps are
necessary:
– Re-mount the VVT drive (50) with hydraulic line (5).
– Restore the connection between the VVT drive (50) and the lever (44)
using the shaft (47), and fix the shaft with two locking rings (48). See
Fig. 5.
45.Check easy movement of all cam followers.
Installing the cam follower 46.During the installation of the inlet and exhaust cam follower with the high-
assembly with high-pres- pressure pump cam follower (10), remove the locking of the high-pres-
sure pump cam follower sure pump drive. To do this, the following work steps are necessary:
(10) – Turn the engine over with the turning gear until the injection cam of
the relevant cylinder is at the TDC position. See Fig. 2/I.
– Remove the mounting bolt (201.023).
Installing other detached 47.Install the push rods (16). See Work Instructions 010.100.030-03.
components 48.If components of the VVT scanning system were removed, they must be
installed in the same positions again. See Work Instructions
010.100.050-02.
49.Check that all lubricating points are supplied with adequate lubrication oil.
50.Re-mount all the pipes removed in Work Sequence 1.
Attaching the cover of the 51.Oil the new seal (7) with lubricating oil.
camshaft casing 52.Fit the oiled seal (7) in the ring groove on the cover (6).
53.Push the cover (6) with seal (7) onto the stud bolts (2) until it comes into
contact with the camshaft casing (1). See Fig. 1.
54.Screw the hex nuts (4) with washers (3) onto the stud bolts (2) and
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tighten the hex nuts.

Cam follower
8 (23) 48/60CR, M010.110.020-01-0011

1 Camshaft casing 4 Hex nut 7 Seal

2 Stud bolt 5 Hydraulic line
3 Washer 6 Cover
Figure 1: Removing and installing the camshaft cover
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Cam follower
48/60CR, M010.110.020-01-0011 9 (23)

8 Crankcase 11 Bearing bracket 14 Cam follower roller

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9 High-pressure pump 12 Cam

drive
10 High-pressure pump – 13 Camshaft I-II Work steps
cam follower
Cam follower
Figure 2: Attaching the high-pressure pump drive
10 (23) 48/60CR, M010.110.020-01-0011

15 Cylinder head 16 Push rod

Figure 3: Removing and installing the push rods
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Cam follower
48/60CR, M010.110.020-01-0011 11 (23)

1 Camshaft casing 17 Inlet cam follower 36 Thrust washer

10 High-pressure pump – 18 Exhaust cam follower N Bore for the mounting
cam follower pin (112.029)
11 Bearing bracket 27 Eccentric shaft
Figure 4: Attaching the eccentric shaft
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Cam follower
12 (23) 48/60CR, M010.110.020-01-0011

1 Camshaft casing 47 Shaft 50 VVT drive

5 Hydraulic line 48 Locking ring 51 Hex bolt
44 Lever 49 Joint head
Figure 5: Removing and installing the VVT drive
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Cam follower
48/60CR, M010.110.020-01-0011 13 (23)

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11 Bearing bracket 19 Coupling shell 51 Inlet cams

Cam follower
13 Camshaft 20 Cap screw 52 Exhaust cams

17 Inlet cam follower 21 Coupling 53 Cam follower roller
18 Exhaust cam follower A Spacing between the
cam follower roller and
the cam
Figure 6: Removing and installing the coupling
14 (23) 48/60CR, M010.110.020-01-0011

17 Inlet cam follower 23 Intermediate shaft B Tightening with

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112.026
18 Exhaust cam follower 25 Cap screw
22 Intermediate shaft A Tightening with I-II Work steps
112.027
Cam follower
Figure 7: Removing and installing the intermediate shaft
48/60CR, M010.110.020-01-0011 15 (23)

1 Camshaft casing 25 Cap screw

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18 Exhaust cam follower A Tightening with

112.027
23 Intermediate shaft B Tightening with I-II Work steps
112.026
Cam follower
Figure 8: Installing and removing the intermediate shaft
16 (23) 48/60CR, M010.110.020-01-0011

18 Exhaust cam follower 28 Plate 39 Thrust washer

26 Hex bolt 29 Hex bolt
27 Eccentric shaft 30 Washer
Figure 9: Attaching the exhaust cam follower; removing and installing the lower hex bolts on the bearing
bracket
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Cam follower
48/60CR, M010.110.020-01-0011 17 (23)

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1 Camshaft casing 11 Bearing bracket 18 Exhaust cam follower

Cam follower
10 High-pressure pump – 17 Inlet cam follower 42 Hex bolt

cam follower
AL Suspension point for L- AV Suspension point for V-
engine engine
Figure 10: Installing and removing the suspension device
18 (23) 48/60CR, M010.110.020-01-0011

30 Washer 32 Hex bolt

Figure 11: Fitting and removing the hex bolts
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Cam follower
48/60CR, M010.110.020-01-0011 19 (23)

1 Camshaft casing 11 Bearing bracket 34 Parallel pin

8 Crankcase 33 Parallel pin
Figure 12: Removing and fitting a cam follower assembly with high pressure pump cam follower
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Cam follower
20 (23) 48/60CR, M010.110.020-01-0011

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11 Bearing bracket 33 Parallel pin 34 Parallel pin

Cam follower
A-A Markings B-B Markings

Figure 13: Bearing bracket with cam followers and tool; markings A-A, B-B
48/60CR, M010.110.020-01-0011 21 (23)

10 High-pressure pump – 38 O-ring 45 Parallel pin

cam follower
11 Bearing bracket 39 Thrust washer 46 Cap screw
17 Inlet cam follower 40 Cap screw G, H Reference dimensions
18 Exhaust cam follower 41 Lever M Markings for full-load or
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part-load positions
27 Eccentric shaft 42 Hex nut U Flat area on the high-
pressure pump – cam
follower
35 Countersunk screw 43 Hex bolt M20x70
Cam follower
36 Thrust washer 44 Lever

Figure 14: Bearing bracket with cam followers (all versions)
22 (23) 48/60CR, M010.110.020-01-0011

17 Inlet cam follower 21 Coupling

18 Exhaust cam follower 22 Intermediate shaft
19 Coupling shell 23 Intermediate shaft
Figure 15: Tightening the coupling bolts
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20 Cap screw 21 Coupling

C – F Marking screws for tight-
ening sequence
Figure 16: Coupling – marking of screws
Cam follower
50547286283
48/60CR, M010.110.020-01-0011 23 (23)

50547286283
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Cam follower
48/60CR, M010.110.020-01-0011
High-pressure pump drive

removing and installing or dismantling and assembling
Summary
execution of work, check components for quality/wear condition.
The drive of the high-pressure pump is to be demounted in the course of the
service and maintenance work.
Separating parts/ components,
Safety requirements
l Engine stopped
2 Spindle 201.034-2 Standard
1 Thrust plate 201.034-3 Standard
1 Hexagon nut 201.034-5 Standard
2 Nut 201.034-15 Standard
1 Pliers for locking ring 002.165 Standard

2018-05-29 - de

48/60CR, M010.110.020-03-0004 1 (12)



Technical data
Reference dimension (A) Dimension 278,1 mm
Reference dimension (B) Dimension 20,0 ±0,1 mm
High-pressure pump drive Weight 90 kg
Flange Weight 49 kg
Roller tappet Weight 33 kg
Work sequence 1 - Removal and dismantling of the high-pressure pump drive

(dismantle on the engine)
Initial situation High-pressure pump and covers of the camshaft covering removed. The nuts
(201.034-15) for retaining the spindles (201.034-2) are unscrewed from them.
Hazard area in case of failure from pre-tensioned compression

spring
The high pre-tension of the compression spring may cause powerful
forces to be released axially in case of failure and thus cause severe
personal injuries.
• Axial alignment of the compression spring is only permitted for removal/
installation and must be kept to a minimum.
• Personal protective equipment must be worn.
• Wear safety goggles.
• Wear protective gloves.
2018-05-29 - de

• Secure or cover moving parts
Work steps 1. Turn the engine so the roller (20) of the rocker arm of the high pressure
pump (21) is on the cam base circle (G) of the triple cam (19). See Fig. 1.
2 (12) 48/60CR, M010.110.020-03-0004

Fitting the removal and in- 2. Fit the thrust piece (201.034-1) on the roller tappet (5). See Fig. 2.
stallation device (201.034)
Tighten spindles evenly

If both spindles (201.034-2) are not screwed in evenly, this can lead to
jamming and damage to parts.
• Screw in both spindles evenly.
• Do not exceed the maximum tightening torque of 30 Nm when screw-
ing in the spindles.
3. Insert both spindles (201.034-2) through the bores in the thrust piece and
screw them into the roller tappet (5) until the spindles rest on the thrust
piece. The permissible torque of 30 Nm must not be exceeded.
4. Put the thrust plate (201.034-3) over the thrust piece and place it on the
plate spring (6). See Fig. 2/I.
5. Screw the hex nut (201.034-5) onto the thrust plate up to contact.
Removal of the compres-
sion spring (8)
Do not overload components

If the maximum torque of 30 Nm is exceeded when screwing in the hex
nut (201.034-5), this will result in damage to components.
• Maximum tightening torque of 30 Nm not exceeded
6. Screw the hex nut (201.034-5) further and press down the compression
spring (8) with it.
7. Remove the locking ring (7).
8. Loosen the hex nut (201.034-5) and release the compression spring (8).
9. Unscrew the hex nut (201.034-5) and remove the thrust plate
(201.034-3).
10.Remove the spring plate (6) and the compression spring (8). See Fig. 2/II.
Removal of the flange (1) 11.Unscrew and remove three hexagon socket bolts (3). See Fig. 3/I.
12.Screw two lifting eye bolts (000.142) into the flange (1) and tighten them.
13.Fasten the endless belt straps (021.419) to the lifting eye bolts and attach
2018-05-29 - de
them to the lifting tackle.

14.Tension the endless belt straps (021.419) lightly.
48/60CR, M010.110.020-03-0004 3 (12)


Lift the flange slowly

If the flange (1) is lifted too quickly for the first 5 mm, the feather key
(18) could damage or wear out the crosspiece of the guide bush
groove.
• Lift the flange slowly and carefully for the first 5mm
• Remove the flange slowly and carefully
15.Detach the flange (1) and place it on a support. See Fig. 3.

16.Cover the opening in the cylinder crankcase (2).
17.Remove the endless belt straps (021.419).
18.Unscrew the lifting eye bolts.
Disassembling into indi- 19.Unscrew the countersunk bolts (11) and washer (12). See Fig. 4.
vidual parts 20.Remove the guide bush (10) from the flange (1). See Fig. 4/I.
21.Remove the plate spring (13) from the roller tappet (5).
22.Unscrew the hexagon socket bolt (15) from the feather key (18) and re-
move the feather key. See Fig. 4/II.
23.Remove the roller tappet (5) from the guide bush (10).
24.Remove the O-ring seals (14 and 16).
Cleaning, checking and 25.Clean all the components and check them for damage. Replace if neces-
measuring components sary. Check the feather key (18) and the groove for the feather key in par-
ticular.
26.Remove any ridges on the inside or outside edges.

28.Check the running surfaces of rollers (17) for damage, smoothing them
2018-05-29 - de
with oil stone if required.

29.Measure and make a note of the axial and radial clearance of the rollers
(17) and compare with the permissible values (see Volume 010.005 En-
gine - Operating Manual).
Replacement of components
If one of the measured clearances is greater than the permissible
value, install a new roller tappet.
4 (12) 48/60CR, M010.110.020-03-0004

Always change the roller tappet and the roller pin at the same
time
If the roller tappet and the roller pin are not changed as one complete
unit, this can result in damage to the components.
• Always change the roller tappet and the roller pin as one complete unit
Work Sequence 2 - Assembly and installation of the high pressure pump drive
Initial situation High-pressure pump, high-pressure pump drive and cover of the camshaft
covering removed. All individual parts are cleaned and free of ridges. Oil bores
are free of dirt. The roller (20) of the high-pressure pump rocker arm (21) is on
the cam base circle (G) of the triple cam (19).

• Secure or cover moving parts
Work steps 1. Oil new O-rings (14 and 16) with clean lubricating oil and insert them into
Assembling the roller tappet the ring groove. In doing so, make sure that they are tensioned evenly
along their entire circumference and not twisted.
2. Oil all moving individual parts with clean lubricating oil.
3. Oil the roller (17) and the roller pins. Pour in oil through the inlet bores,
turning the roller at the same time. Check that the roller moves easily.
4. Carefully push the roller tappet (5) into the guide bush (10) without tilting.
5. Apply MoS2 lubricant to the threads and the contact faces of the
hexagon socket bolt (15).
Mounting the feather key (18) correctly

Incorrectly mounted feather keys (18) can lead to damage.
• The feather key (18) must be in contact with the groove base of the
roller tappet (5).
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• The feather key (18) must be in contact neither with the lower nor the
upper end of the groove in the guide bush (10).
6. Insert the feather key (18) into the roller tappet (5), screw the hexagon
socket bolt (15) into the feather key (18) and tighten the hexagon socket
bolt (15) with the specified torque. See Fig. 4/II. See Work Instructions
010.000.003-05.
7. Check reference dimension “B”. See Fig. 4/II.
48/60CR, M010.110.020-03-0004 5 (12)

8. Check that the feather key (18) moves easily in the groove of the guide
bush (10).
Observe the positioning of the flange relative to the guide bush

In order for the guide bush to be secured on the flange, the grooves for
the hexagon bolt (11) and the washer (12) must line up.
• Position the guide bush correctly relative to the flange
• The parallel pin (31) must engage into the groove on the guide bush
• The grooves for the hexagon bolt (11) and the disc (12) are lined up
9. Insert the guide bush (10) into the flange (1). See Fig. 4/I.
10.Insert the spring disc (13) into the roller tappet (5).
Installing the guide bush 11.Screw two lifting eye bolts (000.142) into the flange (1) and tighten them.
with the flange 12.Fasten the endless lifting belt straps (021.419) to the lifting eye bolts and
suspend from the lifting tackle.
13.Tension the endless lifting belt straps (021.419) lightly.

The feather key (18) should not reach the end position
If the feather key (18) reaches the end position of the groove, the
groove for the feather key may be damaged.
• The feather key should not reach the end position in the groove at any
point throughout assembly.
14.Carefully lift the flange (1) and carefully allow the roller tappet to slide
2018-05-29 - de
downwards.
15.Remove the cover on the opening in the cylinder crankcase (2).
16.Carefully insert the flange (1) into the opening on the cylinder crankcase
(2). In the process, make sure that the parallel pin (30) engages in the
bores on the cylinder crankcase and the flange and is not damaged. See
Fig. 3/II.
17.Screw in three hexagon socket bolts (3) and tighten them to the specified
torque. See Fig. 3/I. See Work Instructions 010.000.003-05.
18.Remove the endless lifting belt straps (021.419) and unscrew the lifting
eye bolts (000.142).
6 (12) 48/60CR, M010.110.020-03-0004

Fitting the compression 19.Insert the spring plate (9) and the compression spring (8) into the guide
spring (8) bush (5). See Fig. 2/II.
20.Fit the thrust piece (201.034-1) on the roller tappet (5). See Fig. 2.
21.Oil the spindles (201.034-2) lightly with clean lubricating oil.
Tighten spindles evenly

If both spindles (201.034-2) are not screwed in evenly, this can lead to
jamming and damage to parts.
• Screw in both spindles evenly.
• Do not exceed the maximum tightening torque of 30 Nm when screw-
ing in the spindles.
22.Insert both spindles (201.034-2) through the bores in the thrust piece and
screw them into the roller tappet (5) until the spindles rest on the thrust
piece. The maximum permissible torque of 30 Nm must not be ex-
ceeded.
Hazard area in case of failure from pre-tensioned compression

spring
The high pre-tension of the compression spring may cause powerful
forces to be released axially in case of failure and thus cause severe
personal injuries.
• Axial alignment of the compression spring is only permitted for removal/
installation and must be kept to a minimum.
• Personal protective equipment must be worn.
• Wear safety goggles.
• Wear protective gloves.
23.Put the thrust plate (201.034-3) over the thrust piece and place it on the
plate spring (9). See Fig. 2/I.
24.Screw the hex nut (201.034-5) onto the thrust plate up to contact.
Do not overload components

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If the maximum torque of 30 Nm is exceeded when screwing in the hex

nut (201.034-5), this will result in damage to components.
• Maximum tightening torque of 30 Nm not exceeded
9007220478736907
25.Screw the hex nut (201.034-5) further and press down the compression
spring (8) with it.
26.Turn the hex nut (201.034-5) until the locking ring groove is visible.
48/60CR, M010.110.020-03-0004 7 (12)

27.Install the locking ring (7). In the process, ensure that the locking ring (7)
slides until it is fully in contact with the groove for the locking ring and is
sitting firmly.
28.Loosen the hex nut (201.043-5) and release the compression spring (8)
until the spring disc (9) is in contact with the locking ring (7).
29.Unscrew the hex nut (201.034-5) and remove the thrust plate
(201.034-3).
30.Unscrew both spindles (201.034-2) from the roller tappet (5) and unscrew
the thrust piece (201.034-1).
31.If retaining the spindles (201-034-2), screw the nuts (201.034-15) onto
them.
32.Check reference dimension A.
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8 (12) 48/60CR, M010.110.020-03-0004

1 Flange 19 Triple cam

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2 Cylinder crankcase 20 Roller of high-pressure

pump rocker arm
4 Stud bolt A Reference dimension
17 Roller G Cam base circle
Figure 1: High-pressure pump drive
48/60CR, M010.110.020-03-0004 9 (12)

1 Flange 7 Locking ring

5 Roller tappet 8 Compression spring
6 Spring plate I-II Work steps
Figure 2: Removing/installing the compression spring

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10 (12) 48/60CR, M010.110.020-03-0004

1 Flange 4 Stud bolt

2 Cylinder crankcase 30 Parallel pin
3 Hexagon socket bolt I-II Work steps
Figure 3: Removing/installing the flange

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48/60CR, M010.110.020-03-0004 11 (12)

1 Flange 15 Hexagon socket bolt

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5 Roller tappet 16 O-ring

10 Guide bush 17 Roller
11 Countersunk bolt 18 Feather key
12 Washer 31 Parallel pin
13 Spring plate B Reference dimension
Figure 4: Removing/installing and dismantling/assembling of the roller tappet
9007220478736907
12 (12) 48/60CR, M010.110.020-03-0004



components
51353926027
1 (1)

High-pressure pump
Summary
High-pressure pumps must be checked and/or replaced during maintenance.
Safety requirements
▪ Engine stopped
surised)
Tools/aids required
1 Removal and fitting device for high-pressure 204.041 Standard
pump
1 Strap 204.041-1 Standard
1 Tensioner 204.024 Standard
1 Power amplifier 008.030 Standard
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1 Protective cover 204.043 Standard

High-pressure pump

1 Lubricant (Molykote P37) - Option

48/60CR, M010.110.050-01-0006 1 (8)


levers
Removing and fitting resistance thermometer to/from high- 010.110.050-05
pressure pump
Dismantle and install high pressure fuel pipe 010.110.052-02
Removing and fitting resistance thermometer to/from high- 010.290.157-03
pressure pump
Technical data
High-pressure pump Weight 110 kg
Warning message

Work sequence 1 – Removing the high-pressure pump

Initial situation Casing of the injection system removed.
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Rocker arm casing located above the high-pressure pump to be removed is

High-pressure pump
dismantled. See Work Instructions 010.100.020-01.

Electrical connections on the high-pressure pump have been removed. See
The resistance thermometer on the high-pressure pump (if installed) has been
removed. See Work Instructions 010.110.050-05 or 010.290.157-03.
The high-pressure fuel pipes between the high-pressure pump and the com-
mon rail accumulator units have been dismantled. See Work Instructions
010.110.052-02.
Work steps 1. Open quick-fit couplings on splash deflector rings (25) and pull off splash
deflector rings from both fuel lines (3). See Fig. 2/I.
2 (8) 48/60CR, M010.110.050-01-0006

Removal of fuel lines (3) 2. Unscrew the cap screws (26 and 27) on both fuel lines (3).
3. Remove both fuel lines (3). See Fig. 2/II.
4. Remove the O-rings (28).
5. Clean ring grooves for O-rings (28).
Removal of high-pressure 6. Turn the engine so the roller (21) of the high pressure pump cam follower
pump (22) is in a cam base circle (G) of the triple cam (23). This means that the
high pressure pump drive (20) is unloaded as far as possible. See Work
Instructions 010.000.004-05. See Fig. 1.
7. Remove all pipes obstructing the removal of the high-pressure pump (1).
8. Bolt the pilot rod (204.042) to the high-pressure pump (1) using hex bolts
(8). See Fig. 3.
9. Screw the strap (204.041-01) fully into the high-pressure pump.
10.Screw the hex bolts (15) fully into the strap until they contact the valve
support of the high-pressure pump and tighten them. The hex bolts (15)
secure the strap to prevent it unscrewing.
11.Fasten the rope (9) with the shackle (002.452) to the strap.
12.Suspend the rope from the hoist.
13.Unscrew the hex nuts (4) from the stud bolts (6). See Fig. 2/I.
14.Before transporting, check that the shackle and the hex bolts (15) are
correctly fastened.
15.Carefully lift the high-pressure pump (1) off the flange (2) using the hoist
and remove. While removing the high-pressure pump, guide it with the
pilot rod (204.042).
16.Cover the resulting opening on the flange (2).
17.Place the high-pressure pump on a clean support surface.
18.Remove the O-ring (13) from the high-pressure pump. See Fig. 3.
19.Clean the ring groove for O-ring (13) on the high-pressure pump (1).
20.Dismantle the rope (9) with the shackle (002.452) from the strap.
21.Unscrew the hex bolts (15) and unscrew the strap from the high-pressure
pump.
22.Unscrew the hex bolts (8) from the high-pressure pump (1) and remove
the pilot rod.
23.Clean the high-pressure pump on the outside.
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Work sequence 2 – installing the high-pressure pump

High-pressure pump
Initial situation High-pressure pump cleaned and checked, parts replaced, if required.
The roller (21) of the high-pressure pump cam follower (22) is on a cam base
circle (G) of the triple cam (23). This means that the high-pressure pump drive
(20) is unloaded as far as possible. See Fig. 1.
Work steps 1. Insert the new O-ring (13) into the ring groove on the high-pressure pump
Installation of high-pressure guide (1). See Fig. 3.
pump 2. Clean the contact surfaces on the high-pressure pump (1) and on the
flange (2).
48/60CR, M010.110.050-01-0006 3 (8)

3. Bolt the pilot rod (204.042) to the high-pressure pump (1) using hex bolts
(8). See Fig. 3.
4. Screw the strap (204.041-01) fully into the high-pressure pump.
5. Screw the hex bolts (15) fully into the strap until they contact the valve
support of the high-pressure pump and tighten them. The hex bolts (15)
secure the strap to prevent it unscrewing.
6. Fasten the rope (9) with the shackle (002.452) to the strap.
7. Suspend the rope from the hoist.
8. Remove cover on the opening on the flange (2).
9. Before transporting, check that the shackle and the hex bolts (15) are
correctly fastened.
10.Lift the high-pressure pump (1) with the hoist and position it above the
flange (2). Guide the high-pressure pump using the pilot rod (204.042)
while installing.
11.Lower the high-pressure pump (1) with the hoist and place it on the
flange (2). Ensure the parallel pin (10) is inserted into the corresponding
bore in the high-pressure pump (1). Guide the high-pressure pump using
the pilot rod (204.042) while lowering and positioning.
12.Dismantle the rope (9) with the shackle (002.452) from the strap.
13.Unscrew the hex bolts (15) and unscrew the strap from the high-pressure
pump.
14.Unscrew the hex bolts (8) from the high-pressure pump (1) and remove
the pilot rod.
Tightening the hex bolts (4) 15.Apply lubricant to the threads and contact area of the hex nuts (4) and
the stud bolts (6). See Fig. 2.
16.Screw the hex nuts (4) onto the stud bolts (6) and tighten the hex nuts (4)
in 3 stages to the specified torque. When tightening the hex nuts (4), the
tightening device (204.024) must be used. See fig. 4. The values to be
set on the torque wrench can be found in the conversion table for the
power amplifier (008.030). See Work Instructions 010.000.003-05. See
the following description for the adjustment of the torque on the torque
wrench.
For setting the correct torque on the torque wrench, proceed as follows:
▪ Take the specified torque value from Work Instructions 010.000.003-05.
▪ Search for the value in the conversion table and determine the tightening
torque from this table.
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▪ Set the determined tightening torque from the conversion table on the
High-pressure pump
torque wrench.
Fitting the fuel line 17.Lubricate O-rings (28, use new O-rings if necessary) and ring grooves for
O-rings with clean lubricating oil. See Fig. 2/II.
18.Insert O-rings (28) into the ring grooves for O-rings.
19.Attach both fuel lines (3).
20.Screw in the cap screws (26 and 27) and tighten them. See Fig. 2/I.
21.Push splash deflector rings (25) onto the fuel lines (3) and engage quick-
fit couplings.
4 (8) 48/60CR, M010.110.050-01-0006

22.Install all lines removed for the removal and installation of the high-pres-
sure pump (1).
*1 High-pressure pump 22 High pressure pump –

cam follower
2 Flange 23 Triple cam
20 Power take-off for high- 24 Camshaft
pressure pump
21 Roller of the high-pressure G Cam base circle
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High-pressure pump
pump cam follower

Figure 1: The roller of the high-pressure pump cam follower is on a cam base
circle of the triple cam
48/60CR, M010.110.050-01-0006 5 (8)

*1 High-pressure pump 12 Socket

2 Flange 25 Splash deflector ring
3 Fuel line 26 Cap screw
4 Hex nut 27 Cap screw
6 Stud bolt 28 O-ring
7 Leakage fuel line I, II Work steps
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High-pressure pump
Figure 2: Attached high-pressure pump
6 (8) 48/60CR, M010.110.050-01-0006

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High-pressure pump
*1 High-pressure pump 10 Parallel pin

8 Hex bolt M12x30 13 O-ring
9 Rope 15 Hex bolt M10x70
Figure 3: Attached removal and installation device
48/60CR, M010.110.050-01-0006 7 (8)

*1 High-pressure pump 2 Flange

Figure 4: Tightening the hex nuts on the high-pressure pump
* The position of the solenoid on the high-pressure pump may differ from the
one shown in the illustrations.
18014423009965835
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High-pressure pump
8 (8) 48/60CR, M010.110.050-01-0006

High-pressure pump
Summary
High-pressure pumps and their Individual parts must be dismantled, checked
and/or replaced as part of maintenance work.
Work sequence 1 – dismantling the high-pressure pump.
Work sequence 2 – installing sealing rings on the pump casing, barrel and
throttle piece.
Work sequence 3 – assembling high-pressure pump with pump element unit.
Required tools/Auxiliary equipment

1 Lug 200.104-2 Standard
1 Spherical disc 200.104-4 Standard
1 Conical socket 200.104-5 Standard
1 Mounting device 204.053 Option
1 Spindle 204.053-1 Option
1 Fixing plate 204.053-2 Option
1 Threaded piece 204.053-4 Option
3 Rod 204.053-5 Option
1 Removal and fitting device for high-pressure 204.041 Standard
pump
1 Strap 204.041-1 Standard
1 Pin spanner 204.039 Standard
1 Assembly fixture 204.032 Standard
1 Assembly taper 204.032-1 Standard
1 Expansion sleeve 204.032-2 Standard
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1 Calibration sleeve 204.032-3 Standard

High-pressure pump
1 Spacer sleeve 204.032-4 Standard

1 Spacer sleeve 204.032-5 Standard
1 Insert open-jaw socket wrench SW32 008.190 Standard
1 Insert adapter 14x18/9x12 001.940 Standard
48/60CR, M010.110.050-02-0004 1 (13)


1 Lubricant (Molub-Alloy Paste White T) - Option
1 Medium-strength screw locking agent (Loctite - Option
243)

Necessary replacement of the suction and delivery valve and of compression springs
To ensure the leak tightness, and thus the functionality, of the high-pressure
pump, it is recommended that the replacement of individual components is
not carried out by on-board personnel. Suction and delivery valve as well as
compression springs are not available for order as separate spare parts.
But it is absolutely imperative to replace the suction- and delivery valves and
both compression springs at prescribed maintenance intervals. If the replace-
ment is not carried out, it may result in component damage and may con-
sequently impair engine operation. See 010.005 Engine – Operating Manual
010.000.047-03.
The high-pressure pump must be dismantled by on-board personnel accord-
ing to the specified maintenance interval, and then it must be re-completed
using a pre-assembled unit (pump element unit).
Once removed, the pump element unit must be sent to MAN Energy Solu-
tions.
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High-pressure pump
2 (13) 48/60CR, M010.110.050-02-0004

Warning messages

Burns caused by hot oil

When submerging the sealing ring in the hot oil bath or removing it
from the hot oil bath there is a risk of burns and irreversible damage to
the skin and the tissue below.
• Place the oil bath on a flat and stable surface
• Use suitable equipment for insertion/removal
Work sequence 1 – Dismantling the high-pressure pump

Initial situation High-pressure pump detached and cleaned externally. See Work Instructions
010.110.050-01.
Work steps 1. Turn back the hex nut (47) on tool (200.104), mount tool (200.104) on the
Removing the valve spring pump casing (20) and fasten it with a hex nut (48).
2. Screw the eye bolt (001.404) into the supporting disc (19). See Fig. 1/I.
3. Screw in the hex nut (47), thereby compressing the valve spring (17) via
the lug (200.104-2) until the support plate (19) can be removed. See
Fig. 1/II.
4. Remove the supporting disk (19) with eye bolt.
5. Unscrew the hex nut (47). See Fig. 1/III.
6. Remove the spring plate (18) and the valve spring (17). See Fig. 1/IV.
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7. Completely detach the tool (200.104).

High-pressure pump
Removing the rod seal A pump element consists of a crosshead piston and a barrel. The crosshead
piston and barrel may only be replaced together because both parts are ad-
justed to each other.
The pump element may only be dismantled in the event of a leak on the rod
seal (8). See Fig. 2. If this is not the case, proceed with Point 11.
8. Unscrew the hexagon socket bolts (16) and the spring plate (15). See
Fig. 2/I.
9. Remove crosshead piston (38) out of barrel (7), and place it down on a
clean support.
48/60CR, M010.110.050-02-0004 3 (13)

10.Unscrew hexagon socket bolts (37), detach sealing plate (9) and remove
rod sealing ring (8). See Fig. 2/I.
Removal of pump cylinder 11.Unscrew and remove the hexagon socket bolts (45). See Fig. 2/II.
with valve block 12.Turn back spindle (204.053-1). See Fig. 2/III.
13.Unscrew hex nuts (6) on rods (204.053-5).
14.Place mounting device (204.053) on high-pressure pump and screw rods
(204.053-5) in pump cylinder to base.
15.Tighten hex nuts (6) on rods (204.053-5).
16.Turn spindle downwards, and simultaneously turn the threaded piece
(204.053-4) into the valve support (3). Tighten threaded piece.
17.Remove the pump cylinder with valve block from pump casing by turning
the spindle.
18.Remove mounting device (204.053).
Transportation of barrel 19.Screw the removal and installation device (204.041) into the valve sup-
with valve block ports and tighten. See Fig. 3/II.
20.Screw in the hex bolt (5) to secure the removal and installation device
(204.041) against autonomous loosening until it makes contact with the
valve support.
21.Fasten the endless lifting belt (021.419) to the shackle (002.452) and sus-
pend it from the hoist. Tension the endless lifting belt slightly.
22.Remove the barrel with valve block from the pump casing (20) and set it
down on a clean support.
23.Remove parallel pin (10) and Variseal sealing ring (11) from pump casing
(20). See Fig. 3/III.
24.Clean all individual parts with clean diesel fuel, and check them for wear
or damage.
Removal of the solenoid 25.Unscrew bolt connection (52). See Fig. 2/II.
with throttle piece 26.Unscrew hexagon socket bolts (36) and remove solenoid (35) with O-ring
seal (34).
27.Remove purging device (54) and O-ring seals (34).
28.Fit pin spanner (204.039) on throttle piece (33), and unscrew throttle
piece (33). See Fig. 3/III.
29.Remove Variseal sealing ring (32), O-ring seal (51) and square ring (50)
from throttle piece (33).
30.Clean sealing ring grooves.
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High-pressure pump
Work sequence 2 – Mounting sealing rings on the pump casing, barrel and throttle piece
Initial situation Old Variseal seals (11, 32, 40), O-rings (39, 51) and square ring (50) removed
from pump casing (20), barrel (7) and throttle piece (33). Seal ring grooves
have been cleaned and checked for damage.
4 (13) 48/60CR, M010.110.050-02-0004

Damage due to assembly of cooled Variseal seals

If the assembly and the calibration of the Variseal seals are not carried
out promptly, the seals will quickly cool in the air and lose their elasti-
city. This will make assembly more difficult and may result in damage
to the Variseal seals during assembly.
• Install the Variseal seals as soon as they are removed from the oil bath.
• Carry out the assembly and calibration of the Variseal seals quickly.
Work steps 1. Heat the new Variseal seals (40) in an oil bath to approx. 140°C.
2. Oil all sliding surfaces on the barrel prior to installation of tools (assembly
cone and sizing sleeves) with clean lubricating oil.
Installation of the upper 3. Fit assembly cone (204.032-1) on barrel (7).
Variseal seal (40) on the WARNING Burns caused by hot oil.
barrel
4. Remove the Variseal seal (40) from the oil bath and place it on the as-
sembly cone. Immediately and quickly slide the Variseal seal into the top
sealing ring groove (A) using the expanding sleeve (204.032-2). Make
sure that the installation position is correct. (See Fig. 4/I and Fig. 3).
5. Extract assembly cone with expanding sleeve.
6. Apply the sizing sleeve (204.032-3) with the side marked "mounting
stages 2, 5, 7" on the barrel and use to press the Variseal seal into the
sealing ring groove. See Fig. 4/II.
7. Pull off the sizing sleeve (204.032-3) again after 2 minutes and place the
side marked "mounting stage 3" on the barrel. Pull out calibration sleeve
again after 2 minutes. See Fig. 4/III.
8. Let the Variseal seal (40) cool down for at least 15 minutes.
Installation of the central 9. Fit the assembly cone (204.032-1) with spacing sleeve (204.032-4) on
Variseal seal (40) on the the barrel (7).
barrel WARNING Burns caused by hot oil.
10.Remove the Variseal seal (40) from the oil bath and place it on the as-
sembly cone. Immediately and quickly slide the Variseal seal into the
central sealing ring groove (B) using the expanding sleeve (204.032-2).
Make sure that the installation position is correct. See Fig. 4/IV and Fig.
3.
11.Pull off assembly cone (204.032-1) and distance sleeve (204.032-4).
12.Apply the sizing sleeve (204.032-3) with the side marked "mounting
2020-12-07 - de
High-pressure pump
sealing ring groove. See Fig. 5/I.

13.Pull off the sizing sleeve (204.032-3) again after 2 minutes.
14.Let the Variseal seal (40) cool down for at least 15 minutes.
Installation of the lower 15.Fit the assembly cone (204.032-1) with spacing sleeves (204.032-4 and
Variseal seal (40) on the 204.032-5) on the barrel (7).
barrel WARNING Burns caused by hot oil.
16.Remove the Variseal seal (40) from the oil bath and place it on the as-
sembly cone. Immediately and quickly slide the Variseal seal into the
lower sealing ring groove (C) using the expanding sleeve (204.032-2).
Make sure that the installation position is correct. See Fig. 5/II and Fig. 3.
48/60CR, M010.110.050-02-0004 5 (13)

17.Pull off the assembly cone with expanding sleeve and spacing sleeve
(204.032-5).
18.Apply the sizing sleeve (204.032-3) with the side marked "mounting
sealing ring groove. See Fig. 5/III.
19.Pull out the sizing sleeve (204.032-3) and spacing sleeve (204.016-4)
again after 2 minutes.
20.Let the Variseal seal (40) cool down for at least 15 minutes.
Fitting the O-ring (39) on 21.Coat the ring groove for the O-ring (39) on the barrel (7) and the O-ring
the barrel (39) with "Molub-Alloy Paste White T" lubricant.
22.Attach the new O-ring (39), treated with "Molub-Alloy Paste White T" lub-
ricant, to the barrel (7). See Fig. 3.
Fitting the rod seal (8) on 23.Oil rod seal (8) lightly with clean lubricating oil and insert into barrel (7).
the barrel See Fig. 2.
24.Fit the sealing plate (9) onto the barrel (7).
25.Brush the thread and the contact surface of the hexagon socket bolts
(37) with medium-strength screw locking agent (Loctite 243).
26.Screw in the hexagon socket bolts (37) and tighten. See Fig. 2/I.
Fitting the Variseal sealing 27.Insert the Variseal sealing ring (11) in the sealing ring groove on the pump
ring (11) on the pump cas- casing (20). See Fig. 3/II.
ing (20)
Fitting the sealing rings (32, 28.Coat the ring grooves for the O-ring (51) and square ring (50) on the
50, 51) on the throttle piece throttle piece (33) as well as the O-ring (51) and the square ring (50) with
(33) "Molub-Alloy Paste White T" lubricant. See Fig. 3/III.
29.Insert the O-ring (51) and the square ring (50) in the ring grooves on the
throttle piece (33).
30.Slide the Variseal seal (32) onto the throttle piece (33) up to the contact
face.
Work sequence 3 – Assembling high-pressure pump with pump element assembly

Initial situation All individual parts cleaned and checked for damage or renewed. Variseal
sealing rings replaced on the barrel (7), pump casing (20) and throttle piece
(33). Sealing plate (9) is fitted.
Work steps 1. Lightly oil all contact surfaces of the individual parts with thin mineral oil
before assembly.
Transport and installation of 2. Unscrew hex nuts (6) of rods (204.053-5). See Fig. 2/III.
the barrel with valve sup-
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3. Screw rods into pump casing to base.

port
High-pressure pump
4. Screw the removal and installation device (204.041) into the valve sup-
ports and tighten. See Fig. 3/II.
5. Screw in the hex bolt (5) to secure the removal and installation device
(204.041) against autonomous loosening until it makes contact with the
valve support.
6. Fasten the endless lifting belt (021.419) to the shackle (002.452) and sus-
pend it from the hoist. Tension the endless lifting belt slightly.
6 (13) 48/60CR, M010.110.050-02-0004

7. Lift the barrel and valve support with endless lifting belt and position over
the pump casing. Observe the position of the parallel pin (10) in doing so.
8. Lower the barrel and valve support so that rods engage into the bores in
the valve support. See Fig. 2/III.
9. Carefully lower the barrel and valve support further until they abut on the
pump casing.
10.Detach removal and installation device (204.041) from the valve support.
Pressing in the barrel with 11.Place the mounting plate (204.053-2) on the rods.
valve support 12.Screw the hex nuts (6) onto the rods and tighten them.
13.Turn the spindle (204.053-1) downwards. At the same time, screw the
threaded piece (204.053-4) into the valve support (3) and tighten the
threaded piece.
14.By turning the spindle carefully, press in the barrel and valve support until
the valve support abuts in the pump casing. Make sure that the parallel
pin (10) slides into the bore in the valve support in doing so.
15.Remove the mounting device (204.053) from the high-pressure pump.
16.Apply lubricant (Molub-Alloy Paste White T) to the thread and contact
surface of hexagon socket bolts (45). See Fig. 2/II.
17.Screw in the hexagon socket bolts (45) until hand-tight and then tighten
crosswise in 3 stages using the specified torque. See Work Instructions
010.000.003-05.
Installation of the crosshead 18.Apply the lubrication oil to the crosshead piston (38).
piston 19.Push the crosshead piston (38) carefully into the barrel (7). See Fig. 2/I.
20.Fit the spring plate (15) onto the barrel.
21.Brush the thread and the contact surface of the hexagon socket bolts
(16) with medium-strength screw locking agent (Loctite 243).
22.Screw the hexagon socket screws (16) and tighten them to the pre-
Installation of the valve 23.Place the valve spring (17) and spring plate (18) onto the spring plate
spring (15). See Fig. 1/IV.
24.Unscrew the hex nut (48), the set tool (200.104) on the pump casing (7)
and the spring plate (18) and fasten with the hex nut (48). See Fig. 1/III.
25.Screw the eye bolt (001.404) into the supporting disc (19).
26.Screw in the hex nut (47) and thus compress the valve spring (17) using
the lug (200.104-2) until the support plate (19) can be inserted between
the crosshead piston (38) and the spring plate (18) with an eye bolt. See
Fig. 1/II.
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High-pressure pump
27.Insert the supporting disc (19) with eye bolt (001.404).

28.Unscrew the hex nut (47).
29.Completely detach the tool (200.104).
Installation of the solenoid 30.Apply lubricant (Molub-Alloy Paste White T) to the thread and to the con-
with throttle piece tact surfaces on the throttle piece (33).
31.Use a pin spanner (204.039) to screw the throttle piece (33) (new sealing
rings are installed) into the pump casing (20) and tighten the throttle piece
to the specified torque. See Work Instructions 010.000.003-05. See Fig.
3/III.
48/60CR, M010.110.050-02-0004 7 (13)

32.Apply lubricant (Molykote G-N Plus) to the threads and contact surface
on pipe union (53).
33.Screw the pipe union (53) into the pump casing (7) and tighten to the pre-
34.Fit the purging device (54) and a new O-ring (34) onto the throttle piece
(33). See Fig. 2/II.
35.Screw the bolt connection (52) onto the pipe union (53).
36.Fit the solenoid (35) with new O-ring (34) in the correct position onto pur-
ging device (54).
37.Apply lubricant (Molub-Alloy Paste White T) to the thread and contact
surface of the hexagon socket bolts (36).
38.Screw the hexagon socket screws (36) and tighten them to the pre-
scribed torque. See Work Instructions 010.000.003-05. See Fig. 2/II.
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High-pressure pump
8 (13) 48/60CR, M010.110.050-02-0004

17 Valve spring 20 Pump casing I-IV Work steps

18 Spring plate 47 Hex nut M24
19 Supporting disc 48 Hex nut M30
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Figure 1: Tensioning/releasing the valve spring in the high-pressure pump

High-pressure pump
48/60CR, M010.110.050-02-0004 9 (13)

2020-12-07 - de
3 Valve support 20 Pump casing 52 Bolt connection

High-pressure pump
6 Hex nut 34 O-ring 53 Pipe union

7 Pump cylinder *35 Solenoid **54 Purging device
8 Rod sealing 36 Hexagon socket bolt 100 Pump element unit
9 Sealing plate 37 Hexagon socket bolt
15 Spring plate 38 Pump plunger
16 Hexagon socket bolt 45 Hexagon socket bolt I-III Work steps
Figure 2: Removing/fitting the pump plunger, pump cylinder and solenoid
10 (13) 48/60CR, M010.110.050-02-0004

5 Hex bolt 32 Variseal sealing ring 51 O-ring

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7 Pump cylinder 33 Throttle piece 100 Pump element unit

High-pressure pump
10 Parallel pin 39 O-ring

11 Variseal sealing ring 40 Variseal sealing ring A,B,C,D Fitting sequence
20 Pump casing 50 Square ring I-III Work steps
Figure 3: Removal/installation of the throttle piece; illustration of sealing rings on the pump cylinder and
throttle piece
48/60CR, M010.110.050-02-0004 11 (13)

7 Barrel 40 Variseal seal I-IV Work steps

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High-pressure pump
Figure 4: Installing and calibrating the Variseal seal
12 (13) 48/60CR, M010.110.050-02-0004

7 Barrel 40 Variseal seal I-III Work steps

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High-pressure pump
Figure 5: Installing and calibrating the Variseal seal
* The position of the solenoid on the high-pressure pump may differ from the
one shown in the illustrations.
** The shape and size of the purging device may differ from the one shown in
the illustrations.
54043213582475659
48/60CR, M010.110.050-02-0004 13 (13)

54043213582475659
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High-pressure pump
48/60CR, M010.110.050-02-0004
Attachment of high-pressure pump to turnover stand using

adaptor plate
Brief description
Various tasks must be carried out at regular intervals on high-pressure
pumps. The mounting plate can be used in connection with a turnover stand
for this purpose.

1 Adapter plate 200.134 Option

Technical data
High-pressure pump Weight 110 kg
Attachment of high-pressure pump to turnover stand using

Work sequence – Attaching high pressure pump to turning device using mounting plate

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Injury due to rotation of the mounting plate

Owing to the non-axial weight distribution, the mounting plate may
start rotating and cause injury to parts of the body in the process.
• When working on component parts, always ensure that the locking
lever is engaged
General, M010.110.050-03-0001 1 (5)

Follow manufacturer’s operating manual

turning device (055.130).
See manufacturer's operating manual in Volume 015.010. Power tools
– 015.010.182 Turning device for cylinder heads.
Initial situation Have an assembly and turning device (055.130) ready. The high-pressure
pump is removed and hooked to the hoist with a suspension device. See
Work steps 1. By turning the hand wheel on the shuttle gearbox (3), place the adapter
head (4) onto the assembly and turning device (055.130) such that the
bore for locking latch (10) is horizontal. Fix the shuttle gearbox in this po-
sition with the locking lever (7).
2. Open the fixing bracket (11).
3. Remove the locking latch (10).
4. Insert the mounting plate (200.134) into the turning device. Ensure that
the stud bolts (30) are facing upwards. See Fig. 2.
5. Slide the locking latch (10) into the bore on the adapter head until it en-
gages. Secure the locking latch with a split pin to prevent it falling out.
6. Close and clamp the fixing bracket (11).
7. Unscrew the hex nuts M27 (31) from the stud bolts (30).
8. Use a hoist and suspension device to place the high-pressure pump (5)
on the mounting plate. Ensure that the stud bolts (30) are inserted into
bores on the high-pressure pump. See Fig. 2.
9. Screw the nuts (31) onto the stud bolts (30) and tighten the bolts.
10.Detach the suspension device from the high-pressure pump. See Work
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adaptor plate
2 (5) General, M010.110.050-03-0001

3 Shuttle gearbox 7 Locking lever

Figure 1: Turning device with fitted mounting plate
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adaptor plate
General, M010.110.050-03-0001 3 (5)

*5 High-pressure pump 31 Hex nut M27x2

30 Stud bolt M27x2
Figure 2: Inserting the high-pressure pump into the mounting plate
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adaptor plate
4 (5) General, M010.110.050-03-0001

3 Shuttle gearbox 7 Locking lever 13 Collecting pan

4 Adapter head 10 Locking latch 30 Stud bolt M27x2
*5 High-pressure pump 11 Support bracket 31 Hex nut M27x2
Figure 3: Mounting plate with inserted high-pressure pump
* The shape and size of high-pressure pump (5) may differ from the one
shown in the illustrations.
18014416569626123
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adaptor plate
General, M010.110.050-03-0001 5 (5)

18014416569626123
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adaptor plate
General, M010.110.050-03-0001
High-pressure pump
checking for leaks
Summary
Check components of the Common-Rail system for tightness. Ensure/re-es-
tablish operating reliability.
evaluation of sealing face,
carrying out a pressure test,
checking for leaks,
test result evaluation.
Safety requirements
▪ Engine stopped
surised)
Tools/aids required
1 Test device for Common-Rail system 435.010 Standard
1 Pressure-testing set 435.005 Standard
1 Screw plug 435.006 Standard
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High-pressure pump

48/60CR, M010.110.050-04-0001 1 (7)


Disassembly and assembly of the high pressure pump 010.110.050-02
Technical data
Test pressure Test pressure 1400 bar
General prerequisites
Casing of the injection system is removed.
Prerequisites for test tool -
high-pressure pump
(009.342)

Read the manufacturer's instructions carefully before commissioning
the high-pressure pump (009.342). See manufacturer's operating
manual in Volume 015.010. Engine tool - 015.010.010 standard tool.
Prior to tightness test check the oil level in the high-pressure pump (009.342).
Use slushing oil

For test procedure, only absolutely clean slushing oil may be used.
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High-pressure pump
Prior to the tightness test, carry out a function test to ensure that the high-
pressure pump (009.342) will cause no pressure drop, which may invalidate
the test result. See manufacturer's operating manual in Volume 015.010.
Tools and back-up spare parts - 015.010.070 Hydraulic tools.
2 (7) 48/60CR, M010.110.050-04-0001

Ensure cleanliness of test tools

All test tools must be cleaned before and after use with greatest accur-
acy. Prevent dirt ingress in Common-Rail injection system.
Carry out visual inspection of sealing faces on tool

Prior to tightness test carry out visual inspection of sealing faces on
tool. The sealing faces on tools must have a compact, smooth surface
without damage.
Work Sequence - Checking the high-pressure pump for leaks

Preliminary information Explanation of the term "high-pressure pump":
High-pressure pump (1) is a common rail component.
The high-pressure pump (009.342) is a pressure generator, which generates
pressure for the leakage test of common rail components.
Initial situation
Operate engine approx. 1 hour with MDO

Prior to tightness tests on common-rail injection system, where the
high-pressure pump (009.342) is used for pressure generation, the en-
gine must run for approx. 1 hour MDO.
Otherwise the high-pressure pump (009.342) may be damaged during
pressure relieving due to back flow of heavy fuel (HFO) in high-pres-
sure pump (009.342).
Prerequisites with attached The high-pressure pump (1) can also be checked for leaks when it is fitted on
high-pressure pump (1) the engine. For this purpose, the following prerequisites must be met:
▪ Both high-pressure fuel pipes fitted to the valve support must be re-
moved. See Work Instructions 010.110.052-02.
Prerequisites with removed The high-pressure pump (1) can also checked for leaks when it is removed.
high-pressure pump (1) For this purpose, the following prerequisites must be met:
▪ Both high-pressure fuel pipes fitted to the valve support must be re-
moved. See Work Instructions 010.110.052-02.
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▪ The pump plunger of the high-pressure pump (1) must be removed. See
High-pressure pump

Work steps
Visual inspection of sealing
faces
48/60CR, M010.110.050-04-0001 3 (7)

Visual inspection of sealing faces

Prior to tightness test a visual inspection of sealing faces on Common-
Rail components must be carried out.
The sealing faces must have a compact, smooth surface without dam-
age.
1. Check whether the sealing faces of high-pressure groups to be tested

are free of notches, indents or other damage and have a compact,
smooth surface.
Result of visual inspection The sealing faces have a compact, smooth surface without damages
of sealing faces (notches, indents):
▪ The pressure test may be carried out.
The tapered sealing face is damaged. Also see figures in Work Instructions
010.110.060-02.
▪ Rework of tapered sealing face according to Work Instructions
010.110.060-02. After successful rectifying of defects the tightness test
may be carried out. Otherwise, replace the component.
Installation of test equip-
ment to the high-pressure
pump (1)
Avoid contamination of the sealing faces

When fitting the test equipment, ensure cleanliness of the metallic
sealing faces. Dirt can cause damage to the sealing elements.
2. Clean the thread and the sealing faces of the high-pressure pump (1),
pressure-testing set (435.005) and screw plug (435.006).
3. Coat the sealing faces and threads of the pressure-testing set (435.005)
and screw plug (435.006) with clean "Optimol Paste White" lubricant.
Hold cone
Hold cone (K) when tightening with torque. If the cone of the test tool is
twisted under pressure, sealing faces may be damaged as a result.
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4. Screw the pressure-testing set (435.005) and the screw plug (435.006)
High-pressure pump
into the holes of the high-pressure pump (1) and tighten them with the
prescribed torque of 280 Nm. In doing so, brace the cone (K). See Fig. 1.
5. Connect the high pressure hose (009.306) to the pressure-testing set
(435.005) and the high-pressure pump (009.342).
Carrying out a leakage test
4 (7) 48/60CR, M010.110.050-04-0001

Test medium under pressure

Due to incorrect installation or pre-damage, there is a residual risk that
a component may fail during the pressure test and thus result in es-
caping fuel or test medium under very high pressure. Severe injuries
may occur as consequence.
• During the tightness test, wear protective clothing, protective gloves
and safety goggles
• Keep a safe distance away from components under pressure
6. Start the high-pressure pump (009.342) (see Work Instructions

015.000.003-01) and build up the pressure slowly, until the test pressure
of 1,400 bar is achieved. At the same time, check the slushing oil level in
the high-pressure pump (009.342) and add slushing oil if necessary.
Re-pumping is not permissible

Re-pumping during the test procedure is not permissible, otherwise
the test result will be invalid.
7. Observe the high-pressure pump (1) for leakages and the pressure indic-
ator of the high-pressure pump (009.342) for pressure drops for the dur-
ation of 1 minute.
8. Record the pressure drop after 1 minute.
9. Depressurize the high-pressure pump (009.342).
10.Check the high-pressure pump (1) for leaks (L21, L22, L23). See Fig. 1.
Test result evaluation
Reference value for pressure drop (bar/min)
Component Leakage point New condition Used (bar/min)
High-pressure pump High pressure sealing seat 0 0

(L21, L22)
Sealing seat of delivery 0 0

valve (L23)
High pressure sealing 0 <= 100

group of valve support /
pump cylinder (L22)
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High-pressure pump
Table 1: Reference values for permissible pressure drop during the leakage test of the high-pressure pump
9007217333827851
Evaluation of leakage points Leakage point L21 (sealing seat facing away from the solenoid):
Sealing seat is leaking.
Check the sealing plug for proper fit (check the tightening torque, check the
threads for damage / burrs, for use of suitable lubricant). Visually inspect the
sealing seats of the relevant components, if necessary rework the tapered
sealing face in the valve support according to Work Instructions
010.110.060-02. In case of irreparable damage, replace the affected com-
ponents.
48/60CR, M010.110.050-04-0001 5 (7)

Leakage point L22 (with attached high-pressure pump (1)):

The sealing seat facing the solenoid or the high pressure sealing group of the
valve support / pump cylinder is leaking.
Check the test tool for proper fit (check tightening torque, check threads for
damage / burrs, for use of suitable lubricant). Visually inspect the sealing seats
of the relevant components, if necessary rework the tapered sealing face in
the valve support according to Work Instructions 010.110.060-02. In case of
irreparable damage, replace the affected components.
If the sealing seat can be excluded as leakage point, the high pressure sealing
group is the leakage point. Table 1 contains a reference value for the permiss-
ible pressure drop. If the leakage in this point is too severe and could cause
operating faults or errors during engine operation, replace the pump element
incl. valve support or replace the complete high-pressure pump if necessary.
The decisive factors for component replacement are the engine's operating
values or possible failures / error messages during engine operation. See
Work Instructions 010.110.050-01 and 010.110.050-02.
Leakage point L23 (with removed high-pressure pump (1)):
Delivery valve is leaky. Replace the pump element of the high-pressure pump,
or the entire high-pressure pump if necessary. See Work Instructions
010.110.050-01 and 010.110.050-02.
For the above described high-pressure pump test, the suction side of the
high-pressure pump is not taken into account. It is not possible to carry out a
pressure test here.
If necessary, dismantle the high-pressure pump according to Work Instruc-
tions 010.110.050-02 and check the relevant parts.
Decision of component replacement

The decisive factors for component replacement are the engine’s oper-
ating values or possible failures / error messages during engine opera-
tion.
9007217333827851
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High-pressure pump
6 (7) 48/60CR, M010.110.050-04-0001

1 High-pressure pump L21 Leakage point – Sealing seat on the side

averted from the solenoid
2 Valve support L22 Leakage point – Sealing seat on the side
facing the solenoid and the high pressure
sealing group of the valve support / pump
cylinder
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3 Solenoid L23 Leakage point – Sealing seat on the deliv-

High-pressure pump
ery valve of the high-pressure pump (1)

K Cone
Figure 1: Test equipment fitted on the high-pressure pump (1)
9007217333827851
48/60CR, M010.110.050-04-0001 7 (7)

9007217333827851
2018-01-08 - de
High-pressure pump
48/60CR, M010.110.050-04-0001


components
51353930763
1 (1)

Fuel injection pipe

Summary
Fuel injection pipes must be removed and refitted to allow other assemblies or
component parts to be removed and refitted.
Safety requirements
▪ Engine stopped
surised)
Tools/aids required
1 open ring spanner insert SW41 009.198 Standard
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Fuel injection pipe

Dismantling and assembling the fuel injection line 010.110.052-05
48/60CR, M010.110.052-01-0003 1 (6)


Work sequence 1 – Removing the fuel injection pipe

Initial situation Casing of the injection system removed. Cylinder head cover is open.
Work steps 1. Loosen and unscrew the hex nuts from the injection valve. See Work In-
structions 010.060.060-01.
2. Loosen the thrust screw (3) and thrust nut (9) with open box wrench in-
sert SW41 (009.198). See Fig. 2/I.
3. Undo the hex screws (10). See Fig. 2/II.
4. Unscrew and remove the thrust screws (3) and thrust nut (9) with open
box wrench insert SW41 (009.198). See Fig. 2/II.
5. First pull the fuel injection pipe (2) from the cone seat on the threaded
piece (8), then pull it out of the cone seat on the control valve support (4).
Remove the fuel injection pipe (2). If several fuel injection pipes are de-
tached, mark them so that each pipe will be re-attached to the same cyl-
inder.
6. Unscrew the hex bolts (10) and remove the flange (6) from the cylinder
head (1).
7. Remove the sealing rings (7, 12 and 14) and backing ring (13) from the
thrust screw (3) and flange (6) and clean the sealing ring grooves. See
Fig. 3.
8. Replace the internal sealing rings. See Work Instructions
010.110.052-05.
9. Clean the exterior of the fuel injection pipe (2).
10.Clean the sealing surfaces of the fuel injection pipe (2) and inspect them
for damage, dismantling or replacing the fuel injection pipe if required.
11.Clean the complete connection hole for the fuel injection pipe (2), includ-
ing the sealing faces and thread on the control valve support (4), and pro-
tect them from damage and contamination.
Work sequence 2 – Installing the fuel injection pipe
Material damage due to tensioned high pressure fuel pipe

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Damage can be caused to components or leakages may occur in the

Common Rail injection system if high pressure fuel pipes are not in-
Fuel injection pipe
stalled without tension.

• Install high pressure fuel pipes without tension.
Initial situation Fuel injection pipe (2) removed and cleaned. Connection hole for the fuel in-
jection pipe (2), including sealing faces and thread on the control valve sup-
port (4), cleaned and checked for damage, and component parts replaced if
necessary. Internal sealing rings on the thrust screw and thrust nut checked
and replaced if necessary.
2 (6) 48/60CR, M010.110.052-01-0003

Work steps 1. Clean the sealing face on the threaded piece (8) and inspect it for dam-
age; replace threaded piece if necessary.
2. Lubricate the cleaned ring grooves for sealing rings on the thrust screw
(3) and flange (6) with lubricant.
3. Lubricate the new O-rings (7 and 14) and support ring (13) with lubricant.
4. Insert the new O-rings (7 and 14) and backing ring (13), coated with lub-
ricant, into the sealing ring grooves of thrust screw (3) and flange (6). En-
sure that the rings are tensioned equally, not twisted, and fitted in the
correct sequence. See Fig. 3.
5. Insert a new sealing ring (12) into the groove in the cylinder head (1).
6. Coat the threads on the thrust screw (3) and the thrust nut (9), the thread
and sealing face on male threaded piece (8) as well as the threads and
contact faces of the hex bolts (10) with lubricant.
7. Slide the flange (6) into the cylinder head (1) until it rests on the sealing
ring (12).
8. Loosely screw in the hex bolts (10) with washers (11) into the cylinder
head (1), but do not tighten them. See Fig. 2/II.
9. Turn the flange (6) to the left by hand until it is in contact with the
threaded piece, hold the flange firmly in this position and tighten the hex
bolts (10) to the specified torque. This means that the threaded piece (8)
can no longer turn when the thrust nut (9) is tightened. See Work Instruc-
tions 010.000.003-05.
10.Apply lubricant to the conical and tapered sealing surfaces of control
valve support (4) and fuel injection pipe (2).
11.Push back the thrust screw (3) and the thrust nut (9) on the fuel injection
pipe (2).
12.First insert the fuel injection pipe (2) into the cone seat on control valve
support (4) and screw in the thrust screw (3) by two or three turns.
13.Insert the fuel injection pipe (2) into the cone seat on threaded piece (8)
and screw on the thrust nut (9) by hand. See Fig./l.
14.Fully screw in the thrust nut (9) and the thrust screw (3) by hand.
15.Screw in the thrust nut (9) using open ring wrench insert size SW41
(009.198) and tighten to the specified torque. See Work Instructions
010.000.003-05.
16.Screw in the thrust screw (3) using open ring spanner insert SW41
(009.198) and tighten to the specified torque. See Work Instructions
010.000.003-05.
17.Tighten the hex nuts on the fuel injection valve to the specified torque.
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See Work Instructions 010.000.003-05 and 010.060.060-01.

Fuel injection pipe
18.Fit the casing on the injection system.

19.Close the cylinder head cover.
48/60CR, M010.110.052-01-0003 3 (6)

1 Cylinder head 3 Thrust screw 5 Common rail accumu-

lator unit
2 Fuel injection pipe 4 Control valve support 9 Thrust nut
Figure 1: Fuel injection pipe fitted
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Fuel injection pipe
4 (6) 48/60CR, M010.110.052-01-0003

1 Cylinder head 7 O-ring 11 Washer

2 Fuel injection pipe 8 Threaded piece
3 Thrust screw 9 Thrust nut
6 Flange 10 Hex bolt I-II Work steps
Figure 2: Removing and fitting the fuel injection pipe
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Fuel injection pipe
48/60CR, M010.110.052-01-0003 5 (6)

2 Fuel injection pipe 7 O-ring 13 Backing ring

3 Thrust screw 9 Thrust nut 14 O-ring
6 Flange 12 Sealing ring
Figure 3: Removing and installing the flange
18014416588737803
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Fuel injection pipe
6 (6) 48/60CR, M010.110.052-01-0003

High-pressure fuel pipe

Summary
High pressure fuel pipes must be removed and refitted to allow other assem-
blies or components to be removed and refitted.
The work sequences are:
Work sequence 1 - removing high pressure fuel pipe.
Work sequence 2 - replacing sealing rings.
Work sequence 3 - installing high pressure fuel pipe.
Safety requirements
▪ Engine stopped
surised)
Tools/aids required
1 open-end ring spanner insert SW36 009.194 Standard
1 open ring spanner insert SW41 (48/60CR) 009.195 Standard
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35/44DF;48/60CR;32/44CR, M010.110.052-02-0001 1 (6)

Warning messages
Damage to thrust screws due to jamming

The thrust screws on a high pressure line may jam and hence damage
components if they are not screwed in and out simultaneously.
a) Screw thrust screws in and out simultaneously.
Work sequence 1 - removing high pressure fuel pipe

Initial situation The high pressure fuel pipe needs to be removed for service or maintenance
work.
Work steps NOTICE Damage to pressure screws due to jamming.
1. Release thrust screws (1) on pressure pipe (2) with open ring spanner in-
sert (009.194, 009.195 or 009.197) and tool holder (008.180) and un-
screw both thrust screws (1) simultaneously.
2. Push the thrust screws (1) back onto the pressure pipe (2).
3. Remove the high-pressure fuel pipe carefully. Make sure that the threads
of the thrust screws (1) and sealing cones (4) on the pressure pipe (2) are
not damaged and have no pressure points. See Work Instructions
010.110.060-02.
4. Clean the thread and sealing surfaces at the engine side.
5. Close off the openings on the engine with suitable auxiliary equipment.
6. Clean the convex sealing cones (4) on the pressure pipe (2) and check for
damage, renew the high-pressure fuel pipe if necessary. See Work In-
structions 010.110.060-02.
7. Close off the openings on pressure pipe (2) with protection caps. Protect
the sealing cones and thread surfaces from contamination.
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2 (6) 35/44DF;48/60CR;32/44CR, M010.110.052-02-0001

1 Thrust screw 4 Sealing cone

2 Pressure pipe 5 Backing ring
3 O-ring
Figure 1: Removed high pressure fuel pipe (schematic)
Work sequence 2 - replacing sealing rings
Damage to sealing rings due to thread

Sealing rings can be damaged by the sharp-edged thread during as-
sembly.
• Cover the thread with suitable auxiliary material before installing the
sealing rings.
Initial situation High-pressure fuel pipe removed and cleaned.

Work steps 1. Clean the thread of the thrust screws (1).
Removal of the sealing 2. Remove the O-rings (3) and backing rings (5) from the thrust screws (1).
rings See Fig. 2.
3. Push back the thrust screws (1), remove the clamping rings (6) and pres-
2020-12-11 - de
sure pieces (7) from the pressure pipe (2).

4. Pull the thrust screws (1) off the pressure pipe (2).
5. Remove the inner O-rings (9) and backing rings (8) from thrust screws (1).
6. Clean all the components, especially the sealing ring grooves on the
thrust screws (1), and check them for damage. Replace if necessary.
Installing the sealing rings 7. Apply clean lubricant to the thrust pieces (7), sealing ring grooves and
counter surfaces on the thrust screws (1) and the pressure pipe sleeving
(10).
8. Replace the O-rings (9) and backing rings (8) if necessary. Coat the O-
rings (9) and support rings (8) with lubricant.
35/44DF;48/60CR;32/44CR, M010.110.052-02-0001 3 (6)

9. Insert the lubricated O-rings (9) and backing rings (8) in the internal seal-
ing ring grooves on the thrust screws (1). In doing so, make sure the
sealing rings are not twisted, are equally tensioned and are fitted in the
correct sequence.
10.Push thrust screws (1) onto pressure pipe (2).
11.Fit the thrust pieces (7) and clamping ring (6) onto the pressure pipe (2).
12.Replace the O-rings (3) and backing rings (5) if necessary. Coat the O-
13.Insert the lubricated O-rings (3) and backing rings (5) in the sealing ring
grooves on the thrust screws (1). In doing so, make sure the sealing rings
are not twisted, are equally tensioned and are fitted in the correct se-
quence.
14.Where necessary, remove thread covering from the thrust screws (1).
2020-12-11 - de
4 (6) 35/44DF;48/60CR;32/44CR, M010.110.052-02-0001

1 Thrust screw 6 Clamping ring

2 Pressure pipe 7 Thrust piece
4 Sealing cone 9 O-ring
5 Backing ring 10 Pressure pipe sleeving
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Figure 2: High-pressure fuel pipe dismantled
35/44DF;48/60CR;32/44CR, M010.110.052-02-0001 5 (6)

Work sequence 3 - installing high pressure fuel pipe

Initial situation High-pressure fuel pipe removed and cleaned. Sealing rings and thrust
screws fitted to pressure pipe.
Work steps 1. Remove protection caps from high pressure fuel pipe.
2. Apply lubricant to the mating and sealing surfaces on the thrust screws
(1) and the sealing cones (4).
3. Apply clean lubricant to the thread surfaces of the thrust screws (1).
5. Remove the equipment that covers the openings on the engine.
6. Press the sealing cones (4) of the pressure pipe (2) into the appropriate
sealing seats on the engine. In the case of high pressure fuel pipes that
are installed between the Common Rail accumulator unit and the high
pressure pump or between the Common Rail accumulator unit and the
valve block, first insert the sealing cone in the conical seat on the high
pressure pump or the valve block and then insert the sealing cone of the
high pressure fuel pipe in the conical seat of the switching valve support
of the Common Rail accumulator unit.
7. Push thrust screws (1) onto pressure pipe (2), and screw in the thrust
screws by one to two thread pitches.
45036009741696523
NOTICE Damage to pressure screws due to jamming.
8. Simultaneously screw in the thrust screws (1) but do not tighten them yet.
9. Tighten thrust screws (1) to the prescribed torque. See Work Instructions
45036009741696523
010.000.003-05.
2020-12-11 - de
6 (6) 35/44DF;48/60CR;32/44CR, M010.110.052-02-0001

High-pressure fuel pipe (spill pipe)

Summary
High pressure fuel pipes must be removed and refitted to allow other assem-
blies or components to be removed and refitted.
The work sequences are:
Work sequence 1 - removing high pressure fuel pipe.
Work sequence 2 - replacing sealing rings.
Work sequence 3 - installing high pressure fuel pipe.
Safety requirements
▪ Engine stopped
surised)
Tools/aids required
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48/60CR, M010.110.052-03-0001 1 (6)

Warning messages
Damage to thrust screws due to jamming

The thrust screws on a high pressure line may jam and hence damage
components if they are not screwed in and out simultaneously.
a) Screw thrust screws in and out simultaneously.
Work Sequence 1 - Removal of high-pressure fuel pipe

Preliminary remark The Work Instructions apply to the high-pressure fuel pipes (spill pipes) in-
stalled between the non-return valve (spill valve) and the distributor section.
See Fig. 1.
Initial situation The disassembly of the high-pressure fuel pipe is necessary because of ser-
vice or maintenance work.
Work steps NOTICE Damage to pressure screws due to jamming.
1. Release the thrust screws (1) on the pressure pipe (2) with open ring
spanner insert (009.197) and tool bracket (008.180) and unscrew both
thrust screws (1) simultaneously.
3. Remove the high-pressure fuel pipe carefully. Make sure that the threads
of the thrust screws (1) and cones (4) on the pressure pipe (2) are not
damaged and have no pressure points. See Work Instructions
010.110.060-02.
4. Clean the thread and sealing surfaces on the engine side.
5. Close off the openings on the engine with suitable auxiliary equipment.
6. Clean the convex sealing cones (4) on the pressure pipe (2) and check for
damage, renew the high-pressure fuel pipe if necessary. See Work In-
structions 010.110.060-02.
7. Close off the openings on the pressure pipe with protective caps. Protect
the sealing cones and thread surfaces against contamination.
Work sequence 2 - Replacing sealing rings

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sembly.
sealing rings.
Initial situation High-pressure fuel pipe removed and cleaned.

Work steps 1. Clean the thread of the thrust screws (1).
2 (6) 48/60CR, M010.110.052-03-0001

Removal of the sealing 2. Remove the O-rings (3) from the thrust screws (1).
rings 3. Push back the thrust screws (1), remove the clamping rings (6) and pres-
sure pieces (7) from the pressure pipe (2). See Fig. 3.
4. Pull the thrust screws off the pressure pipe.
5. Remove the inner O-rings (9) and backing rings (8) from the thrust
screws.
6. Clean all the components, especially the sealing ring grooves on the
thrust screws, and check them for damage. Replace parts if required.
Installing the sealing rings 7. Lubricate the sealing ring grooves and counter surfaces on thrust pieces
(7), thrust screws (1) and pressure pipe sleeving (5) with lubricating oil.
8. Replace the O-rings (9) and backing rings (8) if necessary. Coat the O-
9. Insert the O-rings (9) and backing rings (8) in the internal sealing ring
grooves on the thrust screws (1). In doing so, make sure the sealing rings
are not twisted, are equally tensioned and are fitted in the correct se-
quence. See Fig. 3.
10.Slide the thrust screws onto the pressure pipe.
11.Fit the pressure pieces (7) and the clamping ring (6) onto the pressure
pipe (2).
12.Replace the O-rings (3) if necessary. Apply lubricant to the O-rings (3).
13.Fit the O-rings (3) in the ring grooves on the thrust screws (1).
14.Remove any thread cover from the thrust screws if necessary.
Work Sequence 3 - Fitting of high-pressure fuel pipe

Initial situation High-pressure fuel pipe removed and cleaned. Sealing rings and thrust
screws fitted to pressure pipe.
Work steps 1. Apply lubricant to the counter and sealing surfaces on the thrust screws
(1) and the sealing cones (4).
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2. Apply lubricant to the thread surfaces of the thrust screws (1).

3. Push back the thrust screws (1) onto the pressure pipe.
4. Remove the aids used to cover the openings on the engine side and pro-
tective caps on the high-pressure fuel pipe.
5. Press the sealing cones (4) of the pressure pipes into the appropriate
sealing seat on the engine.
6. Push the thrust screws (1) onto the pressure pipe and screw in the thrust
screws by one to two turns.
18014416595885451
NOTICE Damage to pressure screws due to jamming.
48/60CR, M010.110.052-03-0001 3 (6)

7. Carefully screw on the thrust screws (1), but do not tighten them yet. It
may be necessary to carry out working steps from other Work Instruc-
tions before the final tightening of the thrust screws with the specified
torque.
8. Tighten the thrust screws (1) with the open ring spanner insert (009.197)
and the torque wrench to the specified torque. See Work Instructions
010.000.003-05.
1 Thrust screw 13 Valve group

10 High-pressure fuel pipe (balance pipe) 14 Distributor section
11 Common rail accumulator unit 15 Charge air piping
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12 Non-return valve (balance valve)

Figure 1: Installed high-pressure fuel pipe (spill pipe)
4 (6) 48/60CR, M010.110.052-03-0001

1 Thrust screw 3 O-ring

2 Pressure pipe 4 Sealing cone
Figure 2: High-pressure fuel pipe (balance pipe) removed

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48/60CR, M010.110.052-03-0001 5 (6)

1 Thrust screw 6 Clamping ring

2 Pressure pipe 7 Thrust piece
4 Sealing cone 9 O-ring
5 Pressure pipe sleeving
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Figure 3: High-pressure fuel pipe dismantled

18014416595885451
6 (6) 48/60CR, M010.110.052-03-0001


checking for leaks
Summary
checking for leaks,
Safety requirements
▪ Engine stopped
surised)
Tools/aids required
1 Plug 435.007 Standard
1 Pumping device 435.008 Standard
1 Plug 435.011 Standard
1 Pumping device 435.012 Standard
1 Lock nut 435.038 Standard

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48/60CR, M010.110.052-04-0002 1 (9)



Dismantling and installing the high pressure fuel pipe (spill 010.110.052-03
pipe)
Technical data
high-pressure pump
(009.342)

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Use slushing oil

2 (9) 48/60CR, M010.110.052-04-0002



without damage.
Work Sequence - Checking the high pressure pipes for leaks

Initial situation High pressure fuel pipe to be checked is removed.
See Work Instructions 010.060.060-01 for threaded piece removal.
See Work Instructions 010.110.052-02 for removal of the high pressure fuel
pipe.
See Work Instructions 010.110.052-03 for removal of the spill pipe (if resent).
See Work Instructions 010.110.052-01 for fuel injection pipe removal.
The threaded piece can only be checked if it is fitted to the fuel injection pipe.

Work steps
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faces

age.
48/60CR, M010.110.052-04-0002 3 (9)


smooth surface.
010.110.060-02.
Installing the test equip-
ment

When fitting the test device, ensure cleanliness of the metallic sealing
faces. Dirt can cause damage to the sealing faces.
2. Clean the sealing faces and threads on the components and the tools to
be checked.
3. Coat the sealing faces and threads of the components to be tested and
the tools with clean "Optimol Paste White T" lubricant.
Hold high-pressure fuel pipe

Hold against high-pressure fuel pipe when tightening with the specified
torque. If the sealing faces of a high-pressure group are twisted relat-
ive to each other under pressure, this may result in damage to the
sealing faces.
4. Screw the tools onto the connections of the high-pressure fuel pipe (1) or
the threaded piece (2) and tighten them with the specified torque (see
Table 1). For this purpose, brace components where possible, so that the
sealing faces are not twisted relative to each other under pressure and
are not damaged.
For individual component-tool connections, torques from Table 1 must be ob-
served.
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Component Component / tool Torque (Nm) Relevant fig-

ure
Fuel injection pipe and threaded Thrust screw - 435.008 320 Figure 1
piece 48/60CR
Fuel injection pipe and threaded Thrust nut – threaded piece 320 Figure 1
piece 48/60CR
Fuel injection pipe and threaded Threaded piece - 435.038 200 Figure 1
piece 48/60CR
Fuel injection pipe 48/60CR Thrust screw - 435.008 320 Figure 2
4 (9) 48/60CR, M010.110.052-04-0002

Component Component / tool Torque (Nm) Relevant fig-

ure
Fuel injection pipe 48/60CR Thrust nut – 435.011 320 Figure 2
High pressure fuel pipe 48/60CR Thrust screw - 435.007 320 Figure 3
High pressure fuel pipe 48/60CR Thrust screw - 435.008 320 Figure 3
Spill pipe 48/60CR Thrust screw - 435.011 90 Figure 4
Spill pipe 48/60CR Thrust screw - 435.012 90 Figure 4

Table 1: Torque values for components and test tools (see also relevant figures)
18079094411
5. Connect the high pressure hose (009.306) to the pumping device


and safety goggles


7. Observe the component to be tested and the test equipment for leak-
ages and the pressure indicator of the high-pressure pump (009.342) for
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pressure drop for the duration of one minute.
No pressure drop permissible

During the tightness test on high-pressure fuel pipes, no pressure drop
or leakage is not permissible.

Test result evaluation If a pressure drop or a leakage on the leakage points L41, L42, L51, L52,
L61, and L62 is detected, the corresponding component must be replaced.
48/60CR, M010.110.052-04-0002 5 (9)

Exception for threaded piece (2) (L31 and L32):

If during the leakage test of the fuel injection pipe and threaded piece a pres-
sure drop is detected, test the fuel injection pipe without a threaded piece to
detect the leaking component. The component causing a pressure drop dur-
ing the leakage test must be replaced.
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1 Fuel injection pipe L31 Possible leakage point

2 Threaded piece L32 Possible leakage point
Figure 1: Fuel injection pipe with a threaded piece and fitted test equipment
6 (9) 48/60CR, M010.110.052-04-0002

1 Fuel injection pipe L41 Possible leakage point

Figure 2: Fuel injection pipe with fitted test equipment
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48/60CR, M010.110.052-04-0002 7 (9)

3 High-pressure fuel pipe L52 Possible leakage point

L51 Possible leakage point
Figure 3: High pressure fuel pipe with fitted test equipment
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8 (9) 48/60CR, M010.110.052-04-0002

4 Spill pipe L62 Possible leakage point

L61 Possible leakage point
Figure 4: Spill pipe with fitted test equipment
18079094411

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48/60CR, M010.110.052-04-0002 9 (9)

18079094411
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48/60CR, M010.110.052-04-0002
Fuel injection pipe

Summary
Check the fuel injection pipes for condition/degree of wear to ensure trouble-
free operation of the engine.
Tools/aids required

Work sequence 1 – Dismantling the fuel injection pipe

Initial situation The fuel injection pipe has been removed and cleaned externally.
Work steps 1. Push back the thrust screw (2) and pressure nut (3) on the pressure pipe
(1).
2. Remove the retaining rings (5) and take off the thrust pieces (4). See
Fig. 2 and Fig. 3.
3. Pull out the thrust screw (2) and thrust nut (3) from the pressure pipe (1).
4. Remove the backing rings (6) and O-rings (7) from the thrust screw and
thrust nut.
5. Clean all the components and check them for damage. Replace if neces-
sary. See Work Instructions 010.110.060-02.
Work sequence 2 – Assembling the fuel injection pipe

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Initial situation All individual parts are cleaned, checked for damage or renewed if necessary.
Have some new O-rings (7) ready.
Fuel injection pipe
Work steps 1. Apply lubricant to the sealing ring grooves and counter surfaces on the
pressure pipe (1), thrust screws (2) and thrust nut (3). See Fig. 2 and
Fig. 3.
2. Apply lubricant to the new O-rings (7).
3. Insert new lubricated O-rings (7) into the ring grooves on the thrust
screws (2) and thrust nut (3).
48/60CR, M010.110.052-05-0001 1 (4)

4. Fit the backing rings (6) in the ring grooves on the thrust screw (2) and
thrust nut (3). Ensure that the O-rings (7) and the backing rings (6) are in-
stalled in the correct sequence.
5. Push the thrust screw (2) on the short side (11) on the pressure pipe (1).
See Fig. 1.
6. Push the thrust nut (3) on the long side (10) on the pressure pipe (1).
7. Push back the thrust screw (2) and pressure nut (3) on the pressure pipe
(1).
8. Apply pressure pieces (2-part) to both ends of the pressure pipe (1). See
Fig. 2 and Fig. 3.
9. Secure pressure pieces (2-part) with retaining rings (5).
10.Push forward the thrust screw (2) and thrust nut (3) on the pressure pipe
(1).
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1 Pressure pipe 3 Thrust nut 11 Short side

Fuel injection pipe
2 Thrust screw 10 Long side

Figure 1: Fuel injection pipe mounted, illustration of long side (10) and short
side (11)
2 (4) 48/60CR, M010.110.052-05-0001

1 Pressure pipe 5 Retaining ring I-III Work steps

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2 Thrust screw 6 Backing ring

4 Pressure piece (2- 7 O-ring
Fuel injection pipe
piece)
Figure 2: Removal and installation of the thrust screw
48/60CR, M010.110.052-05-0001 3 (4)

1 Pressure pipe 5 Retaining ring I-III Work steps

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3 Thrust nut 6 Backing ring

4 Pressure piece (2- 7 O-ring
Fuel injection pipe
piece)
Figure 3: Removal and installation of the thrust nut
9007217334275851
4 (4) 48/60CR, M010.110.052-05-0001



components
51353934731
components
1 (1)
components

Common rail accumulator unit

Summary
Ensure correct execution of work, check components for state/wear condi-
tion, ensure / restore operational safety.
Common-Rail accumulator units are to be dismantled within the scope of
maintenance and repair work.
The work/ work steps include:
Installing components,
Safety requirements
▪ Engine stopped
surised)
Tools/aids required
1 Securing compound Loctite 577 - Inventory

2018-01-10 - de

1 Support - Inventory
Technical data
Common-Rail accumulator unit L48/60CR Weight 150 kg
48/60CR, M010.110.054-01-0001 1 (6)


Common-Rail accumulator unit V48/60CR Weight 180 kg

levers
pipe)
Removal and installation of non-return valve (purging) 010.110.054-10
Removal and installation of adaptor with non-return valve 010.110.054-12
(spill valve)
Work sequence 1 - Disassembling a Common-Rail accumulator unit

Rocker arm casing located above the common rail accumulator unit dis-
mantled. See Work Instructions 010.100.020-01.
Electrical connections of the valve groups on corresponding terminal boxes
disconnected. See Work Instructions 010.110.054-14.
High-pressure fuel pipes (spill pipes) between the non-return valve on the
valve group and the distribution piece removed. See Work Instructions
010.110.052-03.
Non-return valves on common rail accumulator unit removed. See Work In-
structions 010.110.054-10 and 010.110.054-12.
Fuel injection pipe dismantled. See Work Instructions 010.110.052-01.
Work steps 1. Remove the high-pressure fuel pipes (7, 8) and close the open ends on
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the engine as well as on the high-pressure connection pipes with protec-

tion caps to protect them from dirt penetration. See Work Instructions
010.110.052-02.
2. Remove the leakage fuel drain pipe (4).
3. Remove the drain pipes (3, 5). See Fig. 1.
4. Screw out the screwed socket (11). See Fig. 3.
5. Remove the fuel supply pipes (2, 6). See Fig. 1.
6. Remove all components (cable ducts, lines, etc.) which obstruct the re-
moval of the common rail accumulator unit (1).
2 (6) 48/60CR, M010.110.054-01-0001

7. Sling endless belt straps (021.419) around the common rail accumulator
unit (1) and attach the endless belt straps (021.419) to the lifting tackle.
Tension the endless belt straps (021.419) slightly. See Fig. 2.
8. Loosen the hexagon socket bolts (9), thus separating the common rail
accumulator unit (1) from the Rail bracket (10). See Fig. 2.

Do not damage components

During the removal and installation of the Common-Rail accumulator
unit, ensure that it does not hit anywhere or get stuck, thus damaging
parts.
9. Move the common rail accumulator unit (1) upwards first and then out-
wards.
Secure Common-Rail accumulator unit against rolling away

When putting the Common-Rail accumulator unit down, ensure that
the valve groups are not damaged and that the Common-Rail accumu-
lator unit is secured against rolling away.
10.Place the common rail accumulator unit (1) on a clean support, ensuring
it cannot turn.
11.Detach the endless belt straps from the common rail accumulator unit.
Work sequence 2 - Assembling a Common-Rail accumulator unit

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Initial situation Common rail accumulator unit and valve groups cleaned and checked, parts
replaced if necessary.
Work steps Carry out the installation by following the same steps in reverse order. In doing
so, observe the following:
Do not damage components

During the removal and installation of the Common-Rail accumulator
unit, ensure that it does not hit anywhere or get stuck, thus damaging
parts.
48/60CR, M010.110.054-01-0001 3 (6)

18079541003
1. To start with, only screw in the hexagon socket bolts (9) hand-tight.
2. Installing the high-pressure fuel pipe. See Work Instructions
010.110.052-02.
3. Apply Loctite 577 securing compound to the threads of the threaded
sockets (11).
4. Screw in the threaded socket (11) and tighten it to the prescribed torque.
See Fig. 3 and Work Instructions 010.000.003-05.
5. Attach the fuel supply pipes (2, 6) and the drain pipes (3, 5). Brace the
threaded socket (11) simultaneously to secure it against further turning
and thus against overtightening.
6. Fit the leakage fuel drain pipe (4).
7. Tighten the hexagon socket bolts (9).
8. Refit all components removed during work sequence 1 (cable ducts,
pipes, etc.).
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1 Common rail accumulator unit 6 Fuel supply lines

2 Fuel supply lines 7 High-pressure fuel pipe
3 Drain pipe 8 High-pressure fuel pipe
4 Leakage fuel drain pipe 10 Rail bracket
5 Drain pipe
Figure 1: Common rail accumulator unit attached
4 (6) 48/60CR, M010.110.054-01-0001

1 Common rail accumulator unit 10 Rail bracket

Figure 2: Removal and installation of the common rail accumulator unit
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48/60CR, M010.110.054-01-0001 5 (6)

1 Common rail accumulator unit 11 Threaded socket

10 Rail bracket
Figure 3: Common rail accumulator unit removed
18079541003
2018-01-10 - de
6 (6) 48/60CR, M010.110.054-01-0001

Holding fixture on turning device

fitting and removal
Summary
Various tasks must be performed on Common Rail accumulator units at regu-
lar intervals. For this purpose, a work holding fixture in connection with a
turnover stand is used.
The work includes:
Fitting the tool components.
Removing the tool components.
Tools/aids required
1 Work holding fixture 437.094 Option
Technical data
Work holding fixture 48/60CR Weight 144 kg

dismantle and assemble the Common Rail accumulator unit 010.110.054-04
Work Sequence 1 - Fitting the work holding fixture to turnover stand
Initial situation Have turning device (055.130) and holding fixture (437.094) ready.
Work steps
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Follow the Operating Manual from the manufacturer

Read the Operating Manual from the manufacturer before and during
use the turning device (055.130).
1. By turning the handwheel (112) on the shuttle gearbox (103), place the
adapter head (104) onto the turning device (055.130) in such a way that
the bore for the locking latch (110) is horizontal. Fix the adaptor head
(104) in this position with the locking lever (107). See Fig. 1.
48/60CR, M010.110.054-02-0001 1 (5)

2. Extract the plug pin (111), open the fixing latch (105) and remove the
locking latch (110).

3. Suspend holding fixture (437.094) with endless belt strap (021.419) and
place holding fixture (437.094) into turning device (055.130). See Figs. 1
and 2.
Injury hazard due to improperly secured tool

If tools and components are not secured properly, there is a risk of
them becoming loose and falling down, causing personal injuries in the
process.
• The locking latch is engaged and secured with a split pin.
• The fixing latch is closed and secured with a plug pin.
• The adapter head is secured with a locking lever.
4. Slide the locking latch (110) into the hole on the adapter head until it is
engaged. In addition, secure the locking latch (110) with a cotter pin
against falling out.
5. Close the fixing latch (105) and secure it with the plug pin (111). See Fig.
2.
6. For take-up, disassembly and assembly of common rail accumulator unit,
see Work Instructions 010.110.054-04.
Work Sequence 2 - Removing the work holding fixture from turnover stand
Initial situation Holding fixture (437.094) is fitted to turning device (055.130). Holding fixture
(437.094) placed in horizontal position. Locking lever (107) engaged in one
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groove on the adapter head (104). All tool components of the holding fixture
(437.094) are fitted to the holding fixture (437.094). No common rail accumu-
lator unit present on the holding fixture (437.094). See Work Instructions
010.110.054-04.
Work steps 1. Sling endless belt straps (021.419) around holding fixture (437.094), sus-
pend the endless belt straps (021.419) in the lifting tackle and tension the
endless belt straps (021.419) slightly.
2. Remove the plug pin (111) and open the locating clamp (105).
3. Remove the cotter and pull out the locking latch (110).
2 (5) 48/60CR, M010.110.054-02-0001


4. Carefully lift the holding fixture (437.094) using an endless belt strap
(021.419) and lifting tackle, and place the holding fixture (437.094) on a
suitable and clean surface.
5. Remove the endless belt strap (021.419) and the lifting tackle from the
holding fixture (437.094).
6. Slide the locking latch (110) into the hole on the adapter head until it is
engaged. In addition, secure the locking latch (110) with a cotter pin
against falling out.
7. Close the fixing latch (105) and secure it with the plug pin (111).

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48/60CR, M010.110.054-02-0001 3 (5)

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103 Shuttle gearbox 107 Locking lever 112 Hand wheel

104 Adapter head 110 Locking latch
105 Fixing latch 111 Plug pin
Figure 1: Fitting/removing the holding fixture (437.094)
4 (5) 48/60CR, M010.110.054-02-0001


104 Adapter head 110 Locking latch
105 Fixing latch 111 Plug pin
Figure 2: Holding fixture (437.094) fitted to turning device (055.130).
18086851979

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48/60CR, M010.110.054-02-0001 5 (5)

18086851979
2018-01-10 - de
48/60CR, M010.110.054-02-0001
Valve group
Summary
execution of work, check components for state/wear condition.
The control valves on the Common-Rail accumulator units are to be replaced
at regular intervals.
The work / work steps include:
Safety requirements
▪ Engine stopped
surised)
Tools/aids required
1 Square insert tool 001.939 Standard
1 Ratchet 008.202 Standard
1 Lubricant (Molykote HSC Plus) - Option

2020-04-20 - de

Valve group
Removal and installation of Common Rail accumulator unit 010.110.054-01

(spill valve)
35/44DF;48/60CR;32/44CR, M010.110.054-03-0001 1 (4)


Work sequence 1 - Dismantling a control valve

Initial situation Non-return valve on valve group removed See Work Instructions
010.110.054-12. Electrical connections of the valve group on corresponding
terminal boxes disconnected. See Work Instructions 010.110.054-14.
Work steps 1. Remove the leaking fuel pipe and fuel supply pipe from the valve group.
2. Detach threaded socket from valve group. See Work Instructions
010.110.054-01.
3. Unscrew and remove the hex socket bolts (4). See Fig. 1.
4. Remove valve group (3) from control valve support (2). Pay attention to
parallel pins (5). Clean valve group (3) and place it on a clean underlay.
5. Remove Variseal sealing ring (6) from the control valve support (2).
Work sequence 2 - Installing a control valve

Initial situation Control valve disassembled and cleaned.
Work steps
Ensure cleanliness of the metallic sealing faces

When installing the non-return valve care must be taken to ensure that
the metallic sealing faces are absolutely clean. Dirt can damage the
sealing faces.
1. Clean the metallic contact and sealing surfaces on the control valve sup-
port (2) and the valve group (3). These sealing surfaces must be free of
dirt and oil.
2. Clean sealing ring groove on control valve support (2) and control valve
(3).
3. Insert new Variseal sealing ring (6) in the sealing ring groove on control
valve support (2).
4. Apply lubricant (Molykote HSC Plus) to the threads and contact surfaces
of the hexagon socket screws (4).
5. Carefully push the valve group (3) onto the control valve support (2). Pay
2020-04-20 - de
attention to the position of parallel pins (5).

6. First screw in the hexagon socket screws (4) until hand-tight and then
tighten in 3 stages: 20 Nm – 50 Nm – 90 Nm. When tightening hexagon
socket screws (4), the tightening sequence A - F must be observed in
each tightening stage. See Figure 1.
Valve group
2 (4) 35/44DF;48/60CR;32/44CR, M010.110.054-03-0001

Pay attention to the strength class of the bolts

When fitting new hexagon socket bolts, make sure that only the spe-
cified hexagon socket bolts with the corresponding strength class are
used.
7. Screw the threaded socket back into the valve group and tighten to the
specified torque. See Work Instructions 010.110.054-01 and
010.000.003-05.
8. Attach removed fuel pipes to valve group. When fitting the fuel pipes,
counter the threaded socket simultaneously to secure it against further
turning and thus against overtightening.
9. Connect electrical connections of the valve group on corresponding ter-
minal boxes. See Work Instructions 010.110.054-14.
10.Install non-return valve on valve group. See Work Instructions
010.110.054-12.
Resetting exhaust gas bal-
ancer
Resetting exhaust gas balancer

After replacing some components of the fuel injection system, the ex-
haust gas balancer has to be reset. For this, refer to work instructions
11.Reset the exhaust gas balancer. Refer to work instructions

2020-04-20 - de
Valve group
35/44DF;48/60CR;32/44CR, M010.110.054-03-0001 3 (4)

1 Common rail accumulator 5 Parallel pin

unit
2 Control valve support 6 Variseal sealing ring
3 Valve group
4 Hexagon socket screw A - F Tightening sequence
Figure 1: Removing and installing a valve group
27021611231679755
2020-04-20 - de
Valve group
4 (4) 35/44DF;48/60CR;32/44CR, M010.110.054-03-0001


Summary
Ensure correct execution of work, check components for state/wear condi-
tion, ensure / restore operational safety.
Control valve supports are to be removed within the scope of maintenance
and repair work.
The work/ working steps include:
Installing components,
Tools/aids required
1 Work holding fixture 437.094 Option
1 Mounting plate 437.094-1 Option
2 Thrust piece, lower 437.094-2 Option
2 Thrust piece, upper 437.094-3 Option
2 Clamping piece, lower 437.094-6 Option
2 Clamping piece, upper 437.094-7 Option
1 Plate holder 437.094-10 Option
1 Fixing plate 437.094-11 Option
1 Holder 437.094-12 Option
1 Adjusting screw 437.094-16 Option
1 Locking bolt 437.094-21 Option
2 Forcing-off bolts 437.094-23 Option
2 Guide pin M16x200 437.094-25 Option
4 Stop 437.094-26 Option
1 Spring clip 437.094-28 Option
3 Ring nut M16 000.188 Option
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1 Quick-acting cleanser Loctite 7061 - Option
1 Paper towels - Inventory
48/60CR, M010.110.054-04-0001 1 (26)


1 Support - Inventory
Technical data
Common-Rail accumulator unit V48/60CR Weight 174 kg
Common-Rail accumulator unit L48/60CR Weight 147 kg
Pressure pipe V48/60CR Weight 103 kg
Pressure pipe L48/60CR Weight 81,6 kg
Jacket pipe V48/60CR Weight 28,4 kg
Jacket pipe L48/60CR Weight 23,0 kg
Control valve support 48/60CR Weight 12,6 kg

installation and removal of work holding fixture on the 010.110.054-02
turnover stand
Removal and installation of valve group 010.110.054-03
removal and installation of the high pressure pump 010.110.054-05
Work Sequence 1 - Disassembly of the Common-Rail accumulator unit

Common rail accumulator unit (50) assembled.
Initial situation The holding fixture (437.094) is correctly installed in the turning device
(055.130) (see Work Instructions 010.110.054-02) and is levelled horizontally.
Locking lever (107) engaged in one groove on adapter head (104). See Fig. 1/
II.
Work steps
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Rotation of the adaptor plate

Owing to the non-axial weight distribution, the adaptor plate may start
rotating and cause injury to parts of the body in the process.
• When working on components, always ensure that the locking lever is
engaged.
Clamping the common rail Initial state: holding fixture (437.094) levelled horizontally and fixed with the
accumulator unit (50) locking lever (107).
2 (26) 48/60CR, M010.110.054-04-0001

1. Both lower thrust pieces (437.094-2) and both lower clamping pieces
(437.094-6) are placed on the adaptor plate (437.094-1) and screwed to
the mounting plate loosely using hex bolts (4, 8) and washers (19). See
Fig. 2.
2. Unscrew the hex bolts (5, 9) with the washers (19, 20). See Fig. 2.
3. Remove both upper thrust pieces (437.094-3), both upper clamping
pieces (437.094-7) with plate bracket (437.094-10), bracket
(437.094-12), fixing plate (437.094-11) and ring nut (14). See Fig. 2.
4. Check whether both lower thrust pieces and both lower clamping pieces
are in contact with the mounting plate and screwed to the adaptor plate
loosely using hex bolts (4, 8) and washers (19).
5. Position the common rail accumulator unit (50) with endless belt strap
(021.419) and lifting tackle (suspended as described in Work Instructions
010.110.054-01) centrally on the lower thrust pieces and the lower
clamping pieces. In the process, ensure that the pipe nozzle (51) on the
jacket pipe (52) is engaged in the groove between the guide rails (30) on
the mounting plate. See Fig. 3.
Observe cutouts (32)

When placing the upper thrust pieces (437.094-3) onto the control
valve support (53), ensure that the cutouts (32) on the upper thrust
pieces (437.094-3) are moved over the detector bolts (57).
6. Place the upper thrust pieces on the control valve support (53), screw in
the hex bolts (5) with washers (20) and tighten the hex bolts (5). In the
process, make sure that there is a gap (65) remaining between the jacket
pipe (52) and the lower clamping pieces. See Fig. 4.
Removal of valve groups 7. Place a receptacle below the cutouts (31) on the mounting plate to col-
(54) lect fuel flowing out of components during disassembly. See Fig. 5.
8. Remove and clean the valve groups (54). See Work Instructions
010.110.054-03.
Removal of the first control 9. Loosen the hex bolts (4) by 1/2 revolution. See Fig. 6/I.
valve support (53) with flow 10.Place the upper clamping pieces on the jacket pipe (52) and bolt them
restrictor (61)
loosely using hex bolts (9) and washers (19). Place the fixing plate with at-
tachment parts on the jacket pipe as shown in the figure. See Fig. 6/II.
11.Screw hex bolts (8) in so far, that the lower clamping piece is in contact
with the jacket pipe (52). Then screw in the hex bolts (8) by ca. 1/2 re-
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volution more. See Fig. 6/III.

12.Tighten the hex bolts (9).
Gap (65) under lower thrust piece provided

Under lower thrust pieces, a small gap (65) must be provided now. See
Fig. 6/IV.
13.Loosen the hexagon socket bolts (58) on both sides but unscrew them
fully only on the side where fixing plate is fitted. See Fig. 7/I.
48/60CR, M010.110.054-04-0001 3 (26)

14.Screw the guide pin (437.094-25) into the pressure pipe (59). See Fig. 7/
II.
15.Unscrew the hex bolts (4) with washers (19) only on the side where the
fixing plate is fitted. See Fig. 7/II.
16.Screw the forcing-off bolts (437.094-23) into the upper thrust piece and
into the lower thrust piece in two diagonally opposite positions. See Fig.
8/I.
17.Press the control valve support (53) with flow limiter (61) out of the jacket
pipe (52) and the pressure pipe (59) by screwing in the forcing-off bolts.
In this step, the parallel pin (60) must remain in the pressure pipe (59).
See Fig. 8/II.
18.Lift the control valve support (53) with the flow limiter (61), upper thrust
piece, lower thrust piece and forcing-off bolts off the mounting plate and
place it on a suitable base.
19.Unscrew the forcing-off bolts at the top of thrust piece and unscrew the
thrust piece at the bottom.
20.Upper and lower thrust piece remain fitted to the control valve support
(53).
21.Unscrew the guide pin from the pressure pipe (59). See Fig. 8/II.
Installing the fixing plate 22.Fold in the fixing plate and fit it to the pressure pipe (59). The fixing plate
(437.094-11) must fit onto the parallel pin (60) and the centring hole of the pressure
pipe (59) without tilting. If necessary, adjust the position of the fixing plate
using the setting screw (437.027-16). See Fig. 9.
23.Insert the hexagon socket bolts (22) through the bores on the fixing plate,
screw them into the pressure pipe (59) and tighten them by hand.
Removal of the 2nd control 24.Unscrew and remove the hexagon socket bolts (58) on the 2nd control
valve support (53) with flow valve support (50). See Fig. 10/I.
limiter (61) 25.Screw the guide pin into the pressure pipe (59). See Fig. 10/I.
26.Unscrew the hex bolts (4) with washers (19) on the second side, where
the fixing plate is not attached.
27.Screw the forcing-off bolts into the upper thrust piece and into the lower
thrust piece at two diagonally opposite positions. See Fig. 10/II.
28.Press the 2nd control valve support (53) with flow limiter (61) out of the
jacket pipe (52) and the pressure pipe (59) by screwing in the forcing-off
bolts. In this step, the parallel pin (60) must remain in the pressure pipe
(59). See Fig. 10/II.
29.Lift off the 2nd control valve support (53) with flow limiter (61), upper
thrust piece, lower thrust piece and the forcing-off bolts from the mount-
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ing plate and place on a suitable base.

30.Unscrew the forcing-off bolts at the top of thrust piece and unscrew the
thrust piece at the bottom.
31.Upper and lower thrust piece remain fitted to the control valve support
(53).
32.Unscrew the guide pin from the pressure pipe (59). See Fig. 10/II.
Removal of the pressure 33.Disengage the locking lever (107).
pipe (59)
4 (26) 48/60CR, M010.110.054-04-0001

34.Position the mounting plate vertically by turning the handwheel (112) so

that fixing plate with the ring nut (14) are accessible from the top. Make
sure that the parallel pin (60) does not fall out of the pressure pipe (59).
See Fig. 11/I.

engaged.
35.Engage the locking lever (107).

36.Fasten the endless belt strap (021.419) to ring nut (14) and hook it into
the lifting tackle. Tension the endless belt strap (021.419) lightly using the
lifting tackle.

37.Remove the spring clip (437.094-28) and the locking bolt (437.094-21)
from the bracket (437.094-12) and the plate bracket (437.094-10). See
Fig. 11/II.
38.Carefully remove the pressure pipe (59) from the jacket pipe (52) upwards
with the lifting tackle. See Fig. 11/III.
39.Carefully place the pressure pipe (59) on a suitable clean base and re-
move the endless belt strap (021.419) from the ring nut (14).
40.Unscrew the hexagon socket bolts (22) and remove the fixing plate from
the pressure pipe (59).
41.Store the hexagon socket bolts (22) by screwing them into the corres-
ponding bores on the mounting plate. See Figs. 1 and 2.
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Cleaning and inspecting the 42.Carefully remove the Variseal sealing rings (62) and O-rings (63) from the
components control valve supports (53) to prevent damage to the sealing ring
grooves. See Fig. 8, Fig. 10 and Fig. 12.
43.Clean the pressure pipe (59) externally. Blow out the bores for the
hexagon socket bolts (58) and the parallel pin (60) in the pressure pipe
(59) using compressed air. Free the central fuel bore in the pressure pipe
(59) of deposits and encrustations and clean it. During installation, the
central fuel-carrying bore must be absolutely clean. If necessary, rub the
metallic sealing face (64) with fibre fleece (see Table 1) radially. See Figs.
11 and 12.
48/60CR, M010.110.054-04-0001 5 (26)

fibre mat - eg. Colour type Grit equiv.

BriteTM Number
7445 White Flint, super fine grade 1200 - 1500
Light Duty
Cleansing
7448 Light Silicon carbide 800 -
Ultra Fine Gray Carbide, ultra fine grade 1000
6448 Dark Gray Silicon Carbide, ultra fine grade 800 - 1000
Light Duty
7447 Maroon Aluminium Oxide, very fine grade 360 - 400

General Purpose
8447 Maroon Aluminium Oxide, very fine grade 360 - 400

Production
Table 1: Nonwoven fabric approved for cleaning the metal sealing faces
44.Free the jacket pipe (52) of deposits and encrustations on the inside and
outside and clean it.
45.Clean the control valve support (53) externally. Blow out the bores for the
hexagon socket bolts (58) and parallel pins (60) using compressed air.
Clean the sealing and contact faces for the O-rings (63) and Variseal seal-
ing rings (62). If necessary, rub the metallic sealing face (64) with fibre
fleece (see Table 1) radially.
46.Clean the hexagon socket bolts (58) and parallel pins (60), blow off using
compressed air if necessary.
Other Work Instructions 47.If necessary, replace the flow limiter (61) on the control valve support (53).
Work Sequence 2 - Assembly of the Common-Rail accumulator unit

Initial situation Control valve supports (53) removed from common rail accumulator unit (50).
Components of common rail accumulator unit (50) cleaned as described in
Work Sequence 1.
Flow limiters (61) fitted to control valve support (53). See Work Instructions
010.110.054-05.
Holding fixture (437.094) positioned vertically and fixed with locking lever
(107). Jacket pipe (52) fitted on mounting plate (437.094-1) using lower
clamping pieces (437.094-6), upper clamping pieces (437.094-7), hex bolts
(8, 9) and washers (19). See Fig. 11/III.
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Have new Variseal sealing rings (62) and new O-rings (63) ready.

engaged.
6 (26) 48/60CR, M010.110.054-04-0001

Work steps 1. Attach the fixing plate (437.094-11) to the pressure pipe (59) using
Fitting the pressure pipe hexagon socket bolts (22). Tighten the hexagon socket bolts (22) by
(59) into the jacket pipe (52) hand. Fasten the endless belt strap (021.419) to the ring nut (14) and
hook it into the lifting tackle. Jacket pipe (52) fixed in the holding fixture as
described in the starting position.

2. Carefully lift the pressure pipe (59) with the lifting tackle. Position it over
jacket pipe (52). See Fig. 11/III.
3. Insert the pressure pipe (59) into the jacket pipe (52) carefully, so that the
plate bracket (437.094-10) may be mounted to the bracket (437.094-12).
See Fig. 11/II.
4. Insert the locking bolts (437.094-21) in the bores on the bracket
(437.094-12) and the plate bracket (437.094-10), and secure them with
spring clips (437.094-28). See Fig. 11/I.
5. Remove the endless belt strap (021.419) from the ring nut (14) and from
the lifting tackle.
Prepare both control valve Initial state: Upper thrust piece (437.094-3) and lower thrust piece (437.094-2)
supports (53) for installa- fitted to control valve support (53) using the hex bolts (5) and washers (20).
tion. See Figs. 13 and 14.
6. Coat the cleaned sealing ring grooves for O-rings (63) and Variseal seal-
ing rings (62) on the control valve support (53) and the new O-rings (63)
with "Molykote HSC Plus" lubricant.
7. Fit the new O-rings (63) and new Variseal sealing rings (62) on the control
valve support (53). During this step, make sure that the O-rings (63) are
not twisted and are equally tensioned around the entire circumference,
and that Variseal sealing rings (62) are not pressed or crushed.
8. If necessary, clean the metallic sealing faces (64) on the pressure pipe
(59) and the control valve support (53) with fibre fleece (see Table 1) using
radial movements to make them free from dirt and fuel deposits. For
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metallic sealing faces (64), see Fig. 12/I.
Cleanliness on metallic sealing faces (64)

After cleaning and during assembling, metallic sealing faces (64) must
be absolutely clean, dry and free from any oil or oil film. Otherwise,
leakages may appear, which may adversely affect correct function of
Common-Rail injection system. See Fig. 12.
48/60CR, M010.110.054-04-0001 7 (26)

9. Clean the metallic sealing faces (64) on the pressure pipe (59) and the
control valve support (53) with fast-acting cleaner (e.g. Loctite 7061) and
paper towel observing the above mentioned notes. See Fig. 12/I.
Installation of the first con- 10.Check whether the pressure pipe (59) is properly secured with fixing plate
trol valve support (53) with (437.094-11), hexagon socket bolts (22), locking bolts (437.094-21) and
flow limiter (61) spring clip (437.094-28). See Fig. 11/I.
11.Disengage the locking lever (107) and turn the mounting plate by 90° us-
ing the handwheel (112), so that adapter plate is levelled horizontally.
During this step, the pressure pipe (59) may move the inside jacket pipe
(52) by several millimetres. See Fig. 13/I.
13.Screw the guide pin (437.094-25) into two adjacent bores on the pres-
sure pipe (59). Tighten slightly. See Fig. 13/I.
14.Position the control valve support (53) prepared for installation with pre-
fitted sealing rings (62, 63) on the mounting plate so that the bores on the
control valve support (53) are flush with the parallel pin (60) and guide pin.
See Fig. 13/I.
When fitting the control valve support make sure that ...
... Variseal sealing ring (62) is not crushed or damaged, and slides into
jacket pipe (52) without distortion.
... parallel pin (60) is fitted in bore on control valve support (53).
15.Insert the control valve support (53) with the flow restrictor (61) into the
guide pin observing the above mentioned note. Slowly insert it into the
jacket pipe (52). See Fig. 13/II.
16.Apply "Molykote HSC Plus" lubricant to the threads and head contact
surfaces of the hexagon socket bolts (58).
17.Screw in 4 hexagon socket bolts (58) several turns crosswise. Make sure
that the control valve support it is not distorted. See Fig. 13/II.
18.Disengage the locking lever (107) and turn the adapter plate by 90° using
the handwheel (112), so that the mounting plate is positioned vertically
and the side with the fixing plate points downwards. See Fig. 13/III.

2018-01-10 - de

engaged.

20.Screw in 4 hexagon socket bolts (58) equally and crosswise, thus press-
ing control valve support (53) into the jacket pipe (52) up to contact with
the pressure pipe (59) without distortion.
21.Loosely screw in the hex bolts (4) with washers (19). Do not tighten the
bolts yet. See Fig. 13/II.
8 (26) 48/60CR, M010.110.054-04-0001

22.Remove the guide pins. Screw in the remaining hexagon socket bolts
(58). Hand-tighten. See Fig. 13/IV.
Tightening the hexagon 23.Check, whether hex bolts (5) on thrust pieces are tightened securely and
socket bolts (58) the hex bolts (4) are screwed in loosely.
Tightening sequence "A1 - A12" when tightening hexagon

socket bolts (58)
Hexagon socket bolts (58) are first tightened by hand and then in 4
steps (see Work Instructions 010.000.003-05 and the following Work
Steps).
For every tightening stage 1 - 4, the tightening sequence "A1 - A12"
must be observed. See Fig. 15.
24.Check, whether the hexagon socket bolts (58) are tightened by hand,
retighten them if necessary.
25.1st stage: Tighten the hexagon socket bolts (58) with 20 Nm.
26.2nd stage: Tighten the hexagon socket bolts (58) with 90 Nm.
27.3rd stage: Tighten the hexagon socket bolts (58) with 155 Nm.
28.4th stage: Tighten the hexagon socket bolts (58) with 210 Nm.
Removal of the fixing plate 29.Disengage the locking lever (107) and turn the adapter plate by 90° using
(437.094-11) the handwheel (112), so that the mounting plate is levelled horizontally.
See Fig. 14/I.

engaged.

31.Check whether the hex bolts (5, 9) are tightened securely and the hex
bolts (4) are screwed in loosely. See Fig. 14/I.
32.Unscrew the hexagon socket bolts (22) from the pressure pipe (59). See
Fig. 14/I.
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33.Fold back the fixing plate with the ring nut (14), bracket (12) and plate
bracket (10) until the ring nut (14) and the hex bolt (16) is in contact with
the jacket pipe (52). See Fig. 14/II.
Installation of the 2nd con- 34.Screw the guide pin into two adjacent bores on the pressure pipe (59).
trol valve support (53) with Tighten slightly. See Fig. 14/II.
flow limiter (61) 35.Position the ready to be installed control valve support (53) including flow
limiter (61) with pre-fitted sealing rings (62, 63) on the mounting plate so
that the bores on the control valve support (53) are flush with the parallel
pin (60) and the guide pin. See Fig. 14/II.
48/60CR, M010.110.054-04-0001 9 (26)

When fitting the control valve support make sure that ...
... Variseal sealing ring (62) is not crushed or damaged, and slides into
jacket pipe (52) without distortion.
... parallel pin (60) is fitted in bore on control valve support (53).
36.Insert the control valve support (53) with the flow restrictor (61) into the
guide pin observing the above mentioned note. Slowly insert it into the
jacket pipe (52). See Fig. 14/II.
37.Apply "Molykote HSC Plus" lubricant to the threads and head contact
surfaces of the hexagon socket bolts (58).
38.Screw in 4 hexagon socket bolts (58) several turns crosswise. Make sure
that the control valve support it is not distorted. See Fig. 14/III.
39.Disengage the locking lever (107) and turn the mounting plate by 90° us-
ing the handwheel (112) so that the adapter plate is positioned vertically
and the control valve support (53) to be fitted is located at the top. See
Fig. 14/IV.
41.Screw in 4 hexagon socket bolts (58) equally and crosswise, thus press-
ing control valve support (53) into the jacket pipe (52) up to contact with
the pressure pipe (59) without distortion.
42.Loosely screw in the hex bolts (4) with washers (19). Do not tighten the
bolts yet. See Fig. 14/III.
43.Remove the guide pins. Screw in the remaining hexagon socket bolts
(58) and tighten hand-tight. See Fig. 14/V.
Tightening the hexagon 44.Check, whether hex bolts (5) on thrust pieces are tightened securely and
socket bolts (58) the hex bolts (4) are screwed in loosely.
Tightening sequence "A1 - A12" when tightening hexagon

socket bolts (58)
Hexagon socket bolts (58) are first tightened by hand and then in 4
steps (see Work Instructions 010.000.003-05 and the following Work
Steps).
For every tightening stage 1 - 4, the tightening sequence "A1 - A12"

must be observed. See Fig. 15.
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45.Check, whether the hexagon socket bolts (58) are tightened by hand,
retighten them if necessary.
46.1st stage: Tighten the hexagon socket bolts (58) with 20 Nm.
47.2nd stage: Tighten the hexagon socket bolts (58) with 90 Nm.
48.3rd stage: Tighten the hexagon socket bolts (58) with 155 Nm.
49.4th stage: Tighten the hexagon socket bolts (58) with 210 Nm.
Installation of valve groups 50.Disengage the locking lever (107) and turn the mounting plate by 90° us-
(54) ing the handwheel (112) so that the common rail accumulator unit (50) is
levelled horizontally. See Fig. 5.
10 (26) 48/60CR, M010.110.054-04-0001


52.If necessary, clean the metallic sealing faces (64) on the control valve
support (53) and the valve groups (54) with fibre fleece (see Table 1) us-
ing radial movements to make them free from dirt and fuel deposits. See
Fig. 12/II.
Cleanliness on metallic sealing faces (64)

After cleaning and during assembling, metallic sealing faces (64) must
be absolutely clean, dry and free from any oil or oil film. Otherwise,
leakages may appear, which may adversely affect correct function of
Common-Rail injection system. See Fig. 12.
53.Clean the metallic sealing faces (64) on the control valve support (53) and
the valve groups (54) with fast-acting cleaner (e.g. Loctite 7061) and with
paper towel observing the above mentioned notes. See Fig. 12.
54.Install valve groups (54). See Work Instructions 010.110.054-03.
Lifting the complete com- Initial state: mounting plate with tensioned common rail accumulator unit (50)
mon rail accumulator unit levelled horizontally. Locking lever (107) engaged. Common rail accumulator
(50) unit (50) completely assembled with valve groups (54), flow limiter (61) and
control valve support (53).
55.Sling the endless belt strap (021.419) around the common rail accumu-
lator unit (50) between clamping pieces and thrust pieces. Attach the
endless belt strap (021.419) to the lifting tackle. Tension the endless belt
strap (021.419) lightly.
56.Unscrew the hex bolts (5, 9) with washers (19, 20). Remove the upper
clamping pieces, upper pressure pieces, plate bracket, bracket and fixing
plate from the common rail accumulator unit (50). See Fig. 2.
57.Lift the common rail accumulator unit (50) with the endless belt strap
(021.419) and the lifting tackle from the holding fixture. Place on a clean,
suitable support, ensuring it cannot turn. In doing so, make sure that the
valve groups (54) are not damaged.
Storage on holding fixture

Refit onto holding fixture tool components removed from adaptor plate
for storage. See Figs. 2, 8, 9 and 13.
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58.Free the holding fixture from dirt and fuel residues.
Illustrations:
The component lengths of Common-Rail accumulator unit (50) and work
holding fixture (437.094) are shown in the Fig.s a little shortened. The proced-
ure for in-line engine and V engine is the same.
48/60CR, M010.110.054-04-0001 11 (26)

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104 Adapter head 110 Locking latch I Tool arrangement
L48/60CR
105 Fixing latch 111 Plug pin II Tool arrangement
V48/60CR
Figure 1: Tool arrangement for in-line and V-engines, work holding fixture (437.094) fitted in turnover stand
(055.130) and locked
12 (26) 48/60CR, M010.110.054-04-0001


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4 Hexagon head bolt 9 Hexagon head bolt 19 Washer

M16x120 M16x250
5 Hexagon head bolt 14 Ring nut M16 20 Washer
M12x170
Figure 2: Work holding fixture (437.094-1) - Removal of tool parts
48/60CR, M010.110.054-04-0001 13 (26)

4 Hexagon head bolt 30 Guide rails 52 Jacket pipe

M16x120
8 Hexagon head bolt 50 Common-Rail accumu-
M12x35 lator unit
19 Washer 51 Pipe nozzle
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Figure 3: Placing Common-Rail accumulator unit (50)
14 (26) 48/60CR, M010.110.054-04-0001

4 Hexagon head bolt 20 Washer 57 Detection screws

M16x120
5 Hexagon head bolt 32 Cutouts 65 Gap present
M12x170
8 Hexagon head bolt 52 Jacket pipe
2018-01-10 - de
M12x35
19 Washer 53 Control valve support
Figure 4: Clamping the Common-Rail accumulator unit (50)
48/60CR, M010.110.054-04-0001 15 (26)

4 Hexagon head bolt 20 Washer 54 Valve group

M16x120
5 Hexagon head bolt 31 Cutouts
M12x170
19 Washer 53 Control valve support
Figure 5: Removal of valve groups (54)
2018-01-10 - de
16 (26) 48/60CR, M010.110.054-04-0001


2018-01-10 - de
4 Hexagon head bolt 19 Washer 65 Gap present

M16x120
8 Hexagon head bolt 50 Common-Rail accumu- 66 No gap present
M12x35 lator unit
9 Hexagon head bolt 52 Jacket pipe I-IV Work Steps
M16x250
Figure 6: Lifting and fixing Common-Rail accumulator unit (50)
48/60CR, M010.110.054-04-0001 17 (26)

4 Hexagon head bolt 19 Washer 58 Hexagon socket bolts

2018-01-10 - de
M16x120
5 Hexagon head bolt 20 Washer I-II Work Steps
M12x170
9 Hexagon head bolt 53 Control valve support
M16x250
Figure 7: 1. Prepare control valve support (53) for removal
18 (26) 48/60CR, M010.110.054-04-0001

5 Hexagon head bolt 59 Pressure pipe 63 O-ring seal

2018-01-10 - de
M12x170
20 Washer 60 Parallel pin I-II Work Steps
52 Jacket pipe 61 Flow limiter
53 Control valve support 62 Variseal sealing ring
Figure 8: Removal of 1st control valve support (53)
48/60CR, M010.110.054-04-0001 19 (26)

13 Hexagon head bolt 22 Hexagon socket bolts 60 Parallel pin

2018-01-10 - de
M16x65 M16x80
14 Ring nut M16 52 Jacket pipe I-II Work Steps
15 Parallel pin 8x50 59 Pressure pipe
Figure 9: Fitting the fixing plate (437.094-11)
20 (26) 48/60CR, M010.110.054-04-0001

5 Hexagon head bolt 58 Hexagon socket bolts 62 Variseal sealing ring

2018-01-10 - de
M12x170
20 Washer 59 Pressure pipe 63 O-ring seal
52 Jacket pipe 60 Parallel pin I-II Work Steps
53 Control valve support 61 Flow limiter
Figure 10: Removal of 2nd control valve support (53)
48/60CR, M010.110.054-04-0001 21 (26)

9 Hexagon head bolt 19 Washer 59 Pressure pipe

2018-01-10 - de
M16x250
14 Ring nut M16 22 Hexagon socket bolts I-III Work Steps
M16x80
15 Parallel pin 8x50 52 Jacket pipe
Figure 11: Removal and installation of pressure pipe (59)
22 (26) 48/60CR, M010.110.054-04-0001


2018-01-10 - de
52 Jacket pipe 60 Parallel pin 64 Metallic sealing face

53 Control valve support 61 Flow limiter 67 Parallel pin
54 Valve group 62 Variseal sealing ring 68 Variseal sealing ring
59 Pressure pipe 63 O-ring seal
I Metallic sealing face (64) between control valve support (53) and pressure pipe (59)
II
Metallic sealing face (64) between control valve support (53) and valve group (54)
Figure 12: Metallic sealing faces (64) on pressure pipe (59), control valve support (53) and valve group (54)
48/60CR, M010.110.054-04-0001 23 (26)

2018-01-10 - de

M16x120
5 Hexagon head bolt 52 Jacket pipe 60 Parallel pin
M12x170
14 Ring nut M16 53 Control valve support 61 Flow limiter
19 Washer 58 Hexagon socket bolts I-VI Work Steps
Figure 13: Installation of 1st control valve support (53)
24 (26) 48/60CR, M010.110.054-04-0001


2018-01-10 - de

M16x120
5 Hexagon head bolt 22 Hexagon socket bolts 60 Parallel pin
M12x170 M16x80
9 Hexagon head bolt 52 Jacket pipe 61 Flow limiter
M16x250
14 Ring nut M16 53 Control valve support
19 Washer 58 Hexagon socket bolts I-V Work Steps
48/60CR, M010.110.054-04-0001 25 (26)

Figure 14: Installation of 2nd control valve support (53)
53 Control valve 58 Hexagon socket A1- Tightening se-

support bolts A12 quence
Figure 15: Tightening sequence "A 1- A12" for hexagon socket bolts (58)
18086844811
2018-01-10 - de
26 (26) 48/60CR, M010.110.054-04-0001

Flow limiter
Summary
Flow limiters must be checked and/or replaced during maintenance.
Tools/aids required
1 Installation device for the flow limiter 437.028 Option
1 Bolt 437.028-1 Option
1 Thrust piece 437.028-2 Option
1 Sleeve 437.028-3 Option
1 Holder 437.029 Option
1 Mounting sleeve 437.029-1 Option
1 Clamping piece 437.029-2 Option
1 Extractor device 48/60CR 437.032 Option
1 Tensioning spindle 48/60CR 437.032-1 Option
1 Conical socket 437.032-2 Option
1 Spherical disc 437.032-3 Option
1 Extractor device 32/44CR 437.033 Option
1 Tensioning spindle 32/44CR 437.033-1 Option
1 Pliers for locking rings D18 002.182 Standard

dismantle and assemble the Common Rail accumulator unit 010.110.054-04
2020-11-17 - de
Technical data
Check dimension (A) 32/44CR Dimension 80 ±0,5 mm
Flow limiter
Check dimension (A) 48/60CR Dimension 93 ±0,5 mm

Control valve support Weight 13 kg
48/60CR;32/44CR, M010.110.054-05-0001 1 (5)

Work Sequence 1 - Removing the flow limiter

Initial situation Control valve support (2) removed and cleaned. See Work Instructions
010.110.054-04.
Work steps 1. Remove the internal parts of the flow limiter (locking ring (20), valve spring
(7) and valve piston (6)) from the flow limiter (1). See Fig. I/0. When re-
moving the locking ring, press the valve piston against the valve spring,
as this is pre-tensioned by the valve spring. Detached internal parts of the
flow limiter must be disposed of and may not be reused. New internal
parts must be used for the installation.
2. Insert the tensioning spindle (437.032-1 or 437.033-1) of the extractor
device (437.032 or 437.033) in the flow limiter (1) and secure it with the
locking ring (20). See Fig. 1/I.
3. Clamp the clamping piece (437.029-2) in a machine vice and set the con-
trol valve support (2) with the flow limiter (1) and tensioning spindle
(437.032-1 or 437.033-1) on the clamping piece (437.029-2). In doing
so, make sure the parallel pins (3) on the control valve support engage in
the bores on the clamping piece. See Fig. 1/II.
4. Guide the mounting sleeve (437.029-1) over the tensioning spindle
(437.032-1 or 437.033-1) and place the mounting sleeve on the control
valve support (2). In doing this, make sure the parallel pin (8) enters the
bore in the control valve support.
5. Screw the hex bolts (12) through the mounting sleeve (437.029-1) into
the clamping piece (437.029-2) and tighten them.
6. Guide the conical socket (437.032-2), spherical disc (437.032-3) and ball
bearing (10) over the tensioning spindle (437.032-1 or 437.033-1) and
the screw hex nut (11) onto the tensioning spindle.
7. Extract the flow limiter (1) from the control valve support (2) by turning the
hex nut (11). See Fig. 1/III.
8. Remove the locking ring (20) with the locking ring pliers (002.182), extract
the flow limiter (1) from the tensioning spindle (437.032-1 or 437.033-1)
and remove it from the extractor device (437.032 or 437.033).
9. Unscrew the extractor device (437.032 or 437.033) from the mounting
sleeve (437.029-1) and remove it through the bore of the mounting
sleeve.
Work Sequence 2 - Installing the flow limiter

Initial situation Old flow limiter removed. Clamping piece clamped in the machine vice. Con-
2020-11-17 - de
trol valve support and mounting sleeve bolted to the clamping piece one by
one. See Fig. 2/II. Have the new flow limiter ready for installation.
Work steps 1. Lightly oil the journal on the flow limiter (1) and the bore for flow limiter in
control valve support (2).
2. Screw the fitting device (437.028) through the opening of the mounting
Flow limiter
sleeve (437.029-1) into the mounting sleeve.

3. Insert the flow limiter (1) in the bore of the control valve support (2).
4. Press the flow limiter (1) into the control valve support (2) until seated by
turning the fitting device (437.028). Make sure that the flow limiter is posi-
tioned slightly off-centre and guided through the fitting device when
2 (5) 48/60CR;32/44CR, M010.110.054-05-0001

screwing it in. When pressing the flow limiter into the control valve sup-
port, the maximum torque of 130 Nm may not be exceeded. See Fig. 2/
III.
5. Remove the complete tool.
6. Check dimension "A". See Fig. IV.
Result of check dimension If the check dimension "A" is outside the tolerance, a new flow limiter (1) must
"A" be fitted.
Resetting the exhaust gas 7. Reset the exhaust gas balancer. After replacing some components of the
balancer fuel injection system, the exhaust gas balancer has to be reset. Refer to
Work Instructions 010.285.000-49 in the folder 010.285 SaCoSone Vol.
36028810487735051
02.
2020-11-17 - de
Flow limiter
48/60CR;32/44CR, M010.110.054-05-0001 3 (5)

2020-11-17 - de
1 Flow limiter 6 Valve piston 11 Hex nut

2 Control valve support 7 Valve spring 12 Hex bolt
Flow limiter
3 Parallel pin 8 Parallel pin 20 Locking ring

5 Machine vice 10 Ball bearing 0-III Work steps
Figure 1: Removal of the flow limiter
4 (5) 48/60CR;32/44CR, M010.110.054-05-0001

2020-11-17 - de
1 Flow limiter 5 Machine vice A Check dimension

Flow limiter
2 Control valve support 12 Hex bolt

3 Parallel pin I-IV Work steps
Figure 2: Flow limiter installation
36028810487735051
48/60CR;32/44CR, M010.110.054-05-0001 5 (5)

36028810487735051
2020-11-17 - de
Flow limiter
48/60CR;32/44CR, M010.110.054-05-0001
Common-Rail accumulator unit

check for tightness
Summary
checking for leaks,
Safety requirements
▪ Engine stopped
surised)
Tools/aids required
2020-04-21 - de

1 Bar magnet - Inventory
35/44DF;48/60CR;32/44CR, M010.110.054-06-0001 1 (8)



(spill valve)
Technical data
high-pressure pump
(009.342)


2020-04-21 - de
Use slushing oil

2 (8) 35/44DF;48/60CR;32/44CR, M010.110.054-06-0001



without damage.
Work Sequence - Checking the Common-Rail accumulator unit for leaks

Initial situation

Prerequisites with Com- The Common-Rail accumulator unit may be checked for tightness, if it is in-
mon-Rail accumulator unit stalled on the engine. For this purpose, the following prerequisites must be
installed met:
Unforeseen switching the valve group

In case of unforeseen switching the valve group with mounted elec-
trical connections to the valve group hydraulic oil will escape under
high-pressure and cause persons injuries resulting in death.
• Electrical connections are removed
▪ The electrical connections on valve groups (10) must be removed from the
2020-04-21 - de
corresponding terminal boxes.

▪ High-pressure fuel pipes connected to the Common-Rail accumulator unit
(1) from below must be removed. See Work Instructions 010.110.052-02.
▪ Fuel injection pipes may remain fitted.
▪ Leakage drain pipe is removed.
Prerequisites with Com- The Common-Rail accumulator unit (1) may also be checked for tightness, if it
mon-Rail accumulator unit is removed from the engine (see Work Instructions 010.110.054-01). Thereby
removed the following conditions are applied:
▪ Common-Rail accumulator unit (1) is secured against rolling.
▪ The bores for the fuel injection pipes can remain unsealed.
35/44DF;48/60CR;32/44CR, M010.110.054-06-0001 3 (8)

Work steps
faces

age.

smooth surface.
010.110.060-02.
Fitting the test devices to
Common-Rail accumulator
unit

When fitting the test device, ensure cleanliness of the metallic sealing
faces. Dirt can cause damage to the sealing faces.
2. Clean the thread and sealing surfaces of the Common-Rail accumulator

unit (1), pressure-testing set (435.005) and locking screw (435.006). See
Figure 1.
3. Apply clean lubricant to the sealing surfaces and threads on the pres-
sure-testing set (435.005) and screw plug (435.006).
2020-04-21 - de
Hold cone
Hold cone (K) when tightening with torque. If the cone of the test tool is
twisted under pressure, sealing faces may be damaged as a result.
4. Screw the pressure-testing set (435.005) and screw plug (435.006) into
the lower bores on the common rail accumulator unit (1) and tighten to
the specified torque of 280 Nm. In doing so hold cone in place.
5. Connect the pressure-testing set (435.005) with high-pressure hose
(009.306) to the high-pressure pump (009.342).
4 (8) 35/44DF;48/60CR;32/44CR, M010.110.054-06-0001

Leakage test of Common-

Rail accumulator unit, step
1 (installed on engine)

and safety goggles
Pressure build-up
Pressure build-up may last several minutes, because the Common-Rail
accumulator unit must be filled with slushing oil first, and the air must
be compressed.
If the pressure is not built up within 10 minutes, continue with tightness
test of Common-Rail accumulator unit, step 2:
6. Start the high-pressure pump (see Work Instructions 015.000.003-01)

and build up the pressure slowly, until the test pressure of 1,400 bar is
achieved. At the same time, check the slushing oil level in the high-pres-
sure pump (009.342) and top up slushing oil if necessary.

7. For the duration of 1 minute, observe the Common-Rail accumulator unit

(1) for leaks and the pressure indication of high-pressure pump (009.342)
for any pressure drops.
9. Depressurise the high-pressure pump (009.342).
2020-04-21 - de
10.Check the component for leakages (L11, L12, L13). See Figure 1.
Component Leakage point New condition Used (bar/min)
Common rail accumulator Connections L11, L12, L13 0 0

unit
35/44DF;48/60CR;32/44CR, M010.110.054-06-0001 5 (8)

Remaining leakage points 0 <= 200

(in this condition not neces-
sarily visible)
Table 1: Reference values for permissible pressure drop during the leakage test of the Common-Rail accu-
mulator unit, step 1
18014411972206603
Evaluation of leakage points Leaks at the leak connections L11, L12 and L13 may have the following
causes:
▪ Incorrect tightening torque of test tools (L11, L12). Check assembly.
▪ High-pressure sealing surfaces damaged (L11, L12). Check again, if ne-
cessary rework the high-pressure sealing surfaces. See Work Instructions
010.110.060-02.
▪ High-pressure groups of valve group / control valve support (L13) leaking.
Check the valve group’s installation. See Work Instructions
010.110.054-03.
▪ High-pressure groups of rail pipe / control valve support (L13) leaking. Re-
place the common rail accumulator unit. See Work Instructions
010.110.054-01.
Pressure drop available, reference value from Table is achieved, however no
leakages flowing out from leak connections:
▪ Carry out tightness test with additional prerequisites for leakage test of
Common-Rail accumulator unit, step 2.
Leakage test of Common- Provide additional prerequisites for leakage test of Common-Rail accumulator
Rail accumulator unit, step unit, step 2:
2 (installed on engine) 11.Remove both balance pipes (if any) and balance valves. See Work In-
structions 010.110.054-12.
12.Remove both low pressure pipes from leakage points L14 and L15.
Perform a leakage test as described in step 1 of the leakage test for the com-
mon rail accumulator unit.
Serious leakages on valve group

Under unfavourable conditions, the main pilot slide valve of the valve
group may be in the open position, thus making pressure build-up im-
possible. During the engine operation, the main pilot slide valve is im-
mediately closed due to the significantly higher feed volume of the
Common-Rail high-pressure pumps.
2020-04-21 - de
If no pressure build-up is possible and the feed volume of the high-pressure

pump (009.342) flows out from below either of the two valve groups (10), pull
the main pilot slide valve (9) of the valve group into its seat using suitable
means (e.g. bar magnet). See Figure 1, Detail "X".
6 (8) 35/44DF;48/60CR;32/44CR, M010.110.054-06-0001

Other very serious leakages on valve group

If very serious leakages on valve group continue, the valve group con-
cerned must be replaced. The decisive factors for component replace-
ment are the engine's operating values or possible failures / error mes-
sages (e.g suction throttle position and exhaust gas temperature) dur-
ing engine operation.

Table 2 is intended to classify the pressure drop or to provide criteria
for component replacement.
Component Leakage point New condition Used
Common rail accumulator Connections L11, L12, L13 0 0

unit
Leakage points L16, L17 0 Dropping leakage permiss-
(main pilot slide valve of ible; flowing leakage not
valve group) permissible
Leakage points L14, L15 0 Dropping leakage permiss-

(flushing pipe connection on ible; flowing leakage not
valve group) permissible
Table 2: Reference values for permissible pressure drop during the leakage test of the Common-Rail accu-
mulator unit, step 2
18014411972206603
Leakage test of Common- The leakage test of the Common-Rail accumulator unit in disassembled con-
Rail accumulator unit in dis- dition must be carried out similar to the tightness test in assembled condition.
assembled condition For this purpose, the Common-Rail accumulator unit must be secured against
rolling away. The Common-Rail accumulator unit must be aligned according
to the position of the main pilot slide valve (9) so that the magnets of valve
groups are pointed upwards. See Figure 1.
2020-04-21 - de
35/44DF;48/60CR;32/44CR, M010.110.054-06-0001 7 (8)

1 Common rail accumulator unit L11 High-pressure sealing surface

2020-04-21 - de
9 Main pilot slide valve L12 High-pressure sealing surface

10 Valve group L13 Leak connection
L14 Leakage point on connection of flushing
pipe
K Cone L15 Leakage point on connection of flushing
pipe
S Seat of main pilot slide valve L16 Non-return valve (splitting) connection
leakage
L17 Non-return valve (splitting) connection
leakage
Figure 1: Testing equipment fitted to the common rail accumulator unit
18014411972206603
8 (8) 35/44DF;48/60CR;32/44CR, M010.110.054-06-0001

Valve block
Summary
The valve block and its component parts must be checked and/or replaced
as part of maintenance work.
Safety requirements
▪ Engine stopped
surised)
▪ Control air shut off / control air pipe depressurised
Tools/aids required
2021-03-05 - de

Valve block

Check the high-pressure fuel pipe for leakage 010.110.052-04
Removal and installation of pressure limiting valve 010.110.054-09
48/60CR, M010.110.054-07-0003 1 (6)


Removal and installation of Rail pressure measuring trans- 010.290.157-01
ducer
Technical data
Jacket pipe, consisting of: purge valve, pres- 15,6 kg
Weight
sure limiting valve
Purge valve Weight 12,8 kg
Pressure-limiting valve Weight 2,8 kg
Warning messages
Incorrectly installed non-return valve may cause injury

If the non-return valve is installed the wrong way around, this may lead
to fuel discharge while the engine is running and cause smoke emis-
sion and injury as a result.
• Observe flow direction
• Install the non-return valve correctly
Work sequence 1 – Removing the valve block

The valve block is located at the end of the longitudinal side of the engine in
front of the common rail accumulator units connected in series.
Rail pressure measuring transducer removed. See Work Instructions
010.290.157-01.
Work steps 1. Remove the high-pressure fuel pipe (5). See Work Instructions
010.110.052-02. See Fig. 1.
2. Loosen the union nuts on the fuel line (6) and remove the fuel line.
3. Loosen the outer nuts on fuel line (1) and fuel line (13) and remove com-
pletely with the non-return valve (8). The non-return valve (8) must be dis-
2021-03-05 - de
mantled together with fuel lines (1) and (13). The nuts on the non-return
valve (8) must not be loosened.
4. Loosen the union nuts on the air pipe (2) and remove the air pipe.
5. Unscrew the cap screws (7) and remove the valve block (3). Pay attention
to the parallel pins (12). See Fig. 2.
Valve block
6. Remove the adapter (9) with sealing ring (15) from the valve block. See
Fig. 3.
7. Clean the valve block and the adapter.
8. If necessary, take the pressure limiting valve (10) out of the flushing valve
(11) and clean both components. See Work Instructions
010.110.054-09.
2 (6) 48/60CR, M010.110.054-07-0003

Work sequence 2 – Installing the valve block

Initial situation Valve block removed.
The pressure-limiting valve is attached to the flushing valve (11).
Valve block cleaned on the outside.
Pressure limiting valve and flushing valve (11) checked. See Work instructions
010.110.054-09.
Work steps 1. Screw adapter (9) with a new sealing ring (15) into the valve block. See
Fig. 3.
2. Attach the valve block with cap screws (7) and parallel pins (12), and then
tighten the cap screws (7). In doing so, be careful not to damage the par-
allel pins (12). See Fig. 2.
3. Check the high-pressure fuel pipes (5) for leakages. See Work instruc-
tions 010.110.052-04.
4. Install the high-pressure fuel line (5). See Work instructions
010.110.052-02. See Fig. 1.
5. Install the rail pressure measuring transducer on the valve block. See
Work instructions 010.290.157-01.
6. Attach the fuel line (6).
27021622310432907
WARNING Incorrectly installed non-return valve may cause injury
7. Attach fuel lines (1 and 13) together with non-return valve (8). Observe
flow direction (A) at the non-return valve (8) when installing. The nuts on
the non-return valve (8) must not be loosened. See Fig. 1.
8. Attach air line (2).
9. Install the previously removed casing.
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Valve block
48/60CR, M010.110.054-07-0003 3 (6)

2021-03-05 - de
1 Fuel line 5 High-pressure fuel pipe 12 Parallel pin

2 Air pipe 6 Fuel line 13 Fuel line
Valve block
3 Valve block 7 Cap screw A Flow direction

4 Block 8 Non-return valve
Figure 1: Attached valve block
4 (6) 48/60CR, M010.110.054-07-0003

2021-03-05 - de
3 Valve block 7 Cap screw 12 Parallel pin

Figure 2: Dismantling the valve block, pipes removed
Valve block
48/60CR, M010.110.054-07-0003 5 (6)

3 Valve block 10 Pressure-limiting valve 15 Sealing ring

9 Adapter 11 Purge valve
Figure 3: Dismantling the socket with sealing ring from the valve block
27021622310432907
2021-03-05 - de
Valve block
6 (6) 48/60CR, M010.110.054-07-0003

Flush valve
disassembly, clean and assembly
Summary
The flushing valve must be checked and/or replaced as part of maintenance
work.
Tools/aids required
1 Degreasing and cold cleaning agent - Inventory

Removal and installation of valve block 010.110.054-07
Removal and installation of pressure limiting valve 010.110.054-09
Warning messages
Damage to the flushing valve due to incorrect cleaning agents

The flushing valve may be damaged if it is cleaned with rough/hard
cleaning cloths or brushes.
• Only clean the flushing valve using a soft cloth or soft paper combined
with white spirit, diesel oil or brake cleaner.
Work sequence 1 – Disassembling and cleaning the flushing valve

2020-11-19 - de
Initial situation Valve block removed. See Work Instructions 010.110.054-07. Pressure-limit-
ing valve removed. See Work Instructions 010.110.054-09.
Work steps 1. Unscrew the stud bolts (8). See Fig. 2.
2. Remove the cover (7).
Flush valve
3. Remove the spring (5) and place it on a clean base.

4. Pull the air piston (3) with control piston (2) out of the piston casing (6)
holding the air piston casing in place so that it will not be released from
the valve body (1).
5. Remove the control piston (2) from the air piston (3), and place both parts
down on a clean base.
35/44DF;48/60CR;32/44CR, M010.110.054-08-0001 1 (4)

NOTICE Damage to the flushing valve due to incorrect cleaning agents

6. Clean all individual parts, check them for damage and renew if necessary.
Work Sequence 2 – Assembling the flushing valve

Initial situation Flush valve disassembled, individual parts checked, cleaned or replaced.
Work steps 1. Carefully insert the air piston (3) with control piston (2) into the air piston
casing (6) and the valve body (1). Make sure that the control piston does
not tilt in valve body.
2. Check air piston (3) and control piston (2) for ease of movement.
3. Fit the spring (5) onto the air piston (3).
4. Fit the cover (7) over the pressure relief pin and place it on the air piston
casing (6).
5. Screw in the cap screws (8) and tighten them crosswise.
Opening the flush valve mechanically

There is an alternative option (e.g. prior to assembly work on the sys-
tem) of opening the flush valve in a purely mechanical manner. In this
case, the air piston is moved against the spring force until it reaches
the stop by fitting and tightening an additional M8 nut on the pressure
relief pin (10), and thus the flush valve is opened.
This is also necessary if the pressure in the common-rail system on the
display cannot be reduced via the common engine stopping proced-
ures. The supply and return flow of the low-pressure fuel supply to the
engine should be shut off only after relieving the pressure in the com-
mon-rail system.
After completion of the installation work, it is mandatory to remove the
nut to ensure regular activation of the flush valve before the next en-
gine start.
The following flush valve positions are indicated by the protrusion
length “A” on the pressure relief pin:
• Flush valve completely closed: protrusion length “A” on the pressure re-
lief pin approx. 10 mm (engine operation)
• Flush valve completely open: protrusion length “A” on the pressure re-
lief pin approx. 22 mm (flushing operation / hot standby)
2020-11-19 - de
27021611233001227
Flush valve
2 (4) 35/44DF;48/60CR;32/44CR, M010.110.054-08-0001

1 Valve body 5 Spring 10 Pressure relief pin

2 Control piston 6 Air piston casing
3 Air piston 7 Cover
4 Sealing ring 8 Cap screw A Protrusion length
Figure 1: Flush valve – sectional view
2020-11-19 - de
Flush valve
35/44DF;48/60CR;32/44CR, M010.110.054-08-0001 3 (4)

1 Valve body 5 Spring 8 Cap screw

2020-11-19 - de
2 Control piston 6 Air piston casing

3 Air piston 7 Cover
Figure 2: Disassembly and assembly of flush valve
27021611233001227
Flush valve
4 (4) 35/44DF;48/60CR;32/44CR, M010.110.054-08-0001

Pressure limiting valve

Summary
execution of work, check components for state/wear condition.
The pressure limiting valve is to be dismantled within the scope of the service
and maintenance work.
Safety requirements
▪ Engine stopped
surised)

2020-09-18 - de

Technical data
Jacket pipe, consisting of: purge valve, pres- 15,6 kg
Weight
sure limiting valve
Purge valve Weight 12,8 kg
Pressure-limiting valve Weight 2,8 kg
35/44DF;48/60CR;32/44CR, M010.110.054-09-0001 1 (4)


Removal and installation of valve block 010.110.054-07
Notice on replacing the pressure limiting valve
Component damage due to worn pressure limiting valve

A worn pressure limiting valve may cause malfunctions during engine
operation or cause damage to other components.
• Emergency operation with an open pressure limiting valve is permiss-
ible for a maximum of 100 hours. After this, the pressure limiting valve
must be replaced.
• The pressure limiting valve must be replaced after 100 switching inter-
vals.
See also 010.005 Engine Operating Instructions, 010.00.034-03.
Note on work sequences

The pressure limiting valve can, in the event of an assembled or disassembled
valve block, be removed from or refitted to the flushing valve.
The relevant method is described in the individual work sequences.
Work Sequence 1 - Dismantling the pressure limiting valve with an attached valve block
Initial situation The valve block is attached to the engine. Casing of the injection system is re-
moved. If necessary, rocker arm casing above the valve block removed.
Work steps 1. Remove all the piping of the pressure limiting valve that hinders its de-
taching.
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2. Remove non-return valve (if present) and piping between the distributor
block and pressure limiting valve (2). See Work Instructions
010.110.054-07.
3. Unscrew pressure limiting valve (2) with open ring spanner insert
(009.682) from the flush valve (1) and clean on the outside. See Fig. 1.
4. Remove O-ring seal (3) from the pressure limiting valve (2) and clean ring
groove for the O-ring seal.
5. Clean the screw thread and valve seating surface on pressure limiting
valve (2) and flush valve (1).
2 (4) 35/44DF;48/60CR;32/44CR, M010.110.054-09-0001

1 Flush valve 3 O-ring

2 Pressure limiting valve
Figure 1: Removed pressure limiting valve
Work Sequence 2 - Assembly of the pressure limiting valve with an attached valve block
Initial situation Pressure limiting valve removed and cleaned on the outside. The flush valve is
mounted on the engine. Close off the bore on the flush valve for the pressure-
limiting valve with suitable material to prevent contamination.
Work steps
Prevent contamination
Ensure extreme cleanliness of the metallic sealing faces when fitting
the pressure limiting valve. Dirt can damage the sealing faces.
1. Apply clean lubricant (Molub-Alloy Paste White T) to a new O-ring (3) and
insert it into the ring groove on the pressure-limiting valve (2). Make sure
the O-ring (3) is not damaged by the thread on the pressure-limiting valve
during assembly and it is equally tensioned after installation and not twis-
ted.
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2. Clean the thread and sealing surfaces on the pressure-limiting valve (2)
and the flush valve (1).
3. Apply clean lubricant (Molub-Alloy Paste White T) to the threads and seal-
ing surfaces between the pressure-limiting valve (2) and the flush valve
(1).
4. Screw pressure limiting valve (2) with an open ring spanner insert
(009.682) into flush valve (1) and tighten it to the specified torque. See
Work Instructions 010.000.003-05. See Figure 1.
5. Install non-return valve (if present) with piping between the distributor
block and pressure limiting valve (2). See Work Instructions
010.110.054-07.
35/44DF;48/60CR;32/44CR, M010.110.054-09-0001 3 (4)

6. Reinstall all the piping of pressure limiting valve (2) that was removed for
its detaching.
Work sequence 3 - Dismantling the pressure limiting valve with disassembled valve
block
Starting position Valve block removed and cleaned externally. See Work Instructions
010.110.054-07.
Work Steps 1. Clamp flush valve (1) with a suitable protection jaw in the vice.
2. Unscrew pressure limiting valve (2) with open ring spanner insert
(009.682) from flush valve (1). See Fig. 1.
3. Remove O-ring seal (3) from pressure limiting valve (2) and clean ring
groove for the O-ring seal.
4. Clean the screw thread and valve seating surface on pressure limiting
valve (2) and flush valve (1).
Work Sequence 4 - Installing the pressure limiting valve with disassembled valve block
Initial situation Pressure limiting valve removed from the flush valve. Components cleaned.
Work steps
Prevent contamination
Ensure extreme cleanliness of the metallic sealing faces when fitting
the pressure limiting valve. Dirt can damage the sealing faces.
45036009741245963
1. Apply clean lubricant (Molub-Alloy Paste White T) to a new O-ring (3) and
insert it into the ring groove on the pressure-limiting valve (2). Make sure
that the O-ring (3) is not damaged by the thread on the pressure-limiting
valve (2) during assembly, and it is equally tensioned and not twisted after
installation.
2. Clean the thread and sealing surfaces on the pressure-limiting valve (2)
and the flush valve (1).
3. Apply clean lubricant (Molub-Alloy Paste White T) to the threads and seal-
ing surfaces between the pressure-limiting valve (2) and the flush valve
(1).
4. Clamp the flush valve (1) in the vice with a suitable protection jaw.
5. Screw pressure limiting valve (2) with an open ring spanner insert
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(009.682) into flush valve (1) and tighten it to the specified torque. See
45036009741245963
Work Instructions 010.000.003-05. See Figure 1.
4 (4) 35/44DF;48/60CR;32/44CR, M010.110.054-09-0001

Non-return valve (purging)

Summary
The non-return valve (flushing) must be checked and/or replaced as part of
maintenance work.
Safety requirements
▪ Engine stopped
surised)
Tools/aids required


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48/60CR, M010.110.054-10-0001 1 (5)

Warning messages
Malfunction due to incorrectly applied non-return valve

If the non-return valve (flushing) is not installed in the place from which
it was removed, the entire common rail injection system will no longer
work correctly.
• Install the non-return valve (flushing) in the precise position from which
it was removed.
Damage to the sealing surfaces due to turning when under

pressure.
If the cone of the valve seat is twisted under pressure, the sealing
faces will be damaged.
• Brace the valve seat when tightening using torque.
Work sequence 1 – Removing the non-return valve

Initial situation The non-return valve (flushing) is located at the end of the in-line common rail
accumulator units, and is attached to each cylinder bank at the bottom of the
common rail accumulator unit. Casing of the injection system upstream of the
non-return valve (flushing) removed.
Work steps 1. Unscrew the union nuts on the fuel supply pipe (3) and remove the fuel
supply pipe. See Fig. 1.
2. Remove the fitting (5) from the non-return valve (4). See Fig. 2/I.
NOTICE Damage to the sealing surfaces due to turning when under pres-
sure.
3. Unscrew the non-return valve (4) using the open ring spanner insert size
41 (009.195), bracing the valve seat using the hexagon socket screw-
driver (000.299).
4. Remove the O-ring (8) and the backing ring (9) from the ring groove on
the non-return valve (4). See Fig. 2/II.
5. Clean the ring groove on the non-return valve (4).

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6. Clean the non-return valve. Be especially sure to clean the sealing sur-
faces and threads on the non-return valve and common rail accumulator
unit.
Work sequence 2 – Installing the non-return valve

Initial situation Non-return valve (4) cleaned; in particular, sealing surfaces and threads on the
non-return valve and in the common rail accumulator unit (7) cleaned. Have a
new O-ring (8) ready. Replace the backing ring (9) if necessary.
Work steps 1. Lubricate the ring groove on the non-return valve (4), new O-ring (8) and
backing ring (9) and the counter surfaces with lubricating oil.
2 (5) 48/60CR, M010.110.054-10-0001

2. Insert the backing ring (9) and the O-ring (8) in the ring groove in the cor-
rect order. See Fig. 2.
3. Apply lubricant to the thread and sealing surfaces of the non-return valve
(4).
sure.
18014416589131787
4. Screw the non-return valve (4) into the threaded bore on the common rail
accumulator unit (7) using the open ring spanner insert size 41 (009.195)
and tighten it to the prescribed torque; in doing so, brace the valve seat
with a hexagon socket screwdriver (000.299). See Work Instructions
010.000.003-05.
5. Screw the socket (5) into the non-return valve (4).
6. Attach the fuel supply pipe (3) with a union nut.
7. Re-installing the casing on the injection system.

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48/60CR, M010.110.054-10-0001 3 (5)

1 Plug-in fuel pipe 4 Non-return valve (flush- 7 Common rail accumu-

ing) lator unit
2 Socket 5 Threaded socket
3 Fuel feed pipe 6 Rail bracket

Figure 1: Installed non-return valve
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4 (5) 48/60CR, M010.110.054-10-0001

1 Plug-in fuel pipe 5 Threaded socket I-II Work steps

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2 Socket 8 O-ring
4 Non-return valve (flush- 9 Backing ring
ing)
Figure 2: Removing and installing the non-return valve (flushing); fuel supply pipe (3) removed
18014416589131787
48/60CR, M010.110.054-10-0001 5 (5)

18014416589131787
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48/60CR, M010.110.054-10-0001

Summary
The non-return valve (flushing) and its individual parts must be checked and/or
replaced as part of maintenance work.
Tools/aids required

Warning messages


sembly.
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sealing rings.
Work sequence 1 – Disassembling the non-return valve

Starting position Non-return valve removed and cleaned on the outside. See Work Instructions
010.110.054-10.
Work Steps 1. Press out thrust pad (1) with valve seat (4) from thrust screw (5). Turn the
thrust pad with the valve seat with hexagon screwdriver (000.299) in the
thrust screw a few times, and restore mobility.
35/44DF;48/60CR;32/44CR, M010.110.054-11-0001 1 (3)

2. Remove backing rings (6 and 8) and O-ring seals (7 and 9) from thrust
screw (5).
3. Clean the thrust piece (1) incl. valve seat (4) and thrust screw (5). Take
special care to clean the sealing ring grooves on the thrust screw.
4. Screw out thrust piece (1) from valve seat (4).
5. Check all individual parts for damage. Especially convex sealing faces on
the valve seat (4) are to be checked for damage. Replace the non-return
valve or pressure spring (2), if required.
Work sequence 2 – Assembling the non-return valve

Initial situation Non-return valve disassembled, cleaned and checked for damage; compon-
ent parts replaced if necessary.
Work steps 1. Clean the sealing surfaces in the valve seat (4) and on the spring piston
(3) and thrust piece (1).
2. Apply lubricant to the thread of the thrust piece (1).
3. Assemble the valve spring (2) and spring piston (3) in the thrust piece (1)
and screw them into the valve seat (4). Tighten the thrust piece in the
valve seat to the prescribed torque. See Work Instructions
010.000.003-05.
4. Apply lubricant to the ring grooves on the thrust screw (5).
27021611231772683
NOTICE Damage to the sealing rings due to thread.
5. Apply lubricant to the new O-rings (7 and 9).
6. Insert the new backing rings (6 and 8) and the lubricated O-rings (7 and
9) in the designated ring grooves on the thrust screw (5) in the correct
positions.
7. Apply lubricant to the contact surface between the thrust piece (1) and
the thrust screw (5) and the bore surface in the thrust screw.
8. Press the valve seat (4) with the thrust piece (1) into the thrust screw (5)
up to the contact surface.
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2 (3) 35/44DF;48/60CR;32/44CR, M010.110.054-11-0001

1 Thrust piece 4 Valve seat 7 O-ring

2 Valve spring 5 Thrust screw 8 Backing ring
3 Spring piston 6 Backing ring 9 O-ring
Figure 1: Non-return valve disassembled
27021611231772683

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35/44DF;48/60CR;32/44CR, M010.110.054-11-0001 3 (3)

27021611231772683
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35/44DF;48/60CR;32/44CR, M010.110.054-11-0001
Adapter with non-return valve (splitting)

Summary
The adapters with non-return valve (splitting) must be checked and/or re-
placed as part of maintenance work.
Safety requirements
▪ Engine stopped
surised)

1 open ring spanner insert size SW32 009.193 Standard


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pipe)
Dismantling and assembling the check valve (flushing) 010.110.054-13
48/60CR, M010.110.054-12-0001 1 (6)

Warning messages
Damage to the sealing surfaces due to turning when under

pressure.
If the cone of the valve seat is twisted under pressure, the sealing
faces will be damaged.
• Brace the valve seat when tightening using torque.

sembly.
sealing rings.
Work sequence 1 – Removing the non-return valve

Initial situation The non-return valves are located at the ends of the common rail accumulator
units. They are screwed into the valve groups. Casing of the injection system
removed.
Work steps 1. Remove the high-pressure fuel pipe (1). See Work Instructions
010.110.052-03.
sure.
2. Unscrew the non-return valve (2) using open ring spanner insert size 41
(009.195), bracing the valve seat at the same time using the hexagon
screwdriver.
3. Take the O-ring (6) out of the ring groove on the non-return valve (2). See
Fig. 3.
4. Clean the ring groove on the non-return valve (2).
5. Clean the non-return valve, especially convex and tapered sealing sur-
faces and threads on the non-return valve (2) and the valve group (3).
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Work sequence 2 – installing the non-return valve

Initial situation Non-return valve (2) cleaned, especially convex and tapered sealing surfaces
and threads on the non-return valve (2) and inside the valve group (3). Have a
new O-ring (6) ready.
Work steps 1. Apply lubricant to the thread and convex sealing surfaces of the non-re-
turn valve (2).
2. Apply lubricant to the ring groove for the O-ring (6).
3. Insert the new O-ring (6) into the ring groove.
4. Remove the thread cover from the thread if necessary.
2 (6) 48/60CR, M010.110.054-12-0001

5. Apply lubricant to the contact surface (9) between the thrust ring (7) and
the thrust screw (8). See Fig. 4.
sure.
6. Screw the non-return valve (2) into the valve group (3) and tighten to the
specified torque. Brace the valve seat simultaneously. See Work Instruc-
tions 010.000.003-05.
7. Install the high-pressure fuel line (1). See Work Instructions
010.110.052-03.
Resetting the exhaust gas 8. Reset the exhaust gas balancer. After replacing some components of the
balancer fuel injection system, the exhaust gas balancer has to be reset. Refer to
Work Instructions 010.285.000-49 in the folder 010.285 SaCoSone Vol.
18014416589144075
02.

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1 High-pressure fuel pipe (balance pipe) 4 Common rail accumulator unit

2 Non-return valve 5 Distributor section
3 Valve group
Figure 1: Installed non-return valve
48/60CR, M010.110.054-12-0001 3 (6)

2 Non-return valve 4 Common rail accumulator unit

3 Valve group
Figure 2: Removing and installing the non-return valve (high-pressure fuel pipe removed)
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4 (6) 48/60CR, M010.110.054-12-0001


2 Non-return valve 4 Common rail accumulator unit
3 Valve group 6 O-ring
Figure 3: Disassembled non-return valve
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48/60CR, M010.110.054-12-0001 5 (6)

6 O-ring 8 Thrust screw

7 Thrust ring 9 Contact surface
Figure 4: Contact surfaces on the thrust ring and thrust screw
18014416589144075
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6 (6) 48/60CR, M010.110.054-12-0001


Summary
The non-return valve (flushing) and its individual parts must be checked and/or
replaced as part of maintenance work.
Tools/aids required
1 Hexagon screwdriver insert 8x12.5 001.854 Standard
1 High-strength screw locking agent (Loctite - Option
272)

(spill valve)

Technical data
Spacing Dimension 7,5 ±0,5 mm
Warning messages
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sembly.
sealing rings.
48/60CR, M010.110.054-13-0001 1 (3)

Damage due to unauthorised opening of the valve seat

The valve seat was calibrated and checked at MAN Energy Solutions
and may only be dismantled by MAN Energy Solutions personnel. If the
(valve seat – stroke limiter) connection is opened, the calibration will
be lost and this could result in property damage.
• Do not open the (valve seat – stroke limiter) connection
Work sequence 1 - Disassembling non-return valve

Initial situation Non-return valve removed and cleaned on the outside. See Work Instructions
010.110.054-12.
Work steps NOTICE Damage due to unauthorised opening of the valve seat
1. Heat thrust ring (7) to max. 200°C until the Loctite 272 screw lock re-
leases and the thrust ring (7) can be easily unscrewed from the stroke
limiter (10) (left-hand thread!). Brace the stroke limiter (10) with hex bolt
screwdriver insert (001.854) whilst doing so. The breakaway torque of the
thrust ring when being dismantled must never be greater than the tight-
ening torque between valve seat (1) and stroke limiter (10).
2. Slide the valve seat (1) and the stroke limiter (10) off the thrust screw (6).
3. Remove the O-ring (8) from the thrust screw (6).
4. Clean the thrust ring (7), thrust screw (6), stroke limiter (10), and valve
seat (1). Especially clean the sealing ring groove on the thrust screw (6).
5. Check all individual parts for damage, and renew if necessary. Especially
convex sealing faces on the valve seat (1) are to be checked for damage.
Work sequence 2 - Assembling non-return valve

Initial situation Non-return valve disassembled, cleaned and components checked for dam-
age; replace individual damaged parts if necessary.

Work steps 1. Apply lubricant to the ring groove for the O-ring (8) on the thrust screw
(6).
2. Apply lubricant to the new O-ring (8).
27021615847259403
3. Insert the new, lubricated, O-ring (8) into the ring groove on the thrust
screw (6).
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4. Apply lubricant to the contact surface between the thrust ring (7) and the
thrust screw (6) and the bore surface in the thrust screw (6).
5. Slide the valve seat (1) and the stroke limiter (10) into the thrust screw (6).
6. Apply screw lock Loctite 272 only to the thread on the valve seat (1).
7. Brace the stroke limiter (10) with hexagon screwdriver insert (001.854)
and simultaneously screw the thrust ring (7) onto the valve seat (1) (left-
hand thread!). Also maintain clearance dimension A. See Figs. 1 and 2.
2 (3) 48/60CR, M010.110.054-13-0001

1 Valve seat 8 O-ring

6 Thrust screw 10 Stroke limiter
7 Thrust ring
Figure 1: Disassembled non-return valve

1 Valve seat 8 O-ring
6 Thrust screw
7 Thrust ring A Spacing
Figure 2: Assembled non-return valve
27021615847259403
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48/60CR, M010.110.054-13-0001 3 (3)

27021615847259403
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48/60CR, M010.110.054-13-0001
connecting and disconnecting
Summary
Ensure correct works performance, ensure/restore operational safety.
The cables of valve groups and high-pressure pumps are to be disconnected
or connected during service and maintenance work.
Removing and disconnecting the components,
Checking the parts/ components,
Installing and connecting the components.
Safety requirements
l Engine stopped
Tools/aids required
1 Torch - Inventory
1 Operating tool for cable terminals (e.g. Wago - Inventory
product)

Disassembly and assembly of the high pressure pump 010.110.050-02
2018-01-15 - de
close the crankshaft oil bore 010.030.010-05
Technical data
Power supply Voltage 90 V
Power supply Current 12 - 18 A
48/60CR, M010.110.054-14-0001 1 (9)

Work Sequence 1 - Disconnecting the cables

Initial situation Component with cabling (valve group, high-pressure pump) must be re-
moved.
Work steps
Disconnect the components
from power supply
Danger due to electric shock

When working on electrical systems, there is a potential hazard of an
electric shock due to direct contact with live parts or due to sparking
voltage which can lead to heart rhythm disorder. Furthermore, there is
a potential hazard of severe burns. Other subsequent injuries could oc-
cur due to uncontrolled movements.
Before any work, five safety rules must be applied according to DIN EN
50110 to eliminate potential hazards.
• Disconnect (switch off all the poles).
• Secure against restart.
• Ensure de-energized state.
• Provide earthing and short-circuit.
• Cover and screen adjacent live parts.
1. Press the emergency stop button.

2. Switch off the fuses for the Injection Module and then disconnect the
cable to be disconnected from power supply.
Removal of cabling
Mark the cable routing and terminals of the cable to be discon-

nected
For the correct installation as well as for the correct connection of the
new cable, it is necessary to mark or to note the cable routing and the
terminal connection in the terminal box.
3. Screw out the screws on the cover (2) of the terminal box (1) for the cable
2018-01-15 - de
(3) to be disconnected and remove the cover (2). See Fig. 1.

4. Disconnect the cable (3) from the cable terminal in the terminal box (1) by
means of the operating tool (e.g. Wago product, see Figure 3).
5. Release all the cable bands between the terminal box (1) and the com-
ponent to be removed.
6. Loosen and remove all cable clips (6) between the terminal box (1) and
the component to be dismantled.
7. Unscrew the union nut (5) from the clamping insert (4), pull the cable (3)
through the clamping insert (4) out of the terminal box (1) and remove the
cable (3) up to the component to be dismantled.
2 (9) 48/60CR, M010.110.054-14-0001

8. Remove the component to be dismantled. See Work Instructions

010.110.054-03 for removal of the valve group, Work Instructions
010.110.050-01 for removal of the high-pressure pump, Work Instruc-
tions 010.110.050-02 for removal of the magnet on the high-pressure
pump, and Work Instructions 010.110.054-01 for removal of the com-
9. Screw the cover onto the terminal box again to protect the cover and the
screws from loss and to protect the internal parts of terminal box from
dirt.
Work Sequence 2 - Connecting the cables

Initial situation Disconnected component is installed. The cabling for the reinstalled compon-
ent (valve group, high-pressure pump) is disconnected from the terminal box
and removed between the component and terminal box.
Work steps
Disconnect the components
from power supply
Danger due to electric shock

When working on electrical systems, there is a potential hazard of an
electric shock due to direct contact with live parts or due to sparking
voltage which can lead to heart rhythm disorder. Furthermore, there is
a potential hazard of severe burns. Other subsequent injuries could oc-
cur due to uncontrolled movements.
Before any work, five safety rules must be applied according to DIN EN
50110 to eliminate potential hazards.
• Disconnect (switch off all the poles).
• Secure against restart.
• Ensure de-energized state.
• Provide earthing and short-circuit.
• Cover and screen adjacent live parts.
1. Press the emergency stop button.

2. Switch off the fuses for the Injection Module and then disconnect the
cable to be disconnected from power supply.
Installing the cabling
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48/60CR, M010.110.054-14-0001 3 (9)

The original cable routing is to be restored.

The original cable routing is to be restored. If necessary, the cable
routing of an adjacent cylinder is to be adopted. Otherwise, the correct
function of the engine could be affected. The following boundary con-
ditions are also valid:
Reconnect the cables according to the circuit diagram.
The cables must be sufficiently fixed with cable bands outside the ter-
minal box.
Do not overtighten the cable bands.
Any protrusion at the cable bands must be cut off flush.
The maximum distance for the cable strap is 250 mm.
The minimum radius for the cable is 50 mm.
The insulation on the cable must have a protrusion of min. 3 mm in re-
lation to the clamping insert in the terminal box.
The cables must not be in contact with each other or scuffed.
The cables must not be in contact inside the terminal box or with the
cover or rub.
3. Check the cables (3) for damage. Replace the cables if necessary.
4. Pull the cables through the cable routing and cable ducts up to the ter-
minal box (1).
5. Unscrew the union nut (5) from the clamping insert (4) and push the union
nut (5) over the cable (3).
6. Push the cable (3) through the clamping insert (4) at the terminal box (1).
7. Let the cable insulation (3) in the terminal box (1) protrude by 3 mm in re-
lation to the clamping clip (4) and fix the cable (3) with the union nut (5).
8. Connect the cables (3) to the corresponding terminals in the terminal box
– as before removal – using the operating tool (e.g. Wago product).
9. Fit the cover (2) on the terminal box (1) and tighten the screws on the
cover (2).
10.Fix the cables (3) by means of cable bands and cable clips (6) according
to their installation position before removal, taking into account the above
stated boundary conditions, and cut off any projection of cable bands
after the cable bands have been tightened. Figure 3 and Figure 4 show
the cabling in new condition. When installing the cabling, the routing
2018-01-15 - de
shown in the illustrations or the new condition of the cable routing must
be restored as precisely as possible.
11.If Viton hoses are fitted at cable clips (6) to protect the cables, they must
be cut to length on the left and right hand side of the cable clip (6) so that
a protrusion of 15 mm is achieved on each side.
4 (9) 48/60CR, M010.110.054-14-0001

Reprogramming of the injection electronics

If the injection modules were de-energized, the system requires repro-
gramming. This process is carried out automatically. The reprogram-
ming process is only finished, when the engine has been operated at
different loads for about 15 min. Until this process is finished, false
alarms may occur on rare occasions. Before replacing a part, first wait
for the reprogramming process to be completed.

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1 Terminal box 3 Cable 5 Union nut

2 Cover 4 Clamping insert 6 Cable clip
Figure 1: Cabling on the terminal box
48/60CR, M010.110.054-14-0001 5 (9)

Figure 2: Terminal box with correctly connected cabling

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6 (9) 48/60CR, M010.110.054-14-0001

Figure 3: Cable routing from terminal box to valve group and high-pressure pump
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48/60CR, M010.110.054-14-0001 7 (9)

Figure 4: Cable routing and cable attachment to valve group

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8 (9) 48/60CR, M010.110.054-14-0001

Figure 5: Operating tool for cable terminals (Wago product)

18089712779

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48/60CR, M010.110.054-14-0001 9 (9)

18089712779
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48/60CR, M010.110.054-14-0001
Leakage points at the common rail injection system

localising and repairing
Summary
If a fracture leakage occurs on the common rail injection system, it must be
located and rectified.
Tools/aids required
1 Adapter 437.021 Standard
1 cleaning agents - Inventory

Check the high pressure pump for leakage 010.110.050-04
pipe)
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Check the Common-Rail accumulator unit for leakage 010.110.054-06
(spill valve)
Carry out a pressure test of the Common-Rail accumulator 010.110.060-01
unit, check for leaks
Removal and installation of detection sensor 010.290.157-02
48/60CR, M010.110.054-15-0001 1 (8)

Work sequence – Locating and repairing leakages

Initial situation The engine control unit indicates a leakage in the breakage leak tank.
Fault tree diagram The diagram shown in Fig. 1 serves as a central instrument for locating and
remedying a leakage on the common-rail injection system. The diagram in-
cludes work steps and decision steps which are numbered and described be-
low. In contrast to normal Work Instructions conventions, the sequence of the
individual work steps and decision steps should be taken from the fault tree
diagram. The diagram should be read by following the arrows and starting at
work step 1.
2020-12-07 - de
1 – 15 Work steps and decision steps y Yes

a, b, c Decision option at step 4 n No
Figure 1: Fault tree diagram for locating and remedying a leakage on the common-rail injection system
Description of the work The engine control unit indicates a leakage in the breakage leak tank.
steps and decision steps:
1 – Work Step (initial situ-
ation)
2 – Work Step ▪ The following safety requirements must be met before work can continue:
2 (8) 48/60CR, M010.110.054-15-0001

– Engine stopped
– Emergency stop activated (this reduces the high pressure in the com-
mon rail injection system to a low pressure level)
– Engine secured against staring: starting air disabled
– Engine fuel system isolated from plant-side fuel system
– Engine fuel system depressurised/emptied (corresponding drain cock
– perhaps on the fuel filter – open, i.e. the supply and return lines in
the engine fuel system are both depressurised)
– Control air shut off/control air pipe depressurised
– Power supply/generation interrupted
3 – Decision step ▪ Locate the common rail accumulator unit which the engine control unit in-
dicated as leaking.
▪ Acknowledge the fault display in the engine control.
▪ Decision: Can the fault be acknowledged? yes/no
4 – Decision step ▪ Remove the casing of the injection system in front of the indicated com-
▪ Mark the installation positions of the detector screws. Marking is import-
ant in identifying the leakage points.
▪ Unscrew the detector screws (31, 32) with the adaptor (437.021) from the
corresponding common rail accumulator unit. See Fig. 3.
▪ Inspect the detector screws (31, 32) for contact with leakage fuel. Contact
between the leakage fuel and a detector screw indicates a leakage. This
contact manifests itself either via adhering leakage fuel in detection area A
of the detector screw or via leakage fuel that has accumulated in the blind

bore of the detector screw. See Fig. 3. See also the description in
010.005 Engine – Operating Instructions 010.000.034-11.
▪ Decision: How many detector screws indicate a leakage?
Number of wetted detector Frequency Cause Action
screws
One Regular occurrence 1 leakage point Proceed to b
Four * Occasional occurrence System is flooded Proceed to a
Detection impossible Rare occurrence Contamination Proceed to a
Two, three Rare occurrence Multiple leakage points Proceed to b
None Rare occurrence Other leakage points Proceed to c

Table 1: Decision-making criteria for paths a, b, c
9007217341136907
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* If the flooding in the system persists, it may be assumed that the cause is
the high-pressure fuel pipe (34) or the fuel injection pipe (33) leaking intensely.
In this case, all 4 pipes (beginning with both high-pressure fuel pipes (34)) are
to be replaced one after another until the leakage is eliminated.
▪ Decision: Proceed to a, b or c? See Fig. 1.
5 – Work Step ▪ Determine the leakage point via the wetted detector screw. The detector
screw (31) indicates leakage in the fuel injection line (33) The detector
screw (32) indicates a leakage in the high-pressure fuel pipe (34) or in the
non-return valve (39) in flushing mode. In flushing mode, for each cylinder
bank, the non-return valve (39) is attached to the outermost common rail
accumulator unit instead of a high-pressure fuel pipe. It should be re-
48/60CR, M010.110.054-15-0001 3 (8)

placed if the corresponding detector bolt (32) on this common rail accu-
mulator unit has come into contact with leakage fuel. See Fig. 2 and
Fig. 3.
▪ Replace the component part that is causing the leak. See Work Instruc-
tions 010.110.052-02 for the high-pressure fuel pipe, Work Instructions
010.110.052-01 for the fuel injection line and/or Work Instructions
010.110.054-10 for the non-return valve (39) for flushing mode.
6 – Work Step ▪ Clean all removed detector screws (31, 32). Detection area “A” and blind
holes in the detector screws must be free of leakage fuel. In HFO opera-
tion use a suitable cleaning agent. See Fig. 3.
▪ Clean the bores for the detector screws in the control valve supports (41).
In HFO operation use a suitable cleaning agent.
▪ Apply lubricant to the thread of the detector screws.
▪ Screw all unscrewed detector screws into the control valve support (41)
with adapter (437.021) and tighten to the specified torque. See Work In-
structions 010.000.003-05.
7 – Work Step ▪ Make sure that the requirements for engine start-up are satisfied:
– Attach the casing of the injection system
– Reconnect the engine fuel system to the plant-side fuel system
– Flood the engine fuel system with fuel from the plant-side fuel system
(the corresponding drain cock should be open, i.e. the supply and re-
turn lines in the engine fuel system should be at low-pressure level)
– Disable the control air shut-off / control air pipe pressurized
– Enable the starting air
– Release the emergency stop
– Reconnect the voltage supply / voltage generation

▪ Start the engine.
8 – Decision step ▪ Prerequisite: engine is running.
▪ Check the engine control unit for error messages:
– Breakage leak tank indicates leakage – yes / no
– Detection sensor indicates leakage – yes / no
▪ Decision: Leakage present yes / no
9 – Work Step ▪ No leakages present.
▪ Repairs completed.
10 – Work Step ▪ Prerequisite: engine is running.
▪ Allow the to engine to run until the first detection sensor in the engine
control unit indicates a leakage.
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11 – Work Step ▪ Remove the balancing pipes (44) and non-return valve (balancing) (43) of
the indicated common rail accumulator unit. See Work Instructions
010.110.052-03 for the spill pipe, and Work Instructions 010.110.054-12
for the non-return valve (spill valve).
▪ Clean the sealing faces and counter surfaces on the distributor piece (38),
spill pipes (44), non-return valves (spill valves) (43) and valve groups (42),
check them for damages and replace any damaged components as re-
quired.
▪ Install spill pipes (44) and non-return valves (spill valves) (43). See Work In-
structions 010.110.052-03 and 010.110.054-12.
12 – Work Step ▪ Remove the casing of the injection system in front of the indicated com-
4 (8) 48/60CR, M010.110.054-15-0001

▪ Remove valve groups. See Work Instructions 010.110.054-03.

▪ Inspect the valve group (42) and the control valve support (41) for leakage
fuel and washout due to leakage fuel at the sealing surfaces and replace
damaged components as required.
▪ Install the valve groups. See Work Instructions 010.110.054-03.
▪ Replace the common rail accumulator unit (30). See Work Instructions
010.110.054-01.
▪ Remove the detection sensor (20) according to the description in Work In-
structions 010.290.157-02, clean it and then re-install it.
15 – Work Step ▪ Replace the cabling of the detection sensor (20) and/or the detection
sensor itself. See Work Instructions 010.290.157-02.
Illustrations:

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48/60CR, M010.110.054-15-0001 5 (8)

20 Detection sensor 38 Distributor section

21 Drain manifold 39 Non-return valve for flushing mode
22 Leakage fuel drain pipe 41 Control valve support
30 Common-Rail accumulator unit 42 Valve group
33 Fuel injection pipe 43 Non-return valve (splitting)
34 High-pressure fuel pipe 44 Spill pipe
36 High pressure pump 50 Fuel injection valve
37 Threaded piece
Figure 2: Common-Rail accumulator unit with fitted components and corresponding detection sensor
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6 (8) 48/60CR, M010.110.054-15-0001


30 Common-Rail accumulator unit 41 Control valve support
31 Detector bolt for fuel injection pipe 42 Valve group
32 Detector bolt for high-pressure fuel pipe or A Detection area
non-return valve (39) for flushing operation
35 Blind hole in the detector bolt B Not a detection area
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Figure 3: Common-Rail accumulator unit with detector bolts
Additional information: In addition to Work Instruction 010.110.054-15, the following Work Instruc-
tions are available. These Work Instructions describe the procedure for leak-
age detection and for evaluation of the tightness and condition of common rail
injection systems.
48/60CR, M010.110.054-15-0001 7 (8)

Additional Work Instructions Work Instructions Title

010.110.060-01 Performing pressure testing on the common rail system, leak
testing
010.110.054-06 Checking the common rail accumulator unit for leaks
010.110.050-04 Checking the high-pressure pump for leaks
010.110.052-04 Checking the high-pressure fuel pipe for leaks
010.110.060-02 Reworking common rail component parts of the sealing surface
(conical)/handling high-pressure fuel pipes
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8 (8) 48/60CR, M010.110.054-15-0001


components
51353938699
1 (1)

Common rail system

carrying out a pressure test, checking for leaks
Summary
Check the operating material system for leaks. Ensure/re-establish operating
reliability.
Locate leakage.
checking for leaks,
Safety requirements
▪ Engine stopped
surised)
Tools/aids required
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Common rail system

48/60CR, M010.110.060-01-0001 1 (13)


Check the high pressure pump for leakage 010.110.050-04
Check the Common-Rail accumulator unit for leakage 010.110.054-06
Localizing and repairing leakages on the Common-Rail in- 010.110.054-15
jection system
Removal and installation of Rail pressure measuring trans- 010.290.157-01
ducer
Technical data
Brief description of the working steps

Work Sequence 1 - Short-time test
describes possibility, enabling to test the common-rail injection system for still
present and sufficient tightness when the engine is stopped from idle running.
Work Sequence 2 - Converting the valve block for pressure test, carrying out
a pressure test
describes possibility, enabling to test the complete fitted common-rail injection
system for tightness. For this purpose certain prerequisites must be fulfilled,
and the valve block must be modified.
Work Sequence 3 - Refitting the valve block after pressure test
describes valve block refitting after the completed tightness test according to
Work Sequence 2.
Work Sequence 4 - Localization of leakages via tightness tests on subsys-
tems
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describes the possibility to locate leakages via tightness tests on subsystems

Common rail system
of the common-rail injection system.
high-pressure pump
(009.342)
2 (13) 48/60CR, M010.110.060-01-0001


Use slushing oil



without damage.
Work Sequence 1 - Short-time test

Preliminary information This short-time test may be carried out after a normal engine stop from idling.
During idle running (engine load = 0 %), the pressure in Common-Rail injec-
tion system is approx. 1600 bar.
HFO MDO MGO
Reference values 1000 1200 1500

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Common rail system
for pressure drop in

bar/min.
Table 1: Reference values for pressure drop during short-time test
Reference values for pressure drop during short-time test

The reference values are used to enable classification of the pressure
drop and wear condition of the Common Rail injection system.
Initial situation
48/60CR, M010.110.060-01-0001 3 (13)


Work steps
Pressure in Common-Rail system after engine stop

When the engine is stopped through switching off the injection, the
high pressure in the Common-Rail injection system remains intact after
engine stop (engine speed = 0 rpm) for 2 minutes. Then high-pressure
relief is then activated automatically via the engine control.
2 minutes after engine has stopped

In 2 minutes after engine stop the pressure or the pressure drop in
Common-Rail system may be observed on the display of engine con-
trol.
1. Release normal engine stop from idling.

2. Immediately after engine stop observe the pressure indication in Com-
mon-Rail system on the display of engine control (starting at engine
speed = 0 1/min.) within 1 minute.
3. After 1 minute record the pressure indicated on the display.
4. The difference between the both values (initial pressure – pressure after 1
minute) gives the pressure drop value in bar/min.
Test result evaluation If the pressure drop is less than or equal to the reference value from Table 1:
▪ the Common-Rail injection system may be further operated.
If the pressure drop is higher than the reference value from Table 1, and alarm
as well as changed engine's operating values are available:
▪ proceed as per Work Sequence 4.
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Common rail system
Alarms and engine's operating values

If at the pressure drop higher than the reference value from Table no
alarm as well as no abnormal engine's operating values are available,
there is no demand for prompt acting. However, at a pressure drop
higher than the reference value from Table 1, fault signals must be
taken into account in foreseeable time.
4 (13) 48/60CR, M010.110.060-01-0001

Work Sequence 2 - Converting the valve block for pressure test, carrying out a pressure
test
Initial situation
Meeting the general prerequisites

Prior to starting the work, ensure that the requirements under "General
prerequisites" are met.
Work steps 1. Remove all leak fuel drain pipes (22) between the common rail accumu-
Removing the leak fuel lator units (30) and the drain pipe (21). See Fig. 2.
drain pipes
Changing over the valve
block
Only remove one rail pressure measuring transducer

To prevent fuel or slushing oil escaping from the adjacent rail pressure
measuring transducer, only one rail pressure measuring transducer
may be removed.
2. Remove a rail pressure measuring transducer (1) from the valve block (2).

When fitting the pressure-testing set, ensure cleanliness of the metallic
3. Screw the pressure-testing set (435.003) into valve block (2) and tighten
to the specified torque 25 Nm. See Fig. 1.
Release the emergency stop. Allow the pressure to build up.

If the emergency stop is actuated, the flushing valve is actuated and a
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pressure build up during the test procedure is not possible.

Common rail system
4. Release the emergency stop (flushing valve closes).

5. Connect the pressure-testing set (435.003) with high pressure hose
(009.306) to the high-pressure pump (009.342).
48/60CR, M010.110.060-01-0001 5 (13)


and safety goggles
The pressure relief valve must be open

During the pressure test, it is absolutely imperative to ensure that the
pressure relief valves on the fuel supply and fuel return lines are open.
Due to functional reasons, leakages occur at high-pressure carrying
common rail components during the pressure test. These leakages are
internally fed directly into the low pressure fuel system. With closed
pressure relief valves on the fuel supply and fuel return lines, imper-
missible high pressures build up in the low-pressure system, resulting
in damage to components and in escaping test fluid. These damages
cause intensive leakages in the fuel injection system during engine op-
eration.
Pressure build-up
Pressure build-up may take several minutes, because the common rail
injection system must be filled with slushing oil first, and the air must
be compressed.
If the pressure build-up fails, this indicates a serious leakage.

of 1,400 bar is achieved.
Test pressure build-up cannot be achieved

Due to the low capacity of the high-pressure pump (009.342) in relation
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to that of the high-pressure pumps of the common rail injection sys-

Common rail system
tem, a pressure drop as low as 1,000 bar/min can lead to the maximum
test pressure of 1,400 not being achieved during the pressure test in
case of severe leakages. In this case, proceed as per Work Sequence
3 and Work Instructions 010.110.054-15.

6 (13) 48/60CR, M010.110.060-01-0001

7. Observe the common rail system for 1 minute, especially checking the
lower area for leakage on the break leak connections of the common rail
accumulator units (30), while simultaneously observing the pressure indic-
ation of the high-pressure pump (009.342) for a pressure drop.
Test result evaluation Pressure drop is less than or equal to 1,000 bar/min:
▪ The common rail system may continue to be operated.
Pressure drop is higher than 1,000 bar/min:
▪ Refit the valve block after the completed leakage test (see Work Se-
quence 3) and then localize and repair the leakage. See Work Instructions
010.110.054-15.
Localizing and repairing leakage

If the procedure described in Work Instructions 010.110.054-15 is un-
successful, the procedure described in Work Sequence 4 in these
Work Instructions may be used.
Work Sequence 3 - Refitting the valve block after pressure test

Initial situation

Pressure test on common rail injection system has been carried out. All sys-
tem components checked for leaks.
Work steps
Keep the sealing faces clean

Ensure cleanliness of the metallic sealing faces when removing the
pressure-testing set and fitting the rail pressure measuring transducer.
Dirt can cause damage to the sealing elements.
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Common rail system
1. Remove the pressure testing set (435.003). See Fig. 1.

2. Install the rail pressure measuring transducer (1) in the valve block (2).
3. Fit the leak fuel drain pipes (22) between the common rail accumulator
units (30) and the drain pipe (21). See Fig. 2.
48/60CR, M010.110.060-01-0001 7 (13)

Work Sequence 4 - Localization of leakages via tightness tests on subsystems

Preliminary information Use this procedure if the procedure described in Work Instructions
010.110.054-15 was unsuccessful.
Initial situation Previous leakage tests of complete common rail injection system resulted in a
pressure drop higher than 1000 bar/min. Leakages could not be located.

Procedure description Subsystems of the common rail injection system are closed with the pressure-
testing set (435.003) and the screw plug (435.006) and tested for leaks. The
pressure-testing set (435.003) is screwed into the valve block. Screwing-in
positions (A, B, C …) for the screw plug (435.006) are on the other end of the
subsystem to be tested. The subsystem can be closed with the screw plug
(435.006) in the screwing-in positions shown on Fig. 3. For the first leakage
test of the subsystem the screw plug is screwed into screwing-in position A.
See Fig. 3. After each leakage test, the tested area of the subsystem is re-
duced by refitting the screw plug (435.006) in the next screwing-in position in
the valve block direction. If the pressure in the subsystem remains constant or
drops considerably slower than during the previous leakage test, it means,
that the leakage is present in the components which were last excluded from
the subsystem. These components may be:
▪ high-pressure fuel pipe or high-pressure pump.
or
▪ high-pressure fuel pipe or common rail accumulator unit.
The area of the leakage can be localised further by carrying out a leakage test
on these components. In doing so, the removed high pressure fuel line is al-
ways tested for leaks first. If the high-pressure fuel pipe is not leaking, test the
high-pressure pump or common rail accumulator unit for leaks. See Work In-
structions 010.110.050-04, 010.110.052-04, 010.110.054-06.
Work steps
Changing over the valve
block
Only remove one rail pressure measuring transducer

2018-01-10 - de
Common rail system
To prevent fuel or slushing oil escaping from the adjacent rail pressure
measuring transducer, only one rail pressure measuring transducer
may be removed.
1. Remove a rail pressure measuring transducer (1) from the valve block (2).
8 (13) 48/60CR, M010.110.060-01-0001


When fitting the pressure-testing set, ensure cleanliness of the metallic
2. Screw the pressure-testing set (435.003) into the valve block (2) and
tighten to the specified torque of 25 Nm. See Fig. 1.
Close the subsystem
Screwing-in position of the screw plug

For the first leakage test of the subsystem the screw plug is screwed
into screwing-in position A. See Fig. 3. After each leakage test, the
tested area of the subsystem is reduced by refitting the screw plug in
the next screwing-in position in the valve block direction. Changing
from one screwing-in position to the next means that one high pres-
sure fuel line and one common rail accumulator unit or one high pres-
sure fuel line and one high-pressure pump are excluded.
3. Remove the high-pressure fuel pipe (34) from the corresponding screw-
ing-in position (high-pressure pump or common rail accumulator unit) of
the subsystem. See Fig. 3.
4. Clean the sealing faces and threads at the corresponding screwing-in po-
sition (high-pressure pump or common rail accumulator unit) and screw
plug (435.006).
5. Coat the sealing faces and threads of the screw plug (435.006) with
clean "Optimol White T" lubricant.
6. Screw the screw plug (435.006) into the corresponding screwing-in posi-
tion (common rail accumulator unit or high-pressure pump) on the other
end of the subsystem and tighten with a prescribed torque of 280 Nm.
7. Connect the high pressure hose (009.306) to the pressure-testing set
Carry out a leakage test of
the subsystem
Release the emergency stop. Allow the pressure to build up.

If the emergency stop is actuated, the flushing valve is actuated and a
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pressure build up during the test procedure is not possible.

Common rail system
8. Release the emergency stop.
48/60CR, M010.110.060-01-0001 9 (13)


and safety goggles
The pressure relief valve must be open

During the pressure test, it is absolutely imperative to ensure that the
pressure relief valves on the fuel supply and fuel return lines are open.
Due to functional reasons, leakages occur at high-pressure carrying
common rail components during the pressure test. These leakages are
internally fed directly into the low pressure fuel system. With closed
pressure relief valves on the fuel supply and fuel return lines, imper-
missible high pressures build up in the low-pressure system, resulting
in damage to components and in escaping test fluid. These damages
cause intensive leakages in the fuel injection system during engine op-
eration.
Pressure build-up
Pressure build-up may take several minutes, because the common rail
injection system must be filled with slushing oil first, and the air must
be compressed.
If the pressure build-up fails, this indicates a serious leakage.


2018-01-10 - de

Common rail system
10.Observe the pressure display of the high-pressure pump (009.342) for a

pressure drop for the duration of 1 minute.
11.Record the pressure drop after 1 minute.
12.Depressurize the high-pressure pump (009.342).
13.Unscrew and clean the screw plug (435.006).
Test result evaluation Pressure drop is higher than 1,000 bar/min, or the test pressure of 1,400 bar
cannot be achieved due to severe leakages:
10 (13) 48/60CR, M010.110.060-01-0001

▪ screw the screw plug (435.006) into the next screwing-in position (A, B,
C, …) and repeat the leakage test.
Pressure drop is lower than 1000 bar/min or significantly lower than during the
previous leakage test:
▪ Leakage is located in the last components excluded from the subsystem
(high-pressure fuel pipe or high-pressure pump; or high-pressure fuel pipe
or common rail accumulator unit).
The area of the leakage can be localised further by carrying out a leakage test
on these components. In doing so, the removed high pressure fuel line is al-
ways tested for leaks first. If no pressure drop is detected during the leakage
test, carry out a leakage test of the high-pressure pump or of the common rail
accumulator unit. See Work Instructions 010.110.050-04, 010.110.052-04
and 010.110.054-06.
Finally When all leakages are eliminated, a final leakage test on the fully assembled
common rail injection system should be carried out. See also Work Se-
quences 2 and 3.
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Common rail system
1 Rail pressure measuring 2 Valve block

transducer
Figure 1: Attaching and removing the pressure-testing set with high pressure
hose on the valve block
48/60CR, M010.110.060-01-0001 11 (13)

20 Detection sensor 38 Distributor section

21 Drain manifold 39 Non-return valve for flushing mode
22 Leakage fuel drain pipe 41 Control valve support
30 Common-Rail accumulator unit 42 Valve group
33 Fuel injection pipe 43 Non-return valve (splitting)
34 High-pressure fuel pipe 44 Spill pipe
36 High pressure pump 50 Fuel injection valve
37 Threaded piece
Figure 2: Common-Rail accumulator unit with fitted components and corresponding detection sensor
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18075489547
Common rail system
12 (13) 48/60CR, M010.110.060-01-0001

2 Valve block A Side connection on valve support of the

high-pressure pump
30 Common rail accumulator unit B Bottom connection on control valve sup-
port of common rail accumulator unit
34 High-pressure fuel pipe C Side connection on valve support of the
high-pressure pump
36 High-pressure pump D Bottom connection on control valve sup-
port of common rail accumulator unit
E Side connection on valve block
Figure 3: Screwing-in positions (A, B, C, …) for screw plug (435.006) for engine type 6L48/60CR
18075489547
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Common rail system
48/60CR, M010.110.060-01-0001 13 (13)

18075489547
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Common rail system
48/60CR, M010.110.060-01-0001
Common-Rail components
Rework sealing face (tapered)/Handling of high-pressure fuel pipes
Summary
Check components for condition/wear condition, ensure/restore operational
safety.
Rework sealing faces of Common-Rail components.
The work includes:
Evaluation of sealing faces.

Tools/aids required
1 Guide bush 437.030 Standard
1 Cone seat milling cutter (left-hand) 437.031 Standard
1 Combination spanner_SW9 002.052 Inventory
1 Single-ended open-jaw spanner_SW46 000.568 Inventory
1 -_Emery paper, 400 or finer siehe Tabelle 1 Inventory
1 Cutting oil - Inventory
1 Antinoise plug - Inventory
1 Vice - Inventory
Work Sequence 1 - Detecting damage on the high pressure sealing faces

The following damage occurs mainly as a result of improper handling during
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installation and storage of high-pressure fuel pipes.

Surface damage may arise when fitting the high-pressure fuel pipe
▪ without the use of clean lubricant (Molub-Alloy Paste White T) or
▪ due to the specified torque being exceeded
35/44DF;48/60CR;32/44CR, M010.110.060-02-0001 1 (18)

Figure 1: Surface damage in seat area of sealing surface high-pressure fuel

pipe
Local dents / Plastification may be caused by

in seat area ▪ improper handling during installation (e.g. collision with sealing area coun-
terpart)
▪ collision with other parts or hard objects
▪ storage without protection caps
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2 (18) 35/44DF;48/60CR;32/44CR, M010.110.060-02-0001

Figure 2: Damage (dents) in seat area of the sealing surface of a high-pressure

fuel pipe
Damage to the jacket pipe is caused by use of impactor tools as a result of hard moving thrust screws.
Hard movement of thrust screws is often caused by insufficient fit accuracy.
This is often caused by improper mounting (e.g.: improper alignment of Com-
mon-Rail components). After high-pressure fuel pipes inserted, the thrust
screws must be easily screwable by hand.
Insufficient fit accuracy may result in:
inclined position of the thrust screw(s) in relation to threads of sealing counter-
part. This may result in damage of the threads during tightening. In case of
damaged threads, the sealing face is normally leaky, because the corres-
ponding torque is achieved until the required contact pressure is applied to
the sealing counterpart. Experience shows that this results in leakages and
damage to sealing surfaces during engine operation (perforation damage of
sealing surfaces). Components with damaged threads often must be re-
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placed.
35/44DF;48/60CR;32/44CR, M010.110.060-02-0001 3 (18)

Figure 3: Damage (local dents) to the jacket pipe of the high-pressure fuel
pipe
Perforation damages in the are erosion damages caused by previous damages.

seat area Previous damages (see Fig. 1 and Fig. 2), among other things, may be
scratches, scores, dents in seat area caused by strong contact with other
components during fitting or storage without protection caps (see above).
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4 (18) 35/44DF;48/60CR;32/44CR, M010.110.060-02-0001

Figure 4: Perforation damage in the seat area of the high-pressure fuel pipe
sealing face — Example 1
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35/44DF;48/60CR;32/44CR, M010.110.060-02-0001 5 (18)

Figure 5: Perforation damage in the seat area of the high-pressure fuel pipe
sealing surface — Example 2
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6 (18) 35/44DF;48/60CR;32/44CR, M010.110.060-02-0001

Figure 6: Perforation damage in the seat area of the tapered sealing surface
Summary Experience shows that damage presented on Figures 1 and 2 results in leak-
ages during engine operation within a short operating period, and thus in
damage to the sealing area counterpart within an operating period shorter
than 1 hour. See Figure 6.
Protection caps To prevent damage during transport and storage of high-pressure fuel pipes,
the sealing areas are protected with protection caps. To ensure a safe protec-
tion of sealing faces, the protection caps must be pushed on according to
Fig. 7. The netting tube fixes the protection caps in place. See Figure 7.
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35/44DF;48/60CR;32/44CR, M010.110.060-02-0001 7 (18)

Figure 7: Left: High-pressure fuel pipe with correctly fitted protection caps. Right: High-pressure fuel pipe
with protection caps and netting tube
Normal installation marks In Figure 8, a tapered sealing surface is shown with normal not critical dents in
on the tapered sealing seat sealing area after removal of the high-pressure fuel pipe. The tapered sealing
face face may be used further.
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8 (18) 35/44DF;48/60CR;32/44CR, M010.110.060-02-0001

Figure 8: Normal dents / mounting traces on the tapered sealing face
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35/44DF;48/60CR;32/44CR, M010.110.060-02-0001 9 (18)

Fuel deposits in HFO mode
Figure 9: HFO – fuel deposits on a tapered sealing face
Figure 9 shows HFO – fuel deposits on a tapered sealing face

To ensure that a high-pressure sealing face does not leak, the fuel deposits
must be removed using nonwoven fabric (e.g. Scotchbrite) prior to refitting.
Work Sequence 2 - Cleaning and reworking the internal tapered sealing face
Initial situation
Information on rework
Tapered sealing face must be only reworked if it is damaged, and the

high pressure sealing area may not be tight without rework.
2020-09-01 - de
The tapered sealing face of high pressure sealing face of Common-Rail com-
ponent (Common-Rail accumulator unit, high pressure pump, valve support)
is damaged (see Work Sequence 1) and must be reworked. The damage is
no deeper than 0.5 mm. Cone seat milling cutter (left-hand) (437.031) and
guide bush (437.030) are cleaned.
Work steps 1. Clean tapered sealing face to be reworked.
10 (18) 35/44DF;48/60CR;32/44CR, M010.110.060-02-0001

Preventing contamination with chips

An anti-noise plug must prevent ingress of chips in fuel-contacting
spaces.
2. Close the hole on sealing face to be reworked with a commercially avail-

able anti-noise plug. See Fig. 14.
3. Coat the shank of the left-hand cone seat milling cutter (437.031) with
clean lubricating oil.
4. Introduce cone seat milling cutter into guide bush (437.030).
5. Wet the tapered sealing face to be reworked with cutting oil and apply
cutting oil to the cutting edges of the cone seat milling cutter (437.031).
6. Screw guide bush by hand in thread of the sealing face to be reworked
and slightly tighten it by hand. See Fig. 10.
7. Using a size 9 ring spanner or open-jaw wrench (002.052), turn the cone
seat milling cutter slowly anti-clockwise, thus machining the tapered seal-
ing face. The feed is adjusted at the guide bush using size 46 single-
ended open-jaw spanner (000.568). During the machining, apply a low
pressure to the milling cutter. See Fig. 11.
Use of cutting oil

Cutting oil must take up machining chips and effect a smoother sur-
face on cone seat.
After each complete turn of cone seat milling cutter the guide bush
must be unscrewed, and milling cutter and tapered sealing face is
complete free of chips and cleaned. Before each next cutting opera-
tion oil the cone seat milling cutter and sealing face with fresh and
clean cutting oil.
Danger of injury from accelerated particles

When blowing-off/cleaning components with compressed air, chips,
grains, particles, deposits or similar may be released at a high speed
and cause severe eye injuries.

2020-09-01 - de
8. After one turn of the cone seat milling cutter, unscrew guide bush, re-
move chips from the milling cutter, and clean them completely. If neces-
sary, clean the cone seat milling cutter with compressed air.
9. Remove chips from the tapered sealing face to be reworked and clean it.
If necessary, blow off the sealing face and hole carefully with compressed
air up to the anti-noise plug.
35/44DF;48/60CR;32/44CR, M010.110.060-02-0001 11 (18)

Finish of rework
Repeat work steps 3 to 9, until the tapered sealing face has a compact,
smooth surface without any notches, grooves or other dents. See
Fig. 12.
Maximum machining depth

The maximum machining depth is 0.5 mm. If damages on the sealing
face cannot be removed completely within this machining depth, the
component concerned must be replaced.
Danger of injury from sharp edges

When handling parts with sharp edges, fingers or hand surfaces may
be injured due to carelessness.
• Wear protective gloves
10.Finally, rework tapered sealing face with non-woven fabric (see Table 1
for approved abrasives) until the surface of the sealing face is similar to
the surface shown in Figure 14. During the grinding process take care of
sharp threads. Should reworking with non-woven fabric not suffice, the
using of emery paper with a grain size 400 or finer is also admissible ex-
clusively for the tapered internal face.
Use of non-woven fabric

Insert finger in the centre of the seat area on the non-woven fabric and
carry out regular rotary movement by +/- 180°.
Prevent any movement transverse to the sealing face.
Make sure that no grinding products residue in the Common-Rail injec-
tion system.
Abrasives for the grinding process are specified in Table 1.
Designation with 3M- Colour Schleifmittel (Abrasive) Grain size (Grit

2020-09-01 - de
Scotch (BriteTM Num- (German) equiv.)

ber) Colour
(English)
7445 Weiß Flintstein, super feiner Grad 1200 – 1500

Light Duty (White) (Flint, super fine grade)
Cleansing
7448 Hell Siliziumkarbid 800 -

(Light) (Silicon carbide)
12 (18) 35/44DF;48/60CR;32/44CR, M010.110.060-02-0001

Ultra Fine Grau Karbid, höchst feiner Grad 1000

(Gray) (Carbide, ultra fine grade)
6448 Dunkel- Siliziumkarbid, höchst feiner 800 – 1000

Light Duty grau Grad
(Dark (Silicon Carbide, ultra fine
Gray) grade)
7447 Braun Aluminiumoxid, sehr feiner 360 – 400

General Purpose (Maroon) Grad
(Aluminium Oxide, very fine
grade)
8447 Braun Aluminiumoxid, sehr feiner 360 – 400

Production (Maroon) Grad
(Aluminium Oxide, very fine
grade)
Table 1: Abrasives approved for grinding of tapered sealing faces
11.When the rework is finished and the tapered sealing face and the hole are
completely free from machining chips and cleaned (if necessary, blow
sealing face and hole clean with compressed air), remove the anti-noise
plug from the hole of the machined component.
2020-09-01 - de
35/44DF;48/60CR;32/44CR, M010.110.060-02-0001 13 (18)

1 Component with tapered B Fuel-contacting hole

sealing face
Figure 10: Cone seat milling cutter and guide bush screwed in the tapered
sealing face thread
2020-09-01 - de
14 (18) 35/44DF;48/60CR;32/44CR, M010.110.060-02-0001

Figure 11: Machining of tapered sealing face on control valve support using a
cone seat milling cutter (left-hand) and open-jaw wrench
2020-09-01 - de
Figure 12: tapered sealing face machined with a cone seat milling cutter
35/44DF;48/60CR;32/44CR, M010.110.060-02-0001 15 (18)

Figure 13: Cleaning of the tapered sealing face with non-woven fabric (e.g.
Scotchbrite)
2020-09-01 - de
16 (18) 35/44DF;48/60CR;32/44CR, M010.110.060-02-0001

Figure 14: Anti-noise plug in the hole of component with tapered sealing face;
sealing face finished with emery paper (grain size 400 or finer);
Work Sequence 3 - Cleaning the outer convex sealing face

Initial situation The outer convex sealing face of a high-pressure sealing face on a common-
rail component (high-pressure fuel pipe) is contaminated and must be cleaned
and must have all deposits removed.
Do not rework the outer convex sealing faces

Any reworking operation on these outer sealing faces is prohibited be-
cause of their unique shape and their edges arrangement in the sealing
area.
Very likely, any reworking of these sealing faces could lead to leaks in
2020-09-01 - de
the seat area.
Work steps
Protecting bores from con-
tamination
35/44DF;48/60CR;32/44CR, M010.110.060-02-0001 17 (18)

Preventing contamination with chips

An anti-noise plug must prevent ingress of chips in fuel-contacting
spaces.
1. Close the bores on the sealing faces to be cleaned with a commercially

available anti-noise plug. See Fig. 14.
Cleaning the convex outer 2. First try to remove the deposits from the sealing face by means of a soft
sealing face rag and diesel fuel.
3. If the deposits can not be completely removed with rag and cleaning
agent, the abrasives listed in Work Sequence 2/Table 1 can be used for
cleaning and polishing the sealing face.
4. If none of the abrasives listed in Work Sequence 2/Table 1 is available,
only use cleaners without grains, particles or cleaning acids. Make sure
that no liquids or particles contaminate or damage the common-rail injec-
tion system.
5. The cleaning and polishing of the sealing surface should be done manu-
ally only in a circular motion in the coaxial direction. Prevent any move-
ment transverse to the sealing face.
6. After the cleaning process is completed and the convex sealing face is
completely free from dirt and deposits, the anti-noise plug must be re-
moved from the bore of reworked component.
Purging with compressed
air
Danger of injury from accelerated particles

When blowing-off/cleaning components with compressed air, chips,
grains, particles, deposits or similar may be released at a high speed
and cause severe eye injuries.
36028810481746955
7. After cleaning, the high-pressure fuel pipe should be blown off with com-
pressed air to ensure that no grains, particles, or deposits remain in the
36028810481746955
high-pressure fuel pipe.
2020-09-01 - de
18 (18) 35/44DF;48/60CR;32/44CR, M010.110.060-02-0001


010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas
51353943051
1 (1)


51353947275
1 (1)

Starting air pilot valve

inspection
Summary
Execute work on time according to the maintenance schedule, ensure/restore
operational safety.
The starting air pilot valve must be removed and overhauled at regular inter-
vals.
Safety requirements
l Engine stopped

Dismantling and assembly of the starting air pilot valve 010.150.010-02
Technical data
Starter pilot air valve Weight 8 kg
2017-09-14 - de
L51/60DF;L48/60B, M010.150.010-01-0001 1 (4)

Work sequence 1 – Removing the starting air pilot valve
Pressurised air system

Working on a pressurised air system when under high pressure (up to
30 bar) causes severe personal injuries.
• Pressurised air system is to be isolated
• Pressurised air system is to be depressurised
• personal protective equipment (protective clothing, protective goggles
etc.) is to be worn
Work Steps 1. Remove the air intake line (8) and starting air line (1) from the starting air
pilot valve (6).
2. Unscrew the hex bolts (3).
3. Remove the starting air pilot valve (6).
4. Remove the spacer disk (2).
5. All openings, open pipes and tubes are to be covered with suitable auxili-
ary equipment (e.g. protective covers), to prevent possible dirt contamin-
ation.
6. Measure the thickness of the spacer disk (2).
Thickness of the spacer disk

If the spacer disk is less than 1.4mm thick, a new spacer disk must be
installed.
7. Clean the starting air pilot valve (6) externally.

8. Dismantle the starting air pilot valve (6). See Work Instructions
010.150.010-02.
Work sequence 2 – Installing the starting air pilot valve

Initial situation Starting air pilot valve has been cleaned and assembled. Thickness of the
spacer disk has been measured.
Work steps 1. Clean the contact surface on the cylinder crankcase (4).
2017-09-14 - de
2. Remove the auxiliary equipment (e.g. protective covers) from all open-
ings, open line ends and pipe ends.
3. Fit the spacer disk (2) onto the starting air pilot valve (6).
4. Fit the starting air pilot valve (6), ensuring that it is installed in the correct
place, and that the position of the dowel pins (5) is correct.
5. Screw in hex bolts (3) and tighten them.
2 (4) L51/60DF;L48/60B, M010.150.010-01-0001

Set gap dimension

By removing foils from the spacer disk, the gap dimension can be set.
If it is not possible to set the gap dimension because the thickness of
the spacer disk is less than 1.4mm, a new spacer disk must be fitted
and the starting air pilot valve changed.
6. Check the gap dimension (B) and adjust if necessary.

For the value for the gap dimension, see Volume 010.005 Engine – Oper-
ating Manual, sheet 010.000.035.-04.
Fitting the pipes

Install all pipes tension-free. If the pipes are not installed tension-free,
this may damage components or cause leakages and shorten the ser-
vice life.
7. Fit the air inlet (8) and the starting air line (1).
2017-09-14 - de
L51/60DF;L48/60B, M010.150.010-01-0001 3 (4)

1 Starting air pipe 7 Starting cam

2 Spacer disk 8 Charge air pipe
3 Hex bolt A Thickness of the spacer
disk
4 Cylinder crankcase B Clearance
5 Dowel pin ST Control side
6 Starting air pilot valve
Figure 1: Starting air pilot valve
9007206263128715
2017-09-14 - de
4 (4) L51/60DF;L48/60B, M010.150.010-01-0001


Summary
Execute work on time according to the maintenance schedule, ensure/restore
operational safety.
The starting air pilot valve must be removed and overhauled at regular inter-
vals.
Tools/aids required
Work sequence 1 - Dismantling the starting air pilot valve

Starting condition Starting air pilot valve has been removed and cleaned externally.
Cleanliness at the workplace

Careful attention must be paid to workplace cleanliness during dis-
mantling and assembling. Dirt particles can cause faults in the starting
system.
Work steps 1. Unscrew the hex bolts (3).

2. Take off the pitot tube (4).
3. Screw the eye bolt (001.405) into the control piston (2) and remove it
from the casing (1).
4. Remove the tool.
2016-09-06 - de
Cleaning the individual parts

To clean the individual parts, use grease-dissolving agent and pressur-
ised air.
5. Clean all individual parts, check for attrition and damage.
General, M010.150.010-02-0003 1 (2)

Work sequence 2 - Assembly of the starting air pilot valve

Starting condition All individual parts cleaned, inspected and replaced where necessary.

Careful attention must be paid to workplace cleanliness during dis-
mantling and assembling. Dirt particles can cause faults in the starting
system.
Work steps 1. Screw the eye bolt (001.405) into the control piston (2).
2. Oil the control piston (2) lightly with clean lubricating oil and insert it into
the casing (1).
3. Remove the tool.
4. Fit the pitot tube (4) onto the casing (1), paying attention to the position of
the dowel pin (5).
5. Coat the threads and contact surface of the hex bolts (3) with Loctite 243
securing compound, screw them in and tighten them.
2016-09-06 - de
1 Casing
2 Control piston
3 Hex bolt
4 Pitot tube
5 Dowel pin
Figure 1: Starting air pilot valve
9007216915354763
2 (2) General, M010.150.010-02-0003


51353951499
1 (1)

Main starting valve

Dismantling and assembling
Summary
Execute work on time according to the maintenance schedule, ensure / re-
The main starting valve must be checked and cleaned at regular intervals and
overhauled if necessary.
Separating parts/ components,
Safety requirements
Tools/aids required
1 Rope - Inventory
Technical data
Main starting valve Weight 54 kg
Work sequence 1 – Removing the main starting valve

Initial situation Compressed air tank is closed. Compressed air line between compressed air
tank and main starting valve deaerated.
2019-05-17 - de

Main starting valve

General, M010.150.020-02-0002 1 (7)

Opening the air-start system

When opening the air-start system, ensure that no dirt can get into
valves and pipes. Seal any open pipe ends with plastic caps or adhes-
ive tape.
Work steps 1. Remove any pipes and connections that could obstruct removal.
Supporting the pipes

Before loosening and removing the bolted connections, support the
pipes using suitable equipment.
2. Unscrew the hex bolts (2). See Fig. 1.

3. Attach the main starting valve (4) to the hoist using suitable equipment.
4. Unscrew the hex bolts (6).
5. Lift the main starting valve (4). Place it onto a clean surface.
6. Remove the rings (3).
Work sequence 2 - Dismantling and assembling the main starting valve

In order to prevent any dirt getting in and to ensure that the compon-
ent functions correctly, items must be dismantled and assembled on a
clean surface.
Initial situation Main starting valve has been removed.

Work steps – Dismantling 1. Mark the position of the casing (10) on the valve seat (14).
2. Unscrew the hex bolts (8) alternately cross-wise. See Fig. 2.
3. Remove the casing (10) from the valve seat (14).
4. Remove the valve pistons (13) and the pressure spring (9) from the cas-
ing (10).
5. Remove the PTFE ring (12) and the O-ring seal (11) from the valve piston
2019-05-17 - de
(13).
6. Unscrew the cap (21) from the valve seat (14). See Fig. 3.
Main starting valve
7. Pull valve seat (16) out of valve seat (14).

8. Unscrew the lock nuts (21) from the ventilation cone (17). Hold the ventil-
ation cone when doing so.
9. Pull the piston (18) from the ventilation cone (17).
10.Remove the PTFE ring (19) and the O-ring seal (20) from the piston (18).
2 (7) General, M010.150.020-02-0002

Replacement of components
If the seating surface of the valve piston (13) or the valve seat (14) ap-
pears damaged, replace both components.
If the seating surface of the valve seat (16) or the ventilation cone (17)
appears damaged, replace both components.
11.Clean and check all parts and renew where necessary.

Work steps – Assembly 12.Push the ventilation cone (17) into the valve seat (16).
13.Insert a new O-ring seal (20) into the piston’s (18) seal ring groove. Make
sure that the O-ring seal is not twisted.
Burns from hot oil

Placing and removing the PTFE ring by hand in the hot oil bath will
lead to burns.
14.Heat up the PTFE ring (19) in oil to 80° – 100°.

15.Slide the PTFE ring (19) into the piston’s (18) seal ring groove.
16.Slide the piston (18) into the valve seat (16). Make sure that the installa-
tion position is correct. See Fig. 3.
17.Screw new lock nuts (21) onto the ventilation cone (17) and tighten them.
Hold the ventilation cone when doing so.
18.Insert valve seat (16) into valve seat (14).
19.Screw the cap (22) into the valve seat (14) and tighten.
20.Insert a new O-ring seal (11) into the valve piston’s (13) seal ring groove.
Make sure that the O-ring seal is not twisted. See Fig. 1.
Burns from hot oil

Placing and removing the PTFE ring by hand in the hot oil bath will
lead to burns.
2019-05-17 - de

Main starting valve
21.Heat up the PTFE ring (12) in oil to 80° – 100°.

22.Slide the PTFE ring (12) into the valve piston’s (13) seal ring groove.
23.Slide the valve piston (13) into the casing (10). Leave to cool for approx.
10 minutes.
24.Pull the valve piston (13) out of the casing (10).
25.Insert the pressure spring (9) into the casing (10).
26.Slide the valve piston (13) into the casing (10).
General, M010.150.020-02-0002 3 (7)

27.Connect the casing (10) and the valve seat (14). In doing so, pay atten-
tion to the marking.
28.Screw in the hex bolts (8) cross-wise and tighten them.
Checking for leaks

After assembling the main starting valve, check for leaks. Seal all
openings with suitable means. Test pressure 45 bar.
If the main starting valve is leaking, disassemble, clean and reas-
semble it.
Work Sequence 3 - Attaching the main starting valve

Initial situation Main starting valve has been overhauled and checked for leaks.

27021604773136779
Work steps 1. Attach the main starting valve (4) to the hoist using suitable equipment.
2. Lift the main starting valve (4). Attach it to the bracket (5).
3. Screw in the hex bolts (6), do not tighten them.
4. Insert new rings (3).
5. Remove the support from the air pipe (1), put on the main starting valve
(4) and screw in hex bolts (2), do not tighten them.
6. Remove the support from the shipyard supply line (7), put on main start-
ing valve (4) and screw in hex bolts (2), do not tighten them.
7. Tighten the hex bolts (2) alternately crosswise. First, tighten the hex bolts
to the air pipe (1).
2019-05-17 - de
8. Tighten the hex bolts (6).

9. Reconnect all removed pipes and connections.
Main starting valve
4 (7) General, M010.150.020-02-0002

1 Air pipe 5 Holder

2 Hex bolt 6 Hex bolt
3 Ring 7 Shipyard supply line
4 Main starting valve
Figure 1: Fitted main starting valve
2019-05-17 - de
Main starting valve
General, M010.150.020-02-0002 5 (7)

8 Hex bolt 11 O-ring seal 14 Valve seat

9 Compression spring 12 PTFE ring 15 Safety valve
10 Casing 13 Valve piston
Figure 2: Main starting valve pos. 4
2019-05-17 - de
Main starting valve
6 (7) General, M010.150.020-02-0002

14 Valve seat 20 O-ring seal

16 Valve seat 21 Locknut
17 Ventilation cone 22 Closing cap
18 Piston 23 Set screw
19 PTFE ring
Figure 3: Unit X of image 2
27021604773136779
2019-05-17 - de
Main starting valve
General, M010.150.020-02-0002 7 (7)

27021604773136779
2019-05-17 - de
Main starting valve
General, M010.150.020-02-0002

010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas
010.170 Intake air
51353955723
1 (1)

010.170 Intake air

51353959947
1 (1)

Charge air pipe for emergency operation

converting
Summary
To enable emergency operation of an engine in the event of failure of a tur-
bocharger, refitting must be done on the charge air system.
refitting the components.
Safety requirements
l Engine stopped
Tools/aids required
1 Cover 280.033 Standard

Technical data
Cover Weight 58 kg
2016-12-05 - de
Work sequence 1 - Converting charge air pipe for emergency operation

Preliminary remark For combustion air suction during emergency operation, the cover at the end
piece of the charge air pipe should be removed and the openings protected
by a cover of wire mesh. Ensure cleanliness in the intake area.
Refer to Volume 010.200 Turbocharger for instructions on emergency opera-
tion with turbocharger inoperable.
Achievable performance During emergency operation, it is possible to achieve a max. output of 15% of
the nominal power in engine operation at variable speed, and a max. output of
20% of the nominal power in engine operation at a constant speed!
L48/60B, M010.170.010-02-0001 1 (5)

The limiting criteria for the achievable engine output during emergency opera-
tion are
▪ maximum exhaust temperature downstream of the cylinder
▪ maximum exhaust temperature upstream of the turbocharger
▪ Exhaust smoke opacity
Initial situation Turbocharger modified for emergency operation (see Volume 010.200 Tur-
bocharger), lubricating oil supply to the turbocharger interrupted.

Work steps 1. Place the receptacle under the charge air pipe section (1), unscrew the
locking bolt and drain condensed water from the charge air pipe section.
2. Screw the screw plugs with sealing ring into the charge air pipe section
(1), remove the receptacle.
3. Suspend the cover (3) from the lifting tackle with suitable means (see sus-
pension example in figure 2).
4. Unscrew the hex bolts (2), remove the cover (3) and place it on a support.
See Fig. 3.
5. Position the cover (280.033) on the charge air pipe section (1), screw in
the hex bolts (2) and tighten them. See Figs. 4 and 5.
6. Remove the O-ring (4 ) and clean the cover (3).
Work sequence 2 - Refitting the charge air pipe

Work steps

2016-12-05 - de

The charge air pipe is essentially reinstalled in reverse order to Work Se-
quence 1. Observe the following points:
1. Lubricate the new O-ring (4) with clean lubricating oil and insert it into the
sealing ring groove. Make sure that the O-ring is not twisted.
2 (5) L48/60B, M010.170.010-02-0001

2. Coat the thread and contact surfaces of the hex bolts (2) with MoS2 lub-
ricant, screw in and tighten them to the specified torque. See Work In-
structions 010.000.003-05.

1 Charge air pipe section 3 Cover
2 Hex bolt 4 O-ring
Figure 1: Charge-air pipe
2016-12-05 - de
L48/60B, M010.170.010-02-0001 3 (5)

3 Cover
Figure 2: Charge air pipe - Attaching the cover (example)
2016-12-05 - de
1 Charge air pipe section 3 Cover

2 Hex bolt 4 O-ring
Figure 3: Charge air pipe - Removing/refitting the cover
4 (5) L48/60B, M010.170.010-02-0001

1 Charge air pipe section 2 Hex bolt

Figure 4: Charge air pipe - Removing/assembling the cover (280.033)

2016-12-05 - de
1 Charge air pipe section 2 Hex bolt

Figure 5: Charge-air pipe
9007206315691147
L48/60B, M010.170.010-02-0001 5 (5)

9007206315691147
2016-12-05 - de
L48/60B, M010.170.010-02-0001
Charge air bypass device

Summary
correct execution of work, ensure / restore operational safety. Control ele-
ments in the charge air/exhaust gas system are to be checked and, if neces-
sary, replaced within the scope of maintenance and repair work.
The work/work steps include: Disassembling /separating components, Re-
newing sealing rings/sealing elements, Assembling/refitting components.
Safety requirements
l Engine stopped

Tools/aids required

Surface examination using penetration method 010.000.003-08
2019-01-21 - de
Work sequence 1 - Detaching the deflection flap with drive head

Starting position Control pipes (22) and bypass pipes of the charge air bypass device are pres-
sureless.
Work steps 1. Disconnect control pipes (22) from the drive head (21).
2. Remove flange bolts (23) (see figure 1).
3. Dismantle any supports on the adapter flange (25).
4. Pull out deflection flap (20) with drive head from the flange connection,
taking care not to damage the seals (24).
General, M010.170.010-04-0001 1 (5)

Work sequence 2 - Replacing the sealing and wear part sets on the drive head
Work Steps 1. Detach the bypass valve (20) and the drive head (21) from the adapter
flange (25).
2. Unscrew the hexagon socket bolts (8) of both covers (7).
3. Remove the cover (7) with the cover seal (6) and pay attention to any ex-
isting return springs (16). Remove the return springs (16) (see Fig. 2).
4. Move both pistons (5) out of the casing (10) of the drive head by rotating
the pinion shaft (11). When removing the two pistons, pay attention to the
guide elements (9).
Work on the drive head

Never move the two pistons of the drive head by means of com-
pressed air from the casing!
In general, the following applies: When working on the drive head, the
connection to the compressed air network must be detached!
5. Remove the guiding rings (4) and O-rings (3).

6. Remove the locking ring (1) with pliers for locking rings (002.121), paying
attention to the backing ring (2).
7. Press the pinion shaft (11) out of the casing (10).
8. Remove the upper and lower slide ring (14 and 15) with the O-rings (12
and 13).
9. Clean all components and check for wear and cracks. See Work Instruc-
tions 010.000.003-08 and 010.000.003-09.
10.Assembly is basically carried out in reverse order to disassembly, when
doing so, use the new set of seals consisting of position (3, 6, 12, 13 and
17) as well as the set of wear parts consisting of position (4, 9, 14 and
15).
Locking ring
Do not overextend locking ring (1) when fitting.
When inserting the piston (5) in the casing (10), make sure that the racks of
2019-01-21 - de
the pistons engage properly into the teeth of the pinion shaft (11) and move
together symmetrically.
Attach the cover (7) and cover seal (6) in the correct position to the casing
(10). Ensure the "UP" marking on the cover is correct.
Work sequence 3 - Attaching the deflection flap with drive head

Initial situation Leak test for bypass valve and drive head performed. Bypass valve and drive
head mounted on the flange.
2 (5) General, M010.170.010-04-0001

Work steps 1. Insert the bypass valve (20) with drive head (21) in the correct position
between the flange connection of the bypass pipes, paying attention to
seals (24) and not damaging them.
2. Attach the flange unions (23) and tighten them across the diagonal.
3. Fit any existing brackets to the adaptor flange (25).
4. Attach the control lines (22) to drive head (21) and check the system for
tightness.
Faulty or leaking bypass valve

If the bypass valve (20) is faulty or leaking, this must be completely re-
placed!
Checking reset feedback
Reset feedback of flow flap

After proper equipment installation, the reset feedback of the flow flap
must be checked. Otherwise, the engine control system will be unable
to recognise the position of the flow flap any longer.
5. Check the reset feedback of the flow flap. For this, refer to work instruc-
27021602013831307
tions 010.180.010-06 in the folder 010.285 SaCoSone Vol. 2.

2019-01-21 - de
General, M010.170.010-04-0001 3 (5)

20 Bypass valve 23 Flange union

21 Drive head 24 Seal
22 Control pipes 25 Adaptor flange
Figure 1: Charge air bypass device
2019-01-21 - de
4 (5) General, M010.170.010-04-0001

1 Locking ring 8 Hex socket bolt 15 lower slide ring

2 Backing ring 9 Guide element 16 Return spring
3 O-ring 10 Casing 17 O-ring
4 Guiding ring 11 Pinion shaft 18 Cap nut
5 Piston 12 O-ring 19 Set screw
6 Cover seal 13 O-ring
7 Cover 14 upper slide ring
Figure 2: Drive head
27021602013831307
2019-01-21 - de
General, M010.170.010-04-0001 5 (5)

27021602013831307
2019-01-21 - de
General, M010.170.010-04-0001

51353964171
1 (1)

Charge air cooler

Summary
Ensure correct execution of work; remove contamination/residue from com-
ponents.
The intercooler definitively influences the operating values and thereby also
the performance of the engine. It is therefore necessary to check and clean it
Recommendation: clean the intercooler in installed condition using the MAN
Energy Solutions ultrasonic cleaning system and PrimeServ Clean MAN C
0186.
If this is not available, remove the intercooler as described below and clean it.
Checking the operating values,
Removing and cleaning the intercooler,
Installing the intercooler.
Safety requirements
l Engine stopped
Tools/aids required
1 Suspension fixture 322.150 Option
1 Digital pressure gauge "Digima-Premo" 009.090 Option
2018-09-18 - de

2 Lifting eye bolt M10 000.141 Inventory
Charge air cooler

48/60CR, M010.170.040-01-0015 1 (18)


1 Sealing compound (High-temperature Silicone) - Inventory
1 cleaning agents - Inventory
1 Hylomar SQ/M - Inventory
4-6% Cleaning agent PrimeServ Clean MAN C 0186 2750.28100-01 Inventory
(1 canister ≙ 30 l) 86

Cleaning the cooling water system 010.000.002-04
Charge air cooler/Measuring the differential pressure 010.000.005-01
Cleaning the charge air cooler in ultrasonic cleaning bath 010.170.040-04
Technical data
Contact protection Weight 34 kg
Cooler bundle: 6L, 7L, 12V, 14V engine Weight 530 kg
Cooler bundle: 8L, 9L, 16V, 18V engine Weight 555 kg
Cover Weight 250 kg
Stuffing box ring Weight 14 kg
Connection chamber Weight 54 kg
Deflection chamber Weight 34 kg
Cooler bundle (water-side) Test pressure 9 bar

The degree of contamination dictates how often the charge air cooler should
be cleaned. Digital pressure gauge (009.090) is therefore connected before
and after the charge air cooler, and differential pressure readings are taken at
regular intervals. See Work Instructions 010.000.005-01.
When is cleaning the charge air cooler's air side necessary?

Cleaning the charge air cooler's air side is necessary if the differential
2018-09-18 - de
pressure compared with new condition has reached the values given in
the load area in Table 1.
Charge air cooler
Differential pressure in- Degree of contamination Duration of the cleaning se-

crease* quence in [h]
to the new condition
in [mm WG]
< 100 mm WG rarely not necessary
100 - 200 mm WG slight Approx. 1
2 (18) 48/60CR, M010.170.040-01-0015

Differential pressure in- Degree of contamination Duration of the cleaning se-

crease* quence in [h]
to the new condition
in [mm WG]
**200 - 300 mm WG strong Approx. 1.5
> 300 mm WG extreme Approx. 2

Table 1: Differential pressure increase - Recommended cleaning duration
* Differential pressure -Increase= Current differential pressure - differential pressure in

new condition (see acceptance report)
** Recommendation: Clean the charge air cooler upon this increase in the differential
pressure at the latest, otherwise an unremovable dirt core starts forming in the
charge air cooler bundle.
Work sequence 2 - Removing the cooler bundle

Initial situation Cooling water has cooled down to at least 50 °C. Covering is removed.

Work steps 1. Screw lifting eye bolt (000.141) with shackle (002.453) into the contact
Removing contact protec- protection (31) and suspend with a rope. See Fig. 2.
tion 2. Pull off the cover (33). See Fig. 1.
3. Unscrew hex bolts (34, 35) and remove contact protection.
Draining the cooling water 4. Drain cooling water from cooling water inlet and outlet pipes.
5. Place a receptacle underneath the intercooler to trap the liquid.
Intercooler without continuous ventilation

On charge air coolers without continuous ventilation open screw plugs.
2018-09-18 - de
Charge air cooler
6. Unscrew screw plugs (29) on the deflection chambers and drain cooling
water from cooler bundles (6 and 7) (about 61 litres for 6L, 7L, 12V, 14V
engines; about 70 litres for 8L, 9L, 16V, 18V engine). See Fig. 4.
7. Screw in screw plug (29) including seal (30) into the deflection chambers
again.
8. Remove the cooling water inlet and outlet pipes and the venting pipe (if
present) from cooler bundles (6 and 7). See Fig. 3.
48/60CR, M010.170.040-01-0015 3 (18)

Removal of the cover (4) 9. Screw lifting eye bolts (000.143) fully into cover (4) and tighten them.
Fasten belt strap (021.419) with shackle (002.453) to lifting eye bolts
(000.143) and attach belt strap (021.419) to the lifting tackle. See Fig. 5.
Lifting eye bolts tightened securely

Check if eye bolts are securely tightened.
10.Unscrew hexagon head bolts (2) and remove them together with expan-
sion sleeves (3).
11.Unscrew hexagon socket bolts (5) from cover (4) and detach cover (4).
See Fig. 5.
12.Place cover (4) aside. Detach the tool.
Removing the stuffing box 13.Unscrew hexagon head bolts (16) and remove them together with wash-
ring (18) ers (17).
14.Remove stuffing box ring (18) including seals (19). See Fig. 6/II.
Forcing-off thread M10 (15)

If necessary, stuffing-box glands (18) may be pressed off using bolts
M10 on forcing-off threads M10 (15) of cooler casing (1).
Removing the HT-cooler 15.Unscrew hexagon socket bolts (5). See Fig. 6/I.
bundle (7) 16.Fasten suspension device (322.150) to HT-cooler bundle (7) using
hexagon head bolts (20). See Fig. 7.
Hexagon bolts (20) tightened securely

Check if hexagon head bolts (20) are securely tightened.
17.Attach lifting tackle to suspension device (322.150), and pull out HT-
cooler bundle (7) upwards out of cooler casing (1) carefully, and lower it
into the cleaning bath. See Fig. 8.
Removing the LT-cooler 18.Fasten suspension device (322.150) to LT-cooler bundle (6) using
bundle (6) hexagon head bolts (20). See Fig. 9.
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Hexagon bolts (20) tightened securely

Charge air cooler
Check if hexagon head bolts (20) are securely tightened.
19.Attach lifting tackle to suspension device (322.150), and pull out LT-
cooler bundle (6) upwards out of cooler casing (1) carefully, and lower it
onto a suitable base. See Fig. 10.
20.Clean the inner faces of the cooler casing to remove deposits.
4 (18) 48/60CR, M010.170.040-01-0015

Removal of deflection 21.Lift cooler bundle (6 or 7).

chambers (27) and of con- 22.Unscrew hexagon socket bolts (28) and remove deflection chamber (27)
nection chambers (22) including seal (26). See Fig. 11/I.
23.Place cooler bundle aside.
24.Unscrew hexagon socket bolts (23) and remove connection chamber (22)
including seal (24). Place the connection chamber on a support. See Fig.
11/II.
25.Detach the tool.
26.Fasten suspension device (322.150) to second cooler bundle (6 or 7) us-
ing hexagon head bolts (20).
27.Attach lifting tackle (21) to suspension device (322.150).
28.Remove deflection chamber (27) and connection chamber (22) of the
second cooler bundle. See work steps 21 to 25.
Work Sequence 3 - Cleaning the cooler bundle

Clean the removed cooler bundle according to the description of Work In-
structions 010.170.040-04.
Prevent deposits drying on charge air cooling bundle

To prevent deposits from drying on tubes, perform the cleaning in a
still wet condition, directly after removal of the water chambers.
Work Sequence 4 - Installing the cooler bundle

Initial situation Cooler casing and cooler bundle cleaned inside.

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Work steps 1. Clean and degrease all sealing faces on cooler casing (1), cooler bundle
Charge air cooler
(6 and 7), connection chambers and deflection chambers.

Fitting the connection 2. Attach suspension device (322.150) to connection chamber (22) using
chamber (22) hexagon head bolts (20) and attach the lifting tackle to suspension device
(322.150).
3. Place connection chamber (22) including new seal (24) on cooler bundle
(25). See Fig. 11/II.
48/60CR, M010.170.040-01-0015 5 (18)

4. Screw hexagon socket bolts (23) in and tighten them according to the
description in the operating manual for charge air cooler (cooler bundle).
Operating manual for cooler bundle see Volume 010.010... 010.190 en-
gine components – 010.170.040 charge air cooler with attachment.
Fitting the deflection cham- 5. Lift cooler bundle (25).
ber (27) 6. Place deflection chamber (27) including new seal (26) on cooler bundle
(25). See Fig. 11/I.
7. Screw hexagon socket bolts (28) in and tighten them according to the
description in the operating manual for charge air cooler (cooler bundle).
Operating manual for cooler bundle see Volume 010.010... 010.190 en-
gine components – 010.170.040 charge air cooler with attachment.
Pressure test and check 8. Carry out a pressure test on cooler bundles (6 and 7).
9. Check that there are no loose parts in cooler casing (1).
Installation of the cooler 10.Move cooler bundle (6 or 7) over cooler casing (1). See Fig. 8 or 10
bundle 11.Apply high-temperature silicone to the sealing face on the top of the
cooler casing.
12.Lower cooler bundle (6 or 7) carefully into cooler casing (1).
13.Align cooler bundle (6 or 7) in cooler casing (1). To do this, push the top
and bottom end of the cooler bundle towards the air inlet.
Installation of the second 14.Fit connection chamber (22) and deflection chamber (27) to second
cooler bundle cooler bundle (6 or 7). Fit cooler bundle (6 or 7) into charge air cooler
casing (1). See work steps 2 to 13.
Fitting the cover (4) 15.Screw lifting eye bolts (000.143) fully into cover (4) and tighten them.
Fasten suspension device (322.150) with shackle (002.453) to lifting eye
bolts (000.143) and attach belt strap (021.419) to the lifting tackle.
16.Coat contact areas at cooler casing (1) and cover (4) with high-temperat-
ure silicone.
17.Attach cover (4) to cooler casing (1).
18.Apply MoS2-lubricant to the threads and contact surfaces of hexagon
head bolts (2), screw them in with expansion sleeves (3), and tighten
them with the specified torque. See Work Instructions 010.000.003-05.
19.Remove the tool.
20.Screw in hexagon socket bolts (5) and tighten them. Tighten the hexagon
socket bolts alternately, across the diagonals, towards the outside start-
ing from the centre.
Fitting the stuffing box rings 21.Clean the ring groove for O-ring in the stuffing box rings (18) and thinly
(18) with new seals (19) apply clean lubricating oil.
2018-09-18 - de
22.Wet the new O-ring with clean lubricating oil.

23.Place the new O-ring into the ring groove of the stuffing box ring. In doing
Charge air cooler
so, make sure that the O-ring is tensioned evenly along its entire circum-
ference and is not twisted.
24.Lift the stuffing box ring (18) with the new O-ring (19) carefully over the
cooler floor and fit it to the cooler casing (1). In doing so, ensure that the
O-ring seal remains completely seated in the ring groove and is not
crushed or turned during assembly. See Fig. 6/II.
25.Tighten hexagon head bolts (16) with washers (17) (starting from the
centre, work outwards, tightening alternate sides, across the diagonal).
6 (18) 48/60CR, M010.170.040-01-0015

Fitting removed pipes 26.Fit the cooling water inlet and drain pipes and venting pipes (if provided)
to charge air cooler bundles (6 and 7).
Fitting contact protection 27.Screw lifting eye bolt (000.141) with shackle (002.453) into the contact
protection (31) and suspend with a rope.
28.Lift the contact protection (31) and place it on the charge air cooler.
29.Screw in hex bolts (34, 35) and tighten them.
30.Remove suspension tools (000.141 and 002.453).
31.Attach the cover (33).
Final measures 32.Open screw plugs (8) after opening the inlet and outlet of the cooling wa-
ter pipes.
Ensure that all air is removed completely

Keep screw plugs open until the air has completely escaped from the
cooling bundle.
33.Check all pipe connections for tightness after commissioning.

34.Check air tightness between cooler casing and cooler bundle (measuring
points M1 and M2).
35.Examine the charge air cooler for leaks.
Note for figures The form and design of the cooler bundle may differ from the one shown in
the illustrations.
2018-09-18 - de
Charge air cooler
48/60CR, M010.170.040-01-0015 7 (18)

31 Contact protection 33 Cover 35 Hex bolt M16x30

32 Spring washer 34 Hex bolt M16x40
Figure 1: Contact protection
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Charge air cooler
8 (18) 48/60CR, M010.170.040-01-0015

Figure 2: Contact protection - Removal and fitting

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Charge air cooler
48/60CR, M010.170.040-01-0015 9 (18)

1 Cooler casing 6 LT-cooler bundle 11 HT-drain line

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2 Hex bolt 7 HT-cooler bundle 12 HT-supply line

3 Expansion sleeve 8 Screw plug 13 LT-drain line
Charge air cooler
4 Cover plate 9 Seal

5 Hexagon socket bolt 10 LT-supply line M1, M2 Differential pressure -
Measuring points
Figure 3: Charge air cooler
10 (18) 48/60CR, M010.170.040-01-0015

29 Screw plug 30 Sealing ring

Figure 4: Charge air cooler - Removal/installation of the cooler bundle
2018-09-18 - de
Charge air cooler
48/60CR, M010.170.040-01-0015 11 (18)

1 Cooler casing 3 Expansion sleeve 5 Hexagon socket bolt

2 Hex bolt 4 Cover 14 Parallel pin
Figure 5: Charge air cooler - Detaching/attaching the cover
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Charge air cooler
12 (18) 48/60CR, M010.170.040-01-0015

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Charge air cooler
1 Cooler casing 15 Forcing-off thread M10 19 Seal

5 Hexagon socket bolt 16 Hex bolt I-II Work steps
6 LT-cooler bundle 17 Washer
7 HT-cooler bundle 18 Stuffing box ring
Figure 6: Charge air cooler - Removing/fitting the stuffing box ring
48/60CR, M010.170.040-01-0015 13 (18)

1 Cooler casing 20 Hex bolt

7 HT-cooler bundle
Figure 7: Charge air cooler - Removal/installation of the HT-cooler bundle
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Charge air cooler
14 (18) 48/60CR, M010.170.040-01-0015

1 Cooler casing 7 HT-cooler bundle

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Figure 8: Charge air cooler - Removal/installation of the HT-cooler bundle

Charge air cooler
48/60CR, M010.170.040-01-0015 15 (18)

1 Cooler casing 20 Hex bolt

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6 LT-cooler bundle
Figure 9: Charge air cooler - Removal/installation of the LT-cooler bundle
Charge air cooler
16 (18) 48/60CR, M010.170.040-01-0015

1 Cooler casing 6 LT-cooler bundle

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Figure 10: Charge air cooler - Removal/installation of the LT-cooler bundle

Charge air cooler
48/60CR, M010.170.040-01-0015 17 (18)

22 Connection chamber 25 Cooler bundle 28 Hexagon socket bolt

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23 Hexagon socket bolt 26 Seal

24 Seal 27 Deflection chamber I-II Work steps
Charge air cooler
Figure 11: Cooler bundle - Removing/refitting the deflection chamber and connection chamber
9007225596622475
18 (18) 48/60CR, M010.170.040-01-0015

Charge air cooler in ultrasonic cleaning bath

cleaning
Summary
Ensure correct execution of work; remove contamination/residue from com-
ponents.
The intercooler definitively influences the operating values and thereby also
the performance of the engine. It is therefore necessary to check and clean it
Recommendation: clean the intercooler in installed condition using the MAN
Energy Solutions ultrasonic cleaning system and PrimeServ Clean MAN C
0186.
If this is not available, the intercooler bundle must be cleaned in detached
condition as described below.
Cleaning the charge air cooler.
Tools/aids required
1 Ultrasonic cleaning system - Option
2 Ultrasonic rod-shaped oscillator - Option
4-6% Cleaning agent PrimeServ Clean MAN C 0186 2750.28100-01 Inventory
(1 canister ≙ 30 l) 86
1 Cleaning trough - Inventory
1 Rope - Inventory


Removal and installation of the charge air cooler 010.170.040-01
Technical data
Intercooler bundle siehe
2018-09-05 - de
Arbeit-
sanlei-
Weight
tung
010.170.
040-01
General, M010.170.040-04-0001 1 (4)

Work Sequence 1 - Cleaning the charge air cooler in ultrasonic bath

Initial situation The intercooler bundle is placed flat inside the cleaning tub with the air inlet
side facing downwards, resting on square wooden blocks or steel profiles that
are approx. 100 mm high. The support ensures that the intercooler bundle is
elevated above the base of the cleaning tub and is surrounded by cleaning
agent. This allows better distribution of the ultrasonic waves.
Lifting tackle and tools are removed.
Work steps
Observe the operating manual

Before the cleaning process, read through and observe the operating
manual of the ultrasonic cleaning system.
Pre-cleaning
Pre-cleaning of the intercooler bundle

If the intercooler bundle has an oily surface, it can first be pre-cleaned.
Cleaning agent PrimeServ Clean MAN C 0186 is used for this purpose.
PrimeServ Clean MAN C 0186 is available from MAN Energy Solutions
and MAN PrimeServ.
Cleaning agent addition of about 1%, pre-cleaning duration about 0.5 -
1 hr.
Pre-cleaning is performed similarly to the actual main cleaning proced-
ure. Deposits on the intercooler bundle cannot be removed in this way.
Main cleaning
Danger of scalding
Due to high temperature of the fresh water scalding may be caused by
contact with hand.
• Wear protective clothing ((protective gloves, safety goggles, safety
shoes)
2018-09-05 - de
Prevent damage to the intercooler bundle

When filling in fresh water, do not direct a strong water jet or steam jet
towards the fins of the intercooler bundle as they may otherwise be
bent or damaged.
1. Fill the cleaning bath with clean, 60°C to 70°C hot fresh water so that the
intercooler bundle is just submerged. In doing so, be careful not to dam-
age the intercooler bundle.
2 (4) General, M010.170.040-04-0001

Addition of cleaning agent - foaming

If the cleaning agent is added at an earlier point, it will tend to foam
more strongly (over-foaming of the cleaning bath).
Required quantity of PrimeServ Clean MAN C 0186

The content of PrimeServ Clean MAN C 0186 cleaning agent must be
4-6 %, to be calculated depending on the water quantity required.
2. Calculate the required quantity of PrimeServ Clean MAN C 0186 cleaning

agent depending on the water quantity used, and add it into the cleaning
bath.
3. Fill up the cleaning bath fully with clean fresh water to produce a homo-
geneous water-cleaning agent mixture.
Rod-shaped oscillators submerged completely

Ensure that the rod-shaped oscillators are completely submerged in
the water-cleaning agent mixture and are not touching the intercooler
bundle or the cleaning bath. There is a danger of overheating if the
rod-shaped oscillators are exposed.
4. Place the rod-shaped oscillators of the ultrasonic cleaning system into

the cleaning bath and fix them.
5. Check the immersion depth and exposure of the rod-shaped oscillators

and correct if necessary.
6. Carry out the cleaning process with the ultrasonic cleaning system ob-
serving the manufacturer's operating manual.
7. Observe the duration of ultrasonic cleaning depending on the level of
contamination. See Table 1 in Work Instructions 010.170.040-01.
8. After completing the cleaning process, remove the rod-shaped oscillators
from the cleaning bath.
9. Drain the contaminated water-cleaning agent mixture into a suitable con-
tainer and dispose of it in an environmentally friendly manner (observe
safety data sheets).
2018-09-05 - de
Purging the intercooler 10.To purge the intercooler bundle, lift it from the cleaning bath using the lift-
ing tackle and suspend it flat above the cleaning bath.
11.Purge the entire intercooler bundle on the air and water side with fresh
water using a hose until only clear water flows out of the intercooler
bundle.
General, M010.170.040-04-0001 3 (4)

Purging process
Run the purging process until all the water-cleaning agent mixture is
removed from the intercooler bundle on the air and water side. If clean-
ing agent residue dries out or heats up, this might result in deposits
being formed.
A contaminated water-cleaning medium mixture must not be used
more than once for cleaning the intercooler.
27021606178145291
2018-09-05 - de
4 (4) General, M010.170.040-04-0001


010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas
010.180 Exhaust gas
51353968395
1 (1)

010.180 Exhaust gas

51353972619
1 (1)

Exhaust pipe
inspecting
Summary
execution of work, ensure / restore operational safety.
The exhaust pipe is to be checked at regular intervals for tightness of the
flanged connections and compensators.
Checking parts/components,
Removing parts/components,
Refitting parts/components.
Safety requirements
l Engine stopped
Tools/aids required
1 Socket spanner insert 17x12.5L 001.754 Option

2019-01-18 - de
Technical data
Exhaust pipe

Quick coupling half Weight 8 kg
Axial compensator Weight 13,5 kg
Pipe section Weight 67,5 kg
L48/60CR;L48/60B, M010.180.010-01-0004 1 (10)

Preliminary remark
Check exhaust pipe for foreign matter

Check the exhaust pipe for foreign matter after damage to a piston or
valve. Broken pieces can be drawn from the exhaust flow into the tur-
bine and cause serious damage.

Starting condition Engine cooled down.
Work steps 1. Check the exhaust pipe for leaks in the flange connections and axial
compensators at the intervals specified in the maintenance schedule.
2. Check covering insulation for dark colouration.
Leaking exhaust pipe

Leaking exhaust pipes are indicated by the black colouring on the cor-
responding areas on the insulation.
Remove covering if necessary, disassemble exhaust pipe and clean.
Work sequence 2 - Removing

Initial situation Engine cooled down. Casing removed.

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Work steps 1. Slacken the nuts (7). Unscrew alternately. See Fig. 3.
2. Remove the upper quick coupling half (5).
3. Screw lifting eye bolts (000.143) into the pipe section (2). See Fig. 4.
Exhaust pipe
4. Fasten the ropes (10) with shackle (002.452) to the lifting eye bolts. Sus-
pend on the lifting tackle. Tension the ropes slightly.
5. Slacken the nuts (12). Unscrew alternately. Remove the two pipe clamp
halves (11 and 14). See Fig. 5/II.
6. Remove the second pipe clamp in the same way (see point 5) and disas-
semble the axial compensator (4) carefully.
2 (10) L48/60CR;L48/60B, M010.180.010-01-0004

7. Place the axial compensator on support.

8. Disassemble the second axial compensator (4) in the same way (see
Steps 5 and 6). See Fig. 5/III.
9. Lift the pipe section (2) carefully and remove it. See Fig. 6.
10.Clean all parts. Check the axial compensators (4) for damage.
Work sequence 3 - Fitting

Work steps

The installation of the pipe section is essentially carried out in reverse order to
removal. The following points must be observed:
1. Thoroughly clean the contact face on the flange (6) and on the adjacent
pipe sections, or on the exhaust turbocharger (3).
2. Assemble all engine parts only loosely at first and tighten them only after
aligning all parts. See points 4 to 11.
3. Ensure the correct installation of the axial compensators (4) in flow direc-
tion. See fig. 2.
Mounting of pipe clamp (15) 4. Apply “Molykote HSC” lubricant to the threads and contact areas of nuts
(12).
5. Apply "Molykote HSC" lubricant to the V-flange (W) of the upper pipe
clamp half (11) and the lower pipe clamp half (14). See fig. 7/I.
6. Apply “Molykote HSC” lubricant to the clamping surfaces (T) on the pipe
section (2), compensator (4), or end cover (17). See fig. 7/II.
7. Guide the threaded bolts (13) through the sleeves on the upper half of the
pipe clamp and screw on the nuts (12) until they are slightly in contact. In
doing so, make sure that the gap (R) is even. See fig. 7/III.
2019-01-18 - de
8. Knock the pipe clamp (15) onto the flanges using a rubber hammer so
that the clamp fits evenly over the circumference. See fig. 7/III.
9. Tighten both nuts (12) to the specified torque of step 1. See Work In-
structions 010.000.003-05. While tightening, lightly tap the pipe clamp
using a rubber mallet. See fig. 7/III.
Exhaust pipe
10.Tighten both nuts (12) to the specified torque of step 2. See Work In-
structions 010.000.003-05. While tightening, lightly tap the pipe clamp
using a rubber mallet. See fig. 7/III.
L48/60CR;L48/60B, M010.180.010-01-0004 3 (10)

Tightening torque for pipe clamps

Depending on the mounting location, the tightening torques for the
pipe clamps may vary. For tightening torques for the respective pipe
clamp see Work Instructions 010.000.003-05.
Mounting of quick coupling 11.Apply lubricant Molykote HSC on the thread and contact surface of the
nuts (7), screw onto the stud bolts (8) and tighten to the specified torque.
2019-01-18 - de
1 Cylinder head 3 Exhaust gas turbocharger

2 Pipe section
Figure 1: Exhaust pipe
Exhaust pipe
4 (10) L48/60CR;L48/60B, M010.180.010-01-0004

2 Pipe section 4 Axial compensator

Figure 2: Exhaust pipe
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Exhaust pipe
L48/60CR;L48/60B, M010.180.010-01-0004 5 (10)

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Exhaust pipe
2 Pipe section 8 Stud bolt

5 upper quick coupling half 9 lower quick coupling half
6 Flange I-II Work steps
7 Nut
Figure 3: Exhaust pipe – Removing/assembling the quick coupling
6 (10) L48/60CR;L48/60B, M010.180.010-01-0004

2 Pipe section 10 Rope

Figure 4: Exhaust pipe - Suspending the pipe section
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Exhaust pipe
L48/60CR;L48/60B, M010.180.010-01-0004 7 (10)

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2 Pipe section 13 Threaded bolt

4 Axial compensator 14 bottom pipe clamp half
11 top pipe clamp half I-III Work steps
Exhaust pipe
12 Nut
Figure 5: Exhaust pipe - Removing/assembling the coupling
8 (10) L48/60CR;L48/60B, M010.180.010-01-0004

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Exhaust pipe
2 Pipe section I-II Work steps

10 Rope
Figure 6: Exhaust pipe - Removing/installing the pipe section
L48/60CR;L48/60B, M010.180.010-01-0004 9 (10)

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2 Pipe section 15 Pipe clamp

Exhaust pipe
4 Axial compensator 17 Cover

11 top pipe clamp half R Gap
12 Nut T Clamping surfaces
13 Threaded bolt W V-flange on pipe clamp halves
14 bottom pipe clamp half I - III Work steps
Figure 7: Installation instructions for pipe clamp (15)
18014405577979915
10 (10) L48/60CR;L48/60B, M010.180.010-01-0004

Exhaust gas blow-off device

Summary
correct execution of work, ensure / restore operational safety. Check control
elements in the exhaust gas system in the course of the service and mainten-
ance work and overhaul if necessary.
The work/work steps include: Disassembling /separating components, Re-
newing sealing rings/sealing elements, Assembling/refitting components.
Safety prerequisites
l Engine stopped
l Control air supply cut off
l Operating media system isolated/depressurized

Tools/aids required
1 High temperature grease XOMOX REINM 050 - Inventory

2020-01-21 - de

Work sequence 1 - Detaching the blow-off flap with drive head

Starting position Control lines (3) and blow-off pipes of the exhaust gas blow-off device pres-
sureless. For position details refer to figure 1.
Work steps 1. Disconnect control pipes (3) from the drive head (2).
2. Remove bolted flange connections (4).
3. Dismantle any supports on the adapter flange (6).
General, M010.180.010-02-0001 1 (6)

4. Pull blow-off flap with drive head from flange joint. Pay attention to seals
(5) and do not damage them.
Work sequence 2 - Exchange of the flap shank seal on the blow-off flap
For position details refer to figure 2.
Work steps 1. Detach blow-off flap and drive head from adapter flange.
2. Remove clamping sleeve (24) from flap shank (3).
3. Unscrew hexagon nut (20) with spring washers (21), remove thrust plate
(17) with thrust ring (16) and flap shank seal (14).
Seal support ring and flap shank bearing

The seal support ring (15) as well as the flap shank bearing (13) need
not be dismounted.
4. Push new flap valve shank seal (14) over the flap shank (3) in bore on flap
housing (1).
5. Fix thrust ring and thrust plate and screw down with hexagon nuts (20).
Do not forget spring washers (21).
6. Install clamping sleeve (24) in flap shank (3).
7. Check flap shank seal for tightness and retighten hexagon nuts (20).
Work sequence 3 - Exchange of the flooring seal on the blow-off flap

For position details refer to figure 2.
Work steps 1. Loosen and remove locking bolt (25) on flap housing (1).
2. Replace sealing ring (26) and replace by a new sealing ring.
3. Screw sealing screws (25) in flap casing (1) and tighten.
Work sequence 4 - Exchange of the seat ring with seat ring seal on the blow-off flap
Position details, see fig. 2.
Work steps 1. Unscrew the hexagon socket bolts (11) and retaining ring (10).
2. Move the valve disc (2) into a slightly open position (valve disc open
against the valve body by about 30 degrees ).
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3. Press off the retaining ring (10) from the valve casing. Screw in two hex
bolts into the threaded bores in the retaining ring and press it out uni-
formly.
4. Check the seat ring seal (8) and replace if necessary. Before inserting the
new seat ring seal, clean sealing ring groove.
5. Move the valve disc (2) into a completely open position (valve disc open
against the valve body by 90 degrees).
6. Clean the sealing surface of the valve disc, as well as the entire valve disc
and valve shaft and check for cracks. See work instructions
010.000.003-07.
7. Move the valve disc (2) into closed position
2 (6) General, M010.180.010-02-0001

8. Place the new seat ring (6) into valve casing (1).
Inserting the seat ring

When inserting the seat ring (6), be careful not to puncture the valve
casing.
9. Replace the retaining ring (10) and screw in the hexagon socket bolts (11)
equally and crosswise. Make sure that the retaining ring sits flat at the
valve body with a maximum projection of 0.2 mm.
10.Carry out the leak test with nominal pressure in the preferred flow direc-
tion.
Work sequence 5 - Changing of the shank seals and of the rotating wing sealing ring on
drive head
Position details, see Fig. 3.
Work Steps 1. Unscrew the fit bolts (8) and hexagon socket bolts (10).
2. Separate the casing upper part (1) from the casing lower part (7) and re-
move the shaft (4) with the rotor (3).
3. Remove the O-rings (5), clean the sealing ring grooves and insert the new
O-rings.
4. Remove the rotor sealing ring (6), clean the sealing ring groove on the ro-
tor (3) and insert the new rotor sealing ring.
5. Clean the sealing faces on the casing upper part and lower part, inspect
the bearing bushes (2) into the casing halves.
6. Insert the shaft (4) with the rotor (3) into the casing lower part. Pay atten-
tion to the O-ring seal (5) and do not damage it.
7. Apply high-temperature grease XOMOX REINM 050 to the sealing faces
of casing halves.
High temperature grease XOMOX REINM 050

Only use high-temperature grease XOMOX REINM 050 for joining the
two halves! Other sealing compounds can damage the drive head!
8. Position the casing upper part. Pay attention to the O-ring seal (5) and do
2020-01-21 - de
not damage it.

9. Screw in the fit bolts (8) using the hexagon nuts (9). Screw in the hexagon
socket bolts (10) with hexagon nuts (9) and tighten them across the diag-
onal.
Work sequence 6 - Attaching the blow-off flap with drive head

Initial situation Leak test for blow-off valve and drive head performed. Blow-off valve and
drive head mounted on the adaptor flange.
Position details, see Fig. 1.
General, M010.180.010-02-0001 3 (6)

Work steps 1. Fit the blow-off valve with the drive head between the flange joint of the
blow-off lines, taking care to ensure proper position. Take care not to
damage seals (5).
2. Mount the flange unions (4) and evenly tighten them crosswise to the
specified torque. See Work Instructions 010.000.003-05. If no torque is
specified in Work Instructions 010.000.003-05, the standard torque must
be used. See Work Instructions M010.000.003-07.
3. Fit any existing brackets between the blow-off line and the adaptor flange
(6).
4. Attach the control lines (3) to drive head (2) and check the system for
tightness.
Checking reset feedback
Reset feedback of flow flap

After proper equipment installation, the reset feedback of the flow flap
must be checked. Otherwise, the engine control system will be unable
to recognise the position of the flow flap any longer.
5. Check the reset feedback of the flow flap. For this, refer to work instruc-
tions 010.180.010-06 in the folder 010.285 SaCoSone Vol. 2.
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1 Blow-off valve 4 Flange union

2 Drive head 5 Seal
3 Control pipes 6 Adapter flange
Figure 1: Exhaust gas blow-off device
4 (6) General, M010.180.010-02-0001

1 Valve casing 11 Hexagon socket screw 19 Set screw

2 Valve flap 12 Disk centring ring 20 Hex nut

3 Flap shaft 13 Flap shaft bearing 21 Snap ring
6 Seat ring 14 Flap shaft seal 24 Clamping sleeve
8 Seat ring seal 15 Seal thrust ring 25 Screw plug
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9 Taper pin 16 Thrust ring 26 Sealing ring

10 Seat retaining ring 17 Thrust plate
Figure 2: Blow-off valve
General, M010.180.010-02-0001 5 (6)

1 Upper casing section 5 O-ring 10 Hexagon socket screw

2 Bearing sleeve 6 Rotor sealing ring 11 Stop screw
3 Rotor 7 Lower casing section 12 Sealing disc
3a Safety ball bearing 8 Fitting screw 13 Washer
4 Shaft 9 Hex nut 14 Hex nut
Figure 3: Drive head
45036000523728651
2020-01-21 - de
6 (6) General, M010.180.010-02-0001


010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas
51353976843
1 (1)


51353981067
1 (1)

Lubricating oil pump

Summary
Ensure correct execution of work, execute work on time according to the
maintenance schedule, prevent operating problems/damages.
Detach the lubricating oil pump(s) in the course of the service and mainten-
ance work.
Safety requirements
l Engine stopped
Tools/aids required
3 Forcing-off bolt M16 - Inventory
1 Hylomar SQ/M - Inventory
Technical data
Lubricating oil pump with gear wheel Weight 640 kg
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Preliminary remark
The work instructions describe the removal/installation of the lubricating oil
pump located on the control side.
The procedure for removing/installing a lubricating oil pump on the exhaust
side is essentially the same as on the control side.
L48/60CR;L48/60B, M010.220.010-01-0001 1 (6)

Work sequence 1 - Removal of lubricating oil pump

Initial situation Lubricating oil is drained from the lubricating oil pump and pipes (pressure
and suction side). Pressure and suction side pipes, and all piping and engine
parts obstructing the removal of the lubricating oil pump have been removed/
detached.

Work steps 1. Screw the lifting eye bolts (000.155) into the lubricating oil pump (4). See
Fig. 2.
2. Attach ropes (5) with shackle (002.453) to the lifting eye bolts and sus-
pend from the lifting tackle. Tension the ropes slightly.
3. Unscrew the hex nuts (2).
4. Screw three forcing-off bolts into the lubricating oil pump (4). Press the
lubricating oil pump off the casing (1).
5. Remove the lubricating oil pump (4) carefully, making sure not to damage
the stud bolts (1). See Fig. 3.
6. Transport lubricating oil pump (4) away and place it aside on a support.
7. Detach the tool.
8. Clean the lubricating oil pump (4) externally.
Work sequence 2 - Attachment of lubricating oil pump

Initial situation Outside of lubricating oil pump cleaned. Contact faces on casing and lubricat-
ing oil pump cleaned.

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Work steps 1. Screw the lifting eye bolts (000.155) into the lubricating oil pump (4).
2. Attach ropes (5) with shackle (002.453) to the lifting eye bolts and sus-
pend from the lifting tackle. Tension the ropes slightly.
2 (6) L48/60CR;L48/60B, M010.220.010-01-0001

3. Coat the contact face on the lubricating oil pump (4) with “Hylomar SQ/
M” sealing agent.
4. Lift the lubricating oil pump (4) and move it up to the engine.
5. Attach the lubricating oil pump (4) carefully, making sure not to damage
the stud bolts (3).
6. Screw the hex nuts (2) onto the stud bolts (3) and tighten them.
7. Detach the tool.
8. Measure the torsional backlash with feeler gauge (000.451) and compare
it with the prescribed value (see Volume 010.005 Engine - Operating
Manual).
9. Fill the lubricating oil pump (4) on the pressure side with clean lubricating
oil.
10.Attach all previously removed engine parts and piping.
11.Before start-up, vent the pressure line at the highest point until lubricating
oil is discharged bubble-free at the venting component.
12.Check the lubricating oil pump (4) and pipes for leaks and noises when
starting the engine. Loud noises show that the lubricating oil pump is
sucking air, therefore the pump cannot deliver the full capacity and cavit-
ations can occur.
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L48/60CR;L48/60B, M010.220.010-01-0001 3 (6)

1 Casing 3 Stud bolt

2 Hex nut 4 Lubricating oil pump
Figure 1: Lubricating oil pump
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4 (6) L48/60CR;L48/60B, M010.220.010-01-0001

1 Casing 4 Lubricating oil pump

2 Hex nut 5 Rope
3 Stud bolt
Figure 2: Lubricating oil pump – removal/installation
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L48/60CR;L48/60B, M010.220.010-01-0001 5 (6)

1 Casing 4 Lubricating oil pump

3 Stud bolt 5 Rope
Figure 3: Lubricating oil pump – removal/installation
18014405578881675
2019-01-21 - de
6 (6) L48/60CR;L48/60B, M010.220.010-01-0001

Lube oil pump

Dismantling and assembling
Summary
Ensure correct execution of work. The lubricating oil pump should be regener-
ated at regular intervals.
The work/work steps include: Removal of components, dismantling and as-
sembly, installation of components.
Tools/aids required
1 Removal device for spindle (set) L3NG 160 300.011 Option
1 Removal device for spindle (set) L3NG 180 300.010 Option

Technical data
Gear Weight 25,5 kg
Work sequence 1 - Removing the gearwheel

Starting position Lubricating oil pump is detached.
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Work steps 1. Thread off all hexagon socket bolts (13) by a few thread pitches. See Fig.
2.
2. Unscrew four hexagon socket bolts (screws 5 - 6 - 7 - 8) and screw into
forcing-off tap holes. See figure 1, 3 and 4.
Lube oil pump
3. Push thrust rings (16 to 19) away from each other by alternately tighten-
ing the hexagon socket bolts (screws 5 - 6 - 7 - 8).
4. Pull out gear wheel (11) and clamping set (12) of driving spindle (14) and
place on support surface. See Fig. 5.
5. Remove clamping set (12) from gear wheel (11). See Fig. 6.
6. Unscrew and remove the hexagon socket bolts (13). See Fig. 7.
51/60DF;48/60CR;48/60B, M010.220.010-02-0005 1 (7)

7. Dismantle clamping set (12), clean it and check for damage. See Fig. 7.
8. Clean locating hole in the gearwheel.
9. Clean lubricating oil pump externally.
10.Dismantle lubricating oil pump (see work sequence 2).
Work Sequence 2 - Disassembly of the lube oil pump

The lubricating oil pump shall be removed or installed in accordance with the
manufacturer's instructions. See in Volume 010.210...010.260 Engine com-
ponents - 010.220.010 lube-oil pump with drive.
Work sequence 3 - Refitting the gearwheel

Initial situation Lube oil pump has been assembled. Lube oil pump, gear wheel and clamping
set have been cleaned.
Work Steps 1. Thinly coat the thrust rings (16 to 19) with clean, low-viscosity lube oil.
Assembling the clamping set

When assembling the clamping set, observe the following points:
• The parting line (N) for the internal and external thrust ring (17 and 19)
must be offset with respect to the separation joint (M) for the front and
rear thrust ring (16 and 18) by 180°. See Fig. 8/I.
• Undrilled points in the rear thrust ring (18) must be assigned to the for-
cing-off tap bores in the front thrust ring (16). See Fig. 8/II.
2. Assemble the clamping set (12).

3. Thinly coat the threads and contact areas of the hexagon socket bolts
(13) with clean, low-viscosity lube oil and screw into clamping set (12).
4. Thinly coat the locating hole in the gear wheel (11) and the locating pin of
the drive spindle (14) with clean, low-viscosity lube oil.
5. Insert the clamping set (12) in the locating hole of the gear wheel (11) and
push them together onto the drive spindle (14).
6. Tighten the hexagon socket bolts (13) slightly; align the gear wheel (11)
with the drive spindle shoulder.
7. Tighten the hexagon socket bolts (13) evenly in three stages to the spe-
cified torque (see Work Instructions 010.000.003-05) - For tightening or-
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der see Figure 1.

8. Check the hexagon socket bolts (13) in the sequence of their arrange-
ment (bolt 1-5-3-7-2-6-4-8) with torque (3rd stage, see Work Instructions
010.000.003-05), re-tighten hexagon socket bolt if necessary.
Lube oil pump
2 (7) 51/60DF;48/60CR;48/60B, M010.220.010-02-0005

1-8 Bolt number/Tightening 11 Gear wheel 13 Hexagon socket bolt

order
10 Lube oil pump 12 Clamping set 14 Drive spindle
Figure 1: Lube oil pump
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Lube oil pump

Figure 2: Lube oil pump - Detaching the gear wheel
51/60DF;48/60CR;48/60B, M010.220.010-02-0005 3 (7)


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Lube oil pump
4 (7) 51/60DF;48/60CR;48/60B, M010.220.010-02-0005

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12 Clamping set 13 Hexagon socket bolt I-II Work steps

Lube oil pump
51/60DF;48/60CR;48/60B, M010.220.010-02-0005 5 (7)

11 Gear wheel 14 Drive spindle

11 Gear wheel 12 Clamping set

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Figure 6: Lube oil pump – Removing the clamping set

Lube oil pump
6 (7) 51/60DF;48/60CR;48/60B, M010.220.010-02-0005


16 Thrust ring, front
17 Thrust ring, outer
18 Thrust ring, rear
19 Thrust ring, inner
Figure 7: Lube oil pump - Dismantling the clamp ring (12)
13 Hexagon socket bolt 18 Thrust ring, inner

16 Thrust ring, front M Parting line (item 16 and
18)
17 Thrust ring, outer N Parting line (item 17 and
19)
18 Thrust ring, rear
Figure 8: Lube oil pump – Assembly of the clamping set (Illustration I: Position
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of the parting lines / Illustration II: Position of the forcing-off tap bore relative to
rear thrust ring)
9007206324726923
Lube oil pump
51/60DF;48/60CR;48/60B, M010.220.010-02-0005 7 (7)

9007206324726923
2016-12-06 - de
Lube oil pump
51/60DF;48/60CR;48/60B, M010.220.010-02-0005

010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas
51353998347
1 (1)


51354002571
1 (1)

Coolant pump
Removing and fitting
Summary
Ensure correct execution of work.
The cooling water pumps must be removed in the framework of the mainten-
ance and repair work.
fitting components.
Safety requirements
l Engine stopped
Tools/aids required
2 Hexagon bolt (M16) with pin - Inventory
1 Rope - Inventory
1 Hylomar M sealing compound - Inventory
Technical data
Cooling water pump with gear wheel Weight 145 kg
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Work sequence 1 - Removing the cooling water pump

Initial situation Coolant pipe shut off, coolant drained from the coolant pipe. Casing cover re-
moved. Coolant pump cooled down.
Coolant pump
General, M010.230.010-01-0005 1 (4)


Work Steps 1. Place collecting container under coolant pipe (16) and drain coolant from
the coolant pipe.
2. Place collecting container under coolant pump (8) and drain coolant from
the coolant pump.
3. Remove coolant pipes (11 and 16) including seals (12 and 17).
4. Remove lube oil pipe (13) from coolant pump (8).
5. Remove leakage drain pipe (7) from the coolant pump (8).
6. Suspend the coolant pump (8) with a rope from the lifting tackle. For sus-
pension points, see the manufacturer’s Operating Manual in Volume
010.210 ... 010.260 Engine components – 010.230.010 HT coolant
pump with drive / 010.230.020 LT coolant pump with drive. Tension the
rope slightly.
7. Screw off hex nuts (4).
8. Press down coolant pump (8) with two hex bolts (M16) with pin.
9. Remove coolant pump (8) carefully, without damaging stud bolts (5).
10.Place coolant pump (8) horizontally on a wooden support surface.
11.Remove rope.
12.Clean the outside of the coolant pump (8).
Work sequence 2 - Installing the cooling water pump

Initial situation Casing cover removed. Outside of coolant pump cleaned.

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Coolant pump
Work Steps 1. Clean the contact area on casing (3) and coolant pump (8).
2 (4) General, M010.230.010-01-0005

2. Suspend coolant pump (8) with a rope from the lifting tackle – see the
manufacturer’s Operating Manual in Volume 010.210 ... 010.260 Engine
components – 010.230.010 HT coolant pump with drive / 010.230.020
LT coolant pump with drive.
3. Apply “Hylomar M” sealing agent to the contact area of coolant pump (8).
Danger of crushing when fitting

When fitting engine components accidents resulting in severe personal
injury may occur.
• When fitting, do not reach between the engine component to be fitted
and the engine’s mating component.
• Wear safety gloves.
Do not damage stud bolts and gearwheels

Do not damage stud bolts (5) and gearwheels (1 and 2) when fitting the
coolant pump.
17757713547
4. Carefully attach coolant pump (8), whilst ensuring the markings (M) on the
casing (3) and eccentric ring (6) are aligned. See Fig. 1.
5. Screw hex nuts (4) on to stud bolts (5) and tighten them crosswise.
6. Remove rope.
7. Measure the rotating shoulder clearance with feeler gauge (000.451),
note it down, and compare with the prescribed target value. See Volume
010.005 Engine – Operating Manual, 010.000.035-04.
8. Attach lube oil pipe (13) to coolant pump (8).
9. Attach leakage drain pipe (7) to coolant pump (8).
10.Attach coolant pipe (11), including a new seal (12).
11.Fill coolant pump (8) with coolant.
12.Attach coolant pipe (16), including a new seal (17).
13.Vent coolant pipes (11 and 16).
14.Check coolant pump (8) and pipe connections for tightness after a short
period in operation.
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Coolant pump
General, M010.230.010-01-0005 3 (4)

1 Gear wheel *7 Leakage drain pipe 13 Lube oil pipe

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2 Gear wheel *8 Coolant pump 14 Hex nut

3 Casing 9 Hex nut 15 Hex bolt
4 Hex nut 10 Hex bolt *16 Coolant pipe
5 Stud bolt *11 Coolant pipe 17 Seal
Coolant pump
6 Eccentric ring 12 Seal M Marking

Figure 1: Coolant pump
* The design of the coolant pump, position of the volute casing and fitting of the coolant pipes and of the leakage
drain pipe may differ from the illustration.
17757713547
4 (4) General, M010.230.010-01-0005

Cooling water pump

Summary
Ensure the work is properly performed, carry out work on time according to
the manufacturer's data, prevent operational problems/damages.
Cooling water pumps are mostly maintenance-free, however some compon-
ents must be precautionary replaced at regular intervals. In case of opera-
tional problems (heavy leakage) it is necessary to replace the individual parts.
Disassembling and Assembling of components,
Tools/aids required
1 Forcing-off device 009.331 Option
1 Forcing-off device 009.331-3 Option
1 Pipe 009.331-6 Option
1 Forcing-off disc 009.331-8 Option
1 Forcing-off bolt 009.331-9 Option
1 Rags - Inventory
1 Vegetable oil - Inventory

2016-12-06 - de
Cooling water pump
Technical data
Gear Weight 20 kg
48/60B;48/60CR, M010.230.010-02-0007 1 (6)

Work Sequence 1 - Removing the gearwheel

Starting position Cooling water pump detached and cleaned externally.
Work Steps 1. Mount forcing-off device (009.331-3) on gearwheel (4) and fit pipe
(009.331-6). See Fig. 2.
2. Release hexagon bolt (5) whilst holding gearwheel (4) with the forcing-off
device.
3. Detach the tool.
4. Unscrew hexagon bolt (5), remove washer (6).
5. Screw hexagon bolt (5) into shaft (3). See Fig. 3.
6. Screw forcing-off bolt (009.331-9) into forcing-off disk (009.331-8) and fit
it into forcing-off device.
7. Fit the forcing-off device to gearwheel (4) and fit-on the pipe.
8. Force-off gearwheel (3) countering it with forcing-off device.
9. Remove tool, unscrew hexagon bolt (5) from the shaft (3).
10.Clean all individual components and check them for wear/damage.
Work Sequence 2 - Dismantling and assembly of cooling water pump

Dismantling and assembly of cooling water pump (1) must be carried out ac-
cording to the manufacturer's instructions. See the manufacturer’s Operating
Manual in Volume 010.210 ... 010.260 Engine components – 010.230.010
HT coolant pump with drive / 010.230.020 LT – coolant pump with drive.
Work Sequence 3 - Refitting the gearwheel

Initial situation All individual parts cleaned and checked for damage or replaced if necessary.
Work steps 1. Soak clean rags with clean, very low-viscosity oil.
Low-viscosity oil
Use low-viscosity oil. Gear wheel is fixed securely only after pushing
out the oil film on the cone.
2. Wet cone (F) on shaft (3) with an oily cloth.

3. Push gear wheel (4) onto shaft (3) tightly.
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4. Wet the thread and contact area of hex bolt (5) as well as washer (6) with
Cooling water pump
an oily cloth, place the washer on the hex bolt, and screw the hex bolt
into shaft (3), tightening it hand-tight.
5. Mount forcing-off device (009.331-3) on gear wheel (4) and fit pipe
(009.331-6). See Fig. 2.
6. Tighten hex bolt (5) to specified pre-torque whilst holding gear wheel (4)
with the forcing-off device. See Work Instructions 010.000.003-05.
7. Pull shaft (3) out until it rests
8. Measure and note distance (A) between gear wheel (4) and coolant pump
casing (1). See Fig. 1.
2 (6) 48/60B;48/60CR, M010.230.010-02-0007

9. Tighten hex bolt (5) to specified end torque whilst holding gear wheel (4)
with the forcing-off device. See Work Instructions 010.000.003-05.
10.Pull shaft (3) out again until it rests and measure distance (A) between
gear wheel (4) and coolant pump casing (1).
Distance must have reduced by 1.0 to 1.3 mm.
Determination of the distance (A)

In order to correctly determine the distance (A), always pull the shaft
out on the same side (see Point 7).
11.Detach the tool.
Starting-up the coolant pump

Do not put coolant pump into operation until 2 hours after gear wheel
mounting.
18176494859
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Cooling water pump
1 Cooling water pump 5 Hex bolt

2 Eccentric ring 6 Washer
3 Shaft A Distance
4 Gear wheel
Figure 1: Cooling water pump
48/60B;48/60CR, M010.230.010-02-0007 3 (6)

1 Cooling water pump 5 Hex bolt 8 Washer

3 Shaft 6 Washer
4 Gear wheel 7 Hexagon bolt M16x100
Figure 2: Cooling water pump - Removing/Fitting the gearwheel
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Cooling water pump
4 (6) 48/60B;48/60CR, M010.230.010-02-0007


3 Shaft 7 Hexagon bolt M16x100
4 Gear wheel 8 Washer
Figure 3: Cooling water pump - Removing the gearwheel
2016-12-06 - de
Cooling water pump
48/60B;48/60CR, M010.230.010-02-0007 5 (6)


3 Shaft 6 Washer
4 Gear wheel F Cone
Figure 4: Cooling water pump - Fitting the gearwheel
18176494859
2016-12-06 - de
Cooling water pump
6 (6) 48/60B;48/60CR, M010.230.010-02-0007


010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas
51354027915
1 (1)


51354032139
1 (1)

Three-way valve M306

inspect
Summary
Check components for quality/wear condition, ensure / restore operational
safety.
Control elements in the compressed air or control air system resp. are to be
checked and, if necessary, overhauled at regular intervals.
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.

Tools/aids required
Work sequence 1 - Disassembling the three-way valve

Initial situation Compressed air/pilot air system depressurised. Valve cleaned on the outside.
Work steps 1. Loosen the pipe connections (mark if necessary) and remove the mount-
ing bolts. Remove the valve.
2. Seal any open pipe ends with suitable means to prevent ingress of dirt.
3. Unscrew the roller lever (11). Unscrew the valve guide (12) with valve tap-
pet (13) and spring.
4. Dismantle the valve further. Clean all individual parts thoroughly.
5. Check wear parts (V) for wear and hardening (in the case of seals) and re-
place parts if necessary.
2017-01-10 - de
6. Check all moving parts for ease of movement before assembly.
Work sequence 2 - Assembling the three-way valve

Assembly is essentially carried out in reverse order to dismantling. The follow-
ing points must be observed here:
General, M010.280.020-02-0001 1 (2)

Faults in the valve or in the compressed air/pilot air system

Careful attention must be paid to cleanliness in the work place during
assembly, as even the tiniest of dirt particles can cause faults in the
valve or in the compressed air/pilot air system.
1. When fitting new seals, make sure that they are not twisted.
2. Apply a thin coat of oil to all parts before assembly.
11 Roller lever 14 Valve seat

12 Valve guide
13 Valve tappet V Wear parts
Figure 1: Cut-away of the three-way valve M306
Principle of operation
Connection 1 2 4
Position I closed connected
Position II connected closed

18014402743051915
2017-01-10 - de
2 (2) General, M010.280.020-02-0001


inspect
Summary
safety.

Tools/aids required
1 Hook wrench - Inventory
Work sequence 1 - Disassembling the three-way valve

3. Unscrew the hexagon socket bolts (11). Remove the casing top section
(12).
4. Use a hook spanner to unscrew the valve guide (15) together with the
piston (13) and valve tappet (14).
2017-01-10 - de
5. Remove the valve seat (16). Remove the valve (17).

6. Dismantle the valve further. Clean all individual parts thoroughly. Blow out
using compressed air.
General, M010.280.020-04-0001 1 (2)

Work sequence 2 - Assembling the three-way valve


11 Hexagon socket bolt 16 Valve seat

12 Casing top section 17 Valve
13 Piston 18 Casing bottom section
14 Valve tappet
15 Valve guide V Wear parts
Figure 1: Cut-away of the three-way valve M317
2017-01-10 - de
Connection 1 2 4
5 pressurised connected closed
5 without pressure closed connected

18014402743078795
2 (2) General, M010.280.020-04-0001

3/2-way solenoid valve M329

inspect
Summary
safety.

Tools/aids required

check the function of the emergency stop unit on the en- 010.280.020-19
gine
Work sequence 1 - Disassembling the 3/2-way solenoid valve

2017-01-10 - de
3. Unscrew the hex bolts (11) and hexagon socket bolts (12).
4. Remove the connecting piece (13) with emergency operation override
(14). Unscrew the hexagon socket bolt (12).
General, M010.280.020-05-0001 1 (3)

Work sequence 2 - Assembling the 3/2-way solenoid valve


Arrangement of the pins in the valve casing

Ensure that the pins are arranged correctly in the valve casing depend-
ing on how the 3/2-way solenoid valve M329 is used. See Fig. 2.
2017-01-10 - de
11 Hexagon bolt 14 Emergency operation

12 Hexagon socket bolt 15 Valve casing
13 Connecting piece V Wear parts
I-V Valve functions
Figure 1: Sectional view of 3/2-way solenoid valve M329
2 (3) General, M010.280.020-05-0001

The functions shown in Figs. 1 and 2 are available, depending on the pin ar-
rangement in the valve casing.

2017-01-10 - de
I Starting valve, marine/sta- IV Emergency stop valve,

tionary engine stationary engine
II Vent valve V Slow-turn valve
III Emergency stop valve,
marine engine
Figure 2: Valve function depending on pin arrangement
18014402743085835
General, M010.280.020-05-0001 3 (3)

18014402743085835
2017-01-10 - de
General, M010.280.020-05-0001

inspect
Summary
safety.

Tools/aids required

Work steps 1. Loosen the pipe connections/disconnect the connecting cable (mark if
necessary) and remove the mounting bolts. Remove the valve.
3. Unscrew the socket (12).

2017-01-10 - de

General, M010.280.020-08-0001 1 (2)


11 Valve casing
12 Socket V Wear parts

Figure 1: Cut-away of the 3/2-way solenoid valve M371
2017-01-10 - de
Connection 1 2 3
Magnet energised closed connected
Magnet deener- connected closed

gised
18014402743616523
2 (2) General, M010.280.020-08-0001


inspect
Summary
safety.

Tools/aids required
Work sequence 1 - Disassembling the 5/2-way valve

3. Dismantle the valve. Clean all individual parts thoroughly.
4. Check wear parts for wear and hardening (in the case of seals) and re-
2017-01-10 - de

General, M010.280.020-10-0001 1 (2)


Figure 1: 5/2-way solenoid valve M367
Connection 5 4 1 2 3
Magnet deenergised connected connected closed

Magnet energised closed connected connected

9007203488941963
2017-01-10 - de
2 (2) General, M010.280.020-10-0001

Pressure reducing valve M409

inspect
Summary
safety.

Tools/aids required
Work sequence 1 - Disassembling the pressure-reducing valve

3. Unscrew the stud bolts (11) and knurled screw (14).
4. Separate the casing top section (12) from the casing bottom section (13).
Remove the wear parts (V).
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Work sequence 2 - Assembling the pressure-reducing valve

General, M010.280.020-11-0001 1 (2)


9007203488987403
11 Cylinder bolt 14 Knurled screw

12 Casing top section
13 Casing bottom section V Wear parts
Figure 1: Cut-away of the pressure-reducing valve M409
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9007203488987403
2 (2) General, M010.280.020-11-0001

Compressed air filter M462

inspecting
Summary
safety.

Tools/aids required
Work sequence 1 - Disassembling the compressed air filter

Initial situation Compressed air/pilot air system depressurised. Filter cleaned on the outside.
ing bolts. Remove the filter.
3. First drain the compressed-air filter via the hex bolt (13).
4. Unscrew the hex nut (11). Remove the pipe clamp.
5. Dismantle the filter. Clean all individual parts thoroughly.

6. Clean the filter insert (12) in accordance with the manufacturer's instruc-
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tions or replace it with a new one if necessary.
Work sequence 2 - Assembling the compressed air filter

Assembly is essentially carried out in reverse order to dismantling. Observe
the following point here:
General, M010.280.020-12-0001 1 (2)


9007203488992907
11 Hex nut
12 Filter insert
13 Hex bolt
Figure 1: Cut-away of the compressed-air filter M462
9007203488992907
2017-01-10 - de
2 (2) General, M010.280.020-12-0001

M470 pressure governor

Inspecting
Summary
safety.

Tools/aids required
Work sequence 1 - Dismantling the pressure controller

Initial situation Compressed air/pilot air system depressurised. Governor cleaned on the out-
side.
3. Unscrew the hexagon socket bolts (11). Carefully remove the pilot regu-
lator (A).
4. Unscrew the hexagon socket bolts (13). Separate the casing top section
2017-01-10 - de
(14) from the casing bottom section (15).

Work sequence 2 - Assembly of the pressure controller

General, M010.280.020-13-0001 1 (2)


9007203489000715
11 Hexagon socket bolt 14 Casing top section A Pilot regulator

12 Locking button 15 Casing bottom section B Main governor
13 Hexagon socket bolt V Wear parts
Figure 1: Cut-away of the pressure governor M470

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9007203489000715
2 (2) General, M010.280.020-13-0001

Limit switch M745

inspect
Summary
safety.
Electric/ electronic control and/or switch elements are to be checked and, if
necessary, overhauled at regular intervals.

Tools/aids required
Work sequence 1 - Disassembling the limit switch

Initial situation No voltage applied to limit switch.
Work steps 1. Disconnect the connecting cable (mark if necessary) and remove the
mounting bolts. Remove the switch.
2. Remove the roller lever (1).
3. Unscrew the stud bolts (2). Remove the button.
4. Unscrew the stud bolts (3). Remove the cover (4).
5. Dismantle the limit switch further. Clean all individual parts thoroughly.
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Work sequence 2 - Assembling the limit switch

Limit switch M745
Assembly is essentially carried out in reverse order to dismantling. Observe

the following point here:

General, M010.280.020-14-0001 1 (2)

9007203489007371
1 Roller lever
2 Cylinder bolt
3 Cylinder bolt
4 Cover
Figure 1: Diagram of the limit switch M745
9007203489007371
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Limit switch M745
2 (2) General, M010.280.020-14-0001

2/2-way solenoid valve M314/M315/M316

inspect
Summary
safety.

Tools/aids required

3. Dismantle the valve. Clean all individual parts thoroughly.
4. Check wear parts for wear and hardening (in the case of seals) and re-
2017-01-11 - de

General, M010.280.020-16-0001 1 (2)


Figure 1: 2/2-way solenoid valve M314/M315/M316

Connection A B
Magnet deenergised closed closed
Magnet energised connected

9007203489071883
2017-01-11 - de
2 (2) General, M010.280.020-16-0001

Pressure regulator station M615

inspect
Summary
safety.

Tools/aids required
Preliminary remarks
In the case of marine systems, the pressure of the starter air tank is reduced
by the pressure-reducing station M615 from 30 to 8 bar. It is arranged in the
operating stand behind the cover. The pressure reducing station (see schem-
atic drawing) consists of 2 filters and 2 reducing valves. It is possible to switch Pressure regulator station M615
over from one branch to another by means of the lever. After that becomes
necessary, the pressure reducing station is to be checked/overhauled at the
next opportunity.
Work on the pressure reducing station should be carried out with the great
care that its significance of the instrument air supply requires, wear parts
2017-01-11 - de
should be stocked and replaced at the right time.
General, M010.280.020-17-0001 1 (3)

1 Hexagon bolt 6 sealing screw on distribu-

tion block
2 Casing 7 Adjusting screw
3 Hexagon bolt 8 Hexagon bolt
4 Casing 9 Switching lever
5 Cylinder screw 10 Drain valve
Figure 1: Pressure reducing station M615 - Cutaway drawing /Schema
Work sequence 1 - Changing the filter inserts

Work steps 1. Remove obtrusive casing sheets.
2. Make system pressureless and open drain cocks in the system and at
the pressure reducing station 615 (item 10).
3. Remove hexagon bolt (3) on both sides, Renew wear parts (V), i.e. filter
insert and sealing ring.
Work sequence 2 - Inspection /Overhauling

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Work steps 1. Remove any obstructive casing panels.

2. Depressurise the system and open the decompression and drain cocks.
3. Loosen the pipe connections (mark if necessary) and remove the mount-
ing bolts. Remove the pressure-reducing station.
4. Seal any open pipe ends to prevent ingress of dirt.
5. Remove the hex bolt (3) on both sides. Replace the wear parts (V), i.e.
the filter insert and seal.
6. Slacken the hex bolt (1). Separate casing (2) from casing (4). Remove the
wear parts (V).
2 (3) General, M010.280.020-17-0001

7. Loosen the stud bolts (5). Remove the wear parts (V).
8. Loosen the screw plugs (6). Remove the wear parts (V).
9. Loosen the adjusting bolts (7). Remove the wear parts (V).
10.Loosen the hex bolts (8). Remove the gear lever unit (9).
11.Unscrew the drain valve (10).
12.Clean the individual parts and blow them out using compressed air.
13.Check the wear parts for wear. Replace them if necessary. Always re-
place the seals.
14.Check all moving parts for ease of movement before and after assembly.

Carry out assembly by following the steps in reverse order. After attaching the
pressure-reducing station to the operating device and connecting the pipes,
check that the pressure-reducing station is working properly and not leaking.
The pressure gauge displays the pressure of both pilot air ducts.
9007203489101963

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General, M010.280.020-17-0001 3 (3)

9007203489101963
2017-01-11 - de
General, M010.280.020-17-0001
Emergency stop unit function on the engine

check
Summary
Check condition/function of components; ensure/restore operating reliability.
Regularly check the control elements in the compressed air or control air sys-
tem and overhaul as necessary.
The work/work steps comprise:
Check of the emergency stop device.

1 Qualified Personnel 0.5
1 Assistant Personnel 0.5
Tools/aids required
1 Ear defenders - Inventory
1 Multimeter/ohmmeter - Inventory

inspect the 3/2-way solenoid valve M329 010.280.020-05
Preliminary remarks
The emergency release unit essentially consists of the emergency stop valve
M329/2 (measuring range designation: 1SZV1012), emergency stop buttons,
and corresponding signal lines. The examination of proper functioning is to be
carried out at regular time intervals according to the maintenance plan. De-
pending on the area of application of the engine differing variants of the emer-
gency stop valve are used. For marine engines the emergency stop valve is
2017-02-14 - de
fitted with an emergency stop button, while most stationary engines do not
have one.
Checking the emergency stop valve after removal/installation

Each time the emergency stop valve is removed/installed, a functional
test must be carried out. This check must first be carried out with the
engine at a standstill, and subsequently during idling.
General, M010.280.020-19-0002 1 (8)

Work sequence 1 - Checking the emergency stop valve

Initial situation The engine is idling, without dynamic load response.
Work Steps Marine engines

1 Emergency stop valve 2 Emergency stop button

M329/2
Figure 1: Emergency stop valve M329/2 (measuring range 1SZV1012) in-
stalled in marine engines
Hazard due to noise

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When actuating the emergency stop valve this is suddenly pressurised

Danger of crushing
When actuating the emergency stop valve the control rods of the injec-
tion pumps are suddenly moved into the “zero filling” position.
• Stopping in the control linkage area is forbidden.
2 (8) General, M010.280.020-19-0002

1. Press emergency stop button (2) on the emergency stop valve (1). In do-
ing so, ensure that the emergency stop button (2) is kept in the pressed
position by the locking mechanism(3). See Fig. 2.
2. Checking effects of the emergency stop:
The triggering of the emergency stop valve (1) is signalled by a loud bang,
among other things.
Engines with conventional injection
The control rods of the injection pumps are in the “zero filling” position,
the engine stops. Manually check on one injection pump that the control
rod can no longer be pushed in.
Engines with Common Rail injection
The Common Rail accumulator is immediately relieved of pressure, the
engine stops. The display of the engine control shows the emergency
stop.
Malfunction of the emergency release unit

Should the engine continue to run despite the emergency stop having
been triggered, the engine must no longer be operated until the emer-
gency stop unit has been restored to full working order. The engine
must be switched off immediately via the engine control/controller
stop. Should the engine continue to run despite the controller stop, the
engine can be stopped by interrupting the fuel supply.

2 Emergency stop button 3 Arresting device
Figure 2: Emergency stop button with arresting device – image on left: normal
position, image on right: locked in emergency stop position
2017-02-14 - de
General, M010.280.020-19-0002 3 (8)

Stationary engines
1 Emergency stop valve 4 Connecting plug

M329/2
5 Lock screw
Figure 3: Emergency stop valve M329/2 (measuring range 1SZV1012) in-
stalled in stationary engines
Hazard due to noise

2017-02-14 - de
When actuating the emergency stop valve this is suddenly pressurised

Danger of crushing
When actuating the emergency stop valve the control rods of the injec-
tion pumps are suddenly moved into the “zero filling” position.
• Stopping in the control linkage area is forbidden.
4 (8) General, M010.280.020-19-0002

3. Remove safety bolts (5) and disconnect connecting plug (4). See Fig. 3.
By disconnecting the connecting plug, (4) the power supply circuit to the
emergency stop valve (1) is interrupted and this is triggered as a result.
among other things.
engine stops. The display of the engine control shows the emergency
stop.
Malfunction of the emergency release unit

Should the engine continue to run despite the emergency stop having
been triggered, the engine must no longer be operated until the emer-
gency stop unit has been restored to full working order. The engine
must be switched off immediately via the engine control/controller
stop. Should the engine continue to run despite the controller stop, the
engine can be stopped by interrupting the fuel supply.
Work sequence 2 - Resetting the emergency stop valve

Starting position Engine stopped.
Work steps Marine engines

1. Release the arresting device (3) for the emergency stop button (2). The
emergency stop button (2) then jumps back out and air is evacuated from
the emergency stop valve (1) (see Fig. 2).
Stationary engines
2. Plug in the connecting plug (4) for the emergency stop valve (1) and
screw in the lock screw (5) (see Fig. 3).
Work sequence 3 – Checking the solenoid valve on the start, emergency stop, and slow-
2017-02-14 - de
turn valve
Initial situation Engine stopped.
Work steps 1. Remove safety bolts (5) and disconnect connecting plug (4). See Fig. 3.
2. Measure ohmic resistance between the opposite, angled contacts and
record in table. See Fig. 4.
3. Attach connecting plug (4) and screw in safety bolt tightly.
General, M010.280.020-19-0002 5 (8)

Figure 4: Measuring ohmic resistance

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Figure 5: Valve with milled casing/valve with cast casing
Valve Resistance
Valve with milled casing 43.0 Ω–48.0 Ω
Valve with cast casing 28.0 Ω–30.0 Ω

Table 1: Ohmic resistance in new condition
6 (8) General, M010.280.020-19-0002

Valve Resistance
Valve with milled casing 34.4 Ω
Valve with cast casing 22.4 Ω

Table 2: Lower limit value of ohmic resistance
Lower limit Date Date Date Date

value
Engine no.
Starting
valve
Emergency
stop valve
Slow-turn
valve
Table 3: Example table for recording values
Replacing the solenoid coil

If the values fall below the lower limit, replace the solenoid coil.
If the upper value for new condition is exceeded, there may be dam-
aged solder connections. The solenoid coil should also be replaced in
this case.
If smaller deviations from the new condition are identified, carry out
more frequent measurements at shorter intervals.
For safety reasons, we recommend replacing the coils at least every
five years.

Work sequence 4 – Checking the emergency stop button
Initial situation Emergency stop valve successfully checked. The engine is idling, without dy-
namic load response.
Work Steps Pressing an emergency stop button (6) causes the triggering of the emer-
gency stop valve (1) via the interaction of engine components.
1. Press one of the engine’s emergency stop buttons (6). The emergency
stop button (6) snaps into the pressed position. An alarm message is
shown on the display.
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among other things.
engine stops.
3. Turn the emergency stop button in the direction of the arrow to unlock it.
4. Acknowledge and reset the alarm on the display.
General, M010.280.020-19-0002 7 (8)

6 Emergency stop button

Figure 6: Emergency stop button
27021601998320395
2017-02-14 - de
8 (8) General, M010.280.020-19-0002

Control valves of the slow-turn function

Adjustment
Summary
Control elements in the compressed air/pilot air system must be checked at
regular intervals and overhauled or replaced if necessary.
The work/steps include the following:
Adjusting the control valves of the slow-turn function,
Checking the slow-turn function.
Safety requirements
l Engine stopped

1 Engineer 0,5

Preliminary information
The slow-turn function is integrated in the 30-bar compressed air and starting
system of the engine. The slow-turn function is used on engines that are star-
ted automatically from the remote control device (e.g. bridge for marine en-
gines).
With the slow-turn function, the engine control system checks whether in-
ternal leakages have collected in the combustion chambers during the stand-
2017-06-13 - de
still period of the engine and whether there is any blocking that prevents the
engine from being started.
The slow-turn function is an automatic function. In other words, the slow-turn
function is activated automatically by the engine control system when the en-
gine is restarted after a certain standstill period.
During this operation, the engine control system checks whether the engine
reaches a specific speed in a certain time period with reduced starting air
pressure. In the process, the starting air pressure is reduced in such a manner
that in case of internal leakage in the combustion chamber no damage (e.g.
caused by water hammer) can occur. To execute the slow-turn function, the
General, M010.280.020-20-0001 1 (4)

engine control system opens the slow-turn valve M329/3 and thus releases
compressed air to the engine for the slow-turn operation via the adjustable
throttle valve M020 and the pressure regulator M470.
Proper adjustment and testing of the slow-turn function is done at the time of
commissioning the engine. The engine control system parameters are con-
figured with the standard (default) values. The adjustment and parameters can
be adapted to specific system conditions.
During commissioning, the air quantity and air pressure of the slow-turn
device are adjusted using the adjustable throttle valve M020 and the pressure
regulator M470 on the engine in such a manner that safe starting of the slow-
turn device and the required engine speed are achieved.
If valves of the slow-turn device are replaced, these adjustments must be
checked and if necessary, they must be readjusted. The present work instruc-
tion describes the procedure for adjusting and testing the slow-turn function.
Work Sequence - Adjusting control valves of the slow-turn function

Initial situation Engine is stopped. Manual Emergency Stop is active. Starting pressure of 30
bar is present at the engine.
Work steps 1. Press and hold the knob (11) on the slow turn valve M329/3 (10) and
A – Adjusting the slow-turn simultaneously adjust 12 bar on the locking knob (21) of the pressure
air pressure regulator M470 (20). Check the slow-turn air pressure reading on the
pressure gauge (22) of the pressure regulator M470. Please refer to the
figure.
2. Release the knob on the slow-turn valve M329/3.
B – Adjusting the slow-turn 3. Undo the knurled nut (32) on the adjustable throttle valve M020 (30) with
air quantity the Tommy bar 8 (000.262).
4. Unscrew the valve spindle (31) from the throttle valve M020 until the di-
mension “A” is set to 55 mm. Please refer to the figure.
5. Tighten the knurled nut.
C – Testing the slow-turn
function
Key parameters for the test

Specified value for the number of revolutions: 2.5 revolutions
Minimum time for 2,5 revolutions: 15 sec.
Maximum time for 2,5 revolutions: 40 sec.
2017-06-13 - de
6. Deactivate the manual Emergency Stop.

7. De-energise the engine control system for approx. 20 minutes. By doing
so, the settings in the engine control system are reset.
8. Start the engine in “Remote mode”. The engine now intends to execute a
start with slow-turn.
9. Check the slow-turn function during the process and, if necessary, adjust
the settings in accordance with the descriptions given in the following.
Possible test results and The engine does not start.
how to react to them
2 (4) General, M010.280.020-20-0001

Test result 1
Reaction to test result 1 Increase the slow-turn air pressure according to section “A – Adjusting the
slow-turn air pressure” slightly in order to achieve the start-up torque of the
engine. See work steps 1 and 2.
Test result 2 The engine starts, but it does not achieve the required number of 2.5 revolu-
tions within the time period of 40 seconds, since the quantity of air is too low.
Reaction to test result 2 Increase the slow-turn air quantity according to section “B – Adjusting the
slow-turn air quantity” by increasing the dimension “A”. By doing so, the
throttle vale M020 is opened further and the air quantity is increased. See
work steps 3 to 5.
Test result 3 The engine starts, but it achieves 2.5 revolutions in less than 15 seconds.
Reaction to test result 3 Reduce the slow-turn air quantity according to section “B – Adjusting the
slow-turn air quantity” by reducing the dimension “A”. By doing so the throttle
vale M020 is closed further and the air quantity is reduced. See work steps 3
to 5.
10.Repeat the adjustment procedures A, B and C until the slow-turn func-
tion completes safely and properly in accordance with the key paramet-
ers specified above.
Carry out the adjustments on the adjustable throttle valve M020 and on
the pressure regulator M470 for the procedure “C – Testing the slow-
turn function” carefully and only in small steps. Back-up the settings
again after readjusting them.
The slow-turn function is an automatic function. It is not possible to
execute the function manually. In case of a fault, the function can be
substituted by turning the engine with the turning gear.

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General, M010.280.020-20-0001 3 (4)

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10 Slow-turn valve 20 Pressure regulator 30 Throttle valve M020

M329/3 M470
11 Pushbutton 21 Locking knob 31 Valve spindle
22 Pressure gauge 32 Knurled nut
A Dimension
Figure 1: Valves of the slow-turn function
23159712523
4 (4) General, M010.280.020-20-0001


010.020 Casing
010.030 Drive train
010.050 Cylinder
010.100 Valve drive
010.170 Intake air
010.180 Exhaust gas 010.290 Engine control and monitoring
51354036363
1 (1)

010.290.010 Installation/Drive speed measuring / indicating

devices
51354040587
devices
1 (1)
devices

Impulse transmitter
Summary
Execute work on time according to the maintenance schedule, free compon-
ents from dirt/residues, ensure / restore operational safety.
Check speed sensors/impulse transmitters at regular intervals and replace if
necessary. Properly functioning speed sensors need not be replaced.
Safety requirements
l Engine stopped
l Drive shaft secured to prevent it from rotating



2018-04-25 - de

Impulse transmitter
Work sequence 1 - Dismantling an impulse transmitter

Work steps 1. Check the cabling of connectors (3, 13). Replace if necessary.
2. Remove the plate (12). See Fig. 1.
3. Unscrew the bolt (2). Pull out plug. See Fig. 2.
4. First, undo the locknut (4), then the hexagon nut (6). Unscrew impulse
transmitter (1).
L48/60CR, M010.290.010-01-0010 1 (5)

Work sequence 2 - Installing an impulse transmitter

Initial situation The impulse transmitter has been removed.
Work steps 1. Check whether one tooth of the sensor disc (5) is located centrally under
the bore of the impulse transmitter (1). Turn engine, if required.
2. First, turn back the locknut (4) followed by the hexagon nut (6) to the new
impulse transmitter (1). Push new sealing ring (7) onto impulse transmit-
ter.
3. Screw in impulse transmitter (1) until it makes contact with the tooth crest
on the sensor disc (5). See Fig. 3/I.
4. Mark the position of impulse transmitter (1) on the camshaft axial bearing
casing (10) and the impulse transmitter.
5. Turn back the impulse transmitter (1) half a revolution. See Fig. 3/II.
6. Continue turning the impulse transmitter back again (1 revolution at the
most) until the direction arrow (M) on the impulse transmitter points in the
rotational direction of the engine. See Fig. 3/III.
7. Apply Loctite 572 for sealing to the thread of the impulse transmitter (1) in
the area of the hex nut (6).
8. Fix the position of the impulse transmitter (1) with the hex nut (6). Tighten
the hex nut (6) to the prescribed torque. Ensure that the impulse trans-
mitter is not turned further when tightening the hex nut (6). See Work In-
structions 010.000.003-05.
Distance between impulse transmitter and tooth crest of

sensor disc
The distance (A) between impulse transmitter and tooth crest of the
sensor disc must be between 0.5 and 2 mm.
9007217431617291
9. Secure hex nut (6) with lock nut (4). Ensure that the impulse transmitter is
not turned further when tightening locknut (4). See Fig. 3/IV.
10.Plug the connector (3, 13) onto the impulse transmitter, making sure that
the individual connectors are correctly assigned. Fasten the connector to
the impulse transmitter with the bolt (10).
11.Attach the plate (12). See Fig. 1.
2018-04-25 - de
Impulse transmitter
2 (5) L48/60CR, M010.290.010-01-0010

1 Impulse transmitter 11 Hex bolt

3 Connector (1 SE 1005) 12 Plate
4 Locknut 13 Connector (2 SE 1005)
6 Hex nut I-II Work steps
10 Camshaft thrust bearing
casing
2018-04-25 - de
Impulse transmitter
Figure 1: Installation and removal of the plate (geometry and size of place may
deviate from figure)
L48/60CR, M010.290.010-01-0010 3 (5)

1 Impulse transmitter 6 Hex nut

2 Bolt 7 Sealing ring
3 Connector (1 SE 1005) 10 Camshaft thrust bearing casing
4 Locknut 13 Connector (2 SE 1005)
5 Sensor disc I-II Work steps
Figure 2: Impulse transmitter - removal/installation 2018-04-25 - de
Impulse transmitter
4 (5) L48/60CR, M010.290.010-01-0010

2018-04-25 - de
Impulse transmitter
1 Impulse transmitter 10 Camshaft thrust bearing casing

4 Locknut A Distance
5 Sensor disc M Direction arrow
6 Hex nut I-IV Work steps
7 Sealing ring
Figure 3: Impulse transmitter adjustment (illustration shows impulse transmitter for clockwise rotational dir-
ection of engine)
9007217431617291
L48/60CR, M010.290.010-01-0010 5 (5)

9007217431617291
2018-04-25 - de
Impulse transmitter
L48/60CR, M010.290.010-01-0010

devices
51354044811
1 (1)

Rail pressure measuring transducer

Summary
Ensure correct execution of work. Ensure / restore operational safety.
Safety requirements
▪ Engine stopped
surised)
Tools/aids required
1 Crowfoot-ring spanner SW27 - 3/8" 009.507 Standard
1 Square insert tool 001.939 Standard Rail pressure measuring transducer

2020-05-05 - de

48/60CR, M010.290.157-01-0002 1 (3)

Work Sequence 1 - Removing the Rail pressure measuring transducer

Initial situation Casing of the injection system is removed. The rail pressure measuring trans-
ducers are located at the free engine end at the end of the series-connected
Common-Rail accumulator units. They are screwed into the valve block.
Work steps 1. Unscrew bolt (4) from the plug (1). Pull out plug (1) from rail pressure
measuring transducer (2). See Fig. 1.
2. Screw rail pressure measuring transducer (2) off the valve block (3).
3. Clean rail pressure measuring transducer (2).
Work Sequence 2 - Fitting the Rail pressure measuring transducer

Initial situation Rail pressure measuring transducer removed and cleaned externally.
Work steps
Ensure cleanliness of the metallic sealing faces

When installing the non-return valve care must be taken to ensure that
the metallic sealing faces are absolutely clean. Dirt can damage the
sealing faces.
18014416579336075
1. Clean the thread and sealing surfaces of the rail pressure measuring
transducer (2) and valve block (3). The sealing faces between the rail
pressure measuring transducer (2) and the valve block (3) must be free of
dirt and oil.
2. Apply clean lubricant to the thread and contact surface on the rail pres-
sure measuring transducer (2).
3. Screw the rail pressure measuring transducer (2) into the valve block (3)
and tighten it to the specified torque. See Work Instructions
010.000.003-05.
4. Fit the plug (1) onto the pressure measuring transducer (2) and secure it
with a screw (4).
2020-05-05 - de
2 (3) 48/60CR, M010.290.157-01-0002

1 Plug 3 Valve block

2 Rail pressure measuring 4 Screw
transducer
Figure 1: Removing and installing a rail pressure measuring transducer
18014416579336075

2020-05-05 - de
48/60CR, M010.290.157-01-0002 3 (3)

18014416579336075
2020-05-05 - de
48/60CR, M010.290.157-01-0002
Detection sensor
Summary
Safety requirements
▪ Engine stopped
surised)
Tools/aids required

2020-09-23 - de
Work Sequence 1 - Removing the detection sensor

Initial situation Covering of the injection system in front of the relevant detection sensor re-
Detection sensor
moved.
Work steps 1. Unscrew round-head bolt (3) from the plug (2). Pull connector (2) from
detection sensor (1). See Fig. 2.
2. Unscrew the detection sensor (1) from the adaptor (5) and place on a
clean base.
3. Remove the sealing ring (4) from the detection sensor.
48/60CR, M010.290.157-02-0002 1 (3)

4. Clean the detection sensor (1), the riser pipe of the detection sensor in
particular must be cleaned to remove leak fuel.
5. Remove leak-fuel from the bypass hole (7) and upstream bore in the in-
termediate piece (5) and clean.
Work Sequence 2 – Installing the detection sensor

Initial situation Detection sensor is removed and cleaned or replaced if necessary. The by-
pass bore and the riser hole in the adaptor have been cleaned and are free
from fuel residues.
Work steps 1. Clean the thread and contact surfaces on the detection sensor (1) and
adaptor (5).
2. Apply lubricant to the thread and contact surfaces on the detection
sensor (1).
3. Screw the detection sensor (1) with a new sealing ring (4) into the adaptor
(5) and tighten the detection sensor to the specified torque. See Work In-
structions 010.000.003-05.
4. Fit the complete plug (2) to the detection sensor (1) and secure with a
roundhead screw (3). If necessary, the plug (2) can be fitted rotated in
90° steps. For this purpose, remove the cube located in the plug and in-
sert it into the plug in the required position again.
2020-09-23 - de
Detection sensor
1 Detection sensor 4 Sealing ring

2 Plug 5 Adaptor
3 Roundhead screw 6 Common rail accumulator
unit
Figure 1: Fitted detection sensor
2 (3) 48/60CR, M010.290.157-02-0002

1 Detection sensor 4 Sealing ring

2 Plug 5 Adaptor
3 Roundhead screw 7 Bypass bore
Figure 2: Removed detection sensor
27021615838884875
2020-09-23 - de
Detection sensor
48/60CR, M010.290.157-02-0002 3 (3)

27021615838884875
2020-09-23 - de
Detection sensor
48/60CR, M010.290.157-02-0002
Resistance thermometer at the high-pressure pump

Summary
Safety requirements
▪ Engine stopped
surised)



2019-02-08 - de

Nm Nm Nm Nm
2 50
Work Sequence 1 – Removing the resistance thermometer

Initial situation The casing of the injection system has been removed from in front of the cor-
responding resistance thermometer.
48/60CR, M010.290.157-03-0001 1 (3)

Work steps 1. Unscrew the round-head bolt (4). Pull the plug (1) off the resistance ther-
mometer (2). See figure.
2. Unscrew the resistance thermometer including the seal (3) from the high-
pressure pump (5) and set it aside on a clean surface.
3. Remove the sealing ring from the resistance thermometer.
4. Clean the resistance thermometer.
Work Sequence 2 – Installing the resistance thermometer

Initial situation The resistance thermometer and plug are removed and have been cleaned or
replaced if necessary. A new sealing ring (3) is ready for installation.
Work steps 1. Clean the threads and contact surfaces at the resistance thermometer (2)
and the high-pressure pump (5).
2. Screw in the resistance thermometer (2) with a new sealing ring (3) into
the high-pressure pump (5) and tighten the resistance thermometer with
the specified torque. See table “Values for bolt tightening”.
Installation options for plug

If necessary, the plug can be fitted rotated in 90° steps.
For this purpose, remove the cube located in the plug and insert it into
the plug in the required position again.
35008038027
3. Plug the complete plug (1) onto the resistance thermometer (2) and se-
cure it with the round-head bolt (4).
2019-02-08 - de
2 (3) 48/60CR, M010.290.157-03-0001

1 Plug 4 Round-head bolt

2019-02-08 - de
2 Resistance thermometer 5 High-pressure pump

3 Sealing ring I, II Work steps
Figure 1: Removing/installing the resistance thermometer at the high-pressure pump
35008038027
48/60CR, M010.290.157-03-0001 3 (3)

35008038027
2019-02-08 - de
48/60CR, M010.290.157-03-0001

Maintenance Instructions - L Engine

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Maintenance Instructions - L Engine

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MAN Energy Solutions

Engine .............................................. L48/60CR

Translation of the original instructions

MAN Energy Solutions SE

2 Work Instructions, arranged by topics

Elastomer Seals storage, cleaning and fitting .............................................. 010.000.003-10

005 Operating values/Operating results

3 Work Instructions, arranged by PDS

Crankcase cover dismounting and attaching......................... 010.020.030-01

Safety valve for crankcase dismounting and attaching .......... 010.020.100-01

Connecting rod bearing bolts inspecting ............................... 010.040.010-02

Upper connecting rod bearing shell inspecting...................... 010.040.010-06

Contact surface conrod small end/conrod shank inspecting . 010.040.010-14

Contact surface conrod small end/conrod shank reworking.. 010.040.010-15

Cylinder head with turnover device working/machining ......... 010.060.020-10

Inlet/exhaust valve Removing and installing ........................... 010.060.030-02

Valve cone inspecting ........................................................... 010.060.030-06

VVT block ............................................................................. 010.100.050-03

Cam follower Removal and installation/inspection ................. 010.110.020-01

High-pressure pump drive removing and installing or dismantling and assem-

Common-Rail components Rework sealing face (tapered)/Handling of high-

Starting air pilot valve inspection ........................................... 010.150.010-01

Compressed air filter M462 inspecting .................................. 010.280.020-12

Pressure regulator station M615 inspect ............................... 010.280.020-17

010.290.010 Installation/Drive speed measuring / indicating devices

Impulse transmitter removing and installing ........................... 010.290.010-01

This page is intentionally left blank

System-related Work Instructions

– Personal protective equipment must be worn.

work is considered as completed only when it is ensured that the en-

General, M010.000.000-01-0001 1 (1)

Structure and content of Work Instructions

How are the required Work Instructions found?

Structure and content of Work Instructions

General, M010.000.000-02-0001 1 (2)

Clearances and tolerances, temperatures and pressures

2 (2) General, M010.000.000-02-0001

2 Bracket 322.056-1 Option

1 Rail 322.056-4 Option

1 Open-jaw and ring spanner (set) 009.231 Option

4 Shackle A0.6 002.452 Standard

1 Hex screwdriver (set) -- Inventory

1 Lifting tackle with rope -- Inventory

General, M010.000.000-03-0001 1 (1)

2 Work Instructions, arranged by topics

This page is intentionally left blank

001 Operating media systems/Pipes

001 Operating media systems/Pipes

This page is intentionally left blank

Operating Fluid Systems

1. Lube oil system

cleanliness before filling the system.

Prevent bearing damages

General, M010.000.001-01-0007 1 (9)

1.3 Flushing oil to be used

1.5 Performance of the first purging process

2 (9) General, M010.000.001-01-0007

tion tank and is drained via the filling pipe again.

1.7 Carrying out the second purging process

General, M010.000.001-01-0007 3 (9)

Check differential pressure

1.8 Measures after carrying out the second flushing process

1.9 Running in filter on the engine