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V32 40 Working Instructions
V32 40 Working Instructions
Technical Documentation
Engine
Working Instructions
Engine................................................ V32/40
010.005
2010-08-06 - de
2010-08-06 - de
Table of contents
Table of contents
1 Introduction
1.1 Preface
1.2 How the working instructions/Work Cards are organized, and
how to use them
1.3 Status/Availability Required Tools/Auxiliary Equipment
034.03 Piston pin and piston pin bush removing and installing/checking
Table of contents
034.04 Piston dismantling and assembling
034.05 Piston rings assessing
034.07 Piston rings with chrome ceramic coating assessing
050 Top land ring/cylinder liner
050.01 Top land ring removal and installation
050.02 Cylinder liner measure
050.03 Cylinder liner (with backing ring) removal and installation
050.04 Cylinder liner (without backing ring) removal and installation
050.05 Cylinder liner honing
055 Cylinder head/Valve seat rings/Safety valve
055.01 Cylinder head bolts inspection, loosening and tightening
055.02 Cylinder head removing and refitting
055.03 Cylinder head cleaning
055.04 Sealing face on the cylinder head and the sealing groove in the
top land ring grinding
055.05 Cylinder head with reversing device working/machining
071 Dead centre indicator/Speed sensor
071.01 Speed sensor inspection, removal and installation
073 Crankcase cover/safety valve
073.01 Safety valve on crankcase cover inspecting
100 Control device operating mechanism
100.01 Studs for intermediate wheel axles inspecting
100.02 Control device operating mechanism inspecting
101/102 Camshafts/Camshaft bearings
101.10 Injection camshaft Removing and installing camshaft section
102.02 Injection/valve camshaft Check thrust bearing
101 Torsional vibration damper Camshaft
101.02 Torsional vibration damper of the valve camshaft inspecting
111 Rocker arm casing/Rocker arm
111.02 Valve clearance inspection and adjustment
111.03 Rocker arm bracket with control levers removing and refitting
112 Push rods
112.01 Cam follower with valve cams checking and evaluation
112.02 Push rods removal and installation
113/114 Inlet and exhaust valves
113.01 Valve rotator Checking rotating motion
113.02 Inlet/exhaust valve/valve rotator removing and installing or disas-
sembling and assembling
113.03 Inlet and exhaust valves Check and assess valve cone and valve
seating surfaces
113.04 Valve seat rings removal and installation
113.05 Valve guide in cylinder head inspection, removal and installation
113.06 Valve seating surface working/machining
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Table of contents
434.02 Fuel injection pipe dismantling and assembling
434.03 Fuel injection pipe Grind sealing faces on pressure tube
434.04 Buffer piston inspecting
4 Appendix
4.1 Insulation
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1 Introduction
2 Work Cards, Classified by Subjects
3 Work Cards, classified into sub-assem-
blies
4 Appendix
Introduction
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Preface
Introduction
Preface
Work cards and maintenance The work instructions/Work Cards are closely connected to the engine main-
schedule tenance schedule, contained in Volume 010.005 of the Technical Documen-
tation. While this only specifies the necessary maintenance work in terms of
keywords, the work sequences required in order to maintain the operational
safety and efficiency of the engine are described here step by step and clari-
fied with the help of images. The Work Cards describe, by way of introduc-
tion, the purpose of the work and, amongst other things, they contain infor-
mation regarding the required tools and auxiliary equipment. Several Work
Cards are to be taken into account for most of the work which is involved.
Work cards are for a specific purpose, i.e. they fulfil the primary information
needs in simple language.
Filing System The Work Cards are classified by subjects/keywords in the first part, and
according to the sub-assembly system of the engine in the second part.
Both parts contain a table of contents of the relevant Work Cards for your
engine.
Introduction
General
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How the working instructions/Work Cards are organized, and how to use
Introduction
them
How the working instructions/Work Cards are organized, and how to use them
Make-up In general, the Work Cards contain the following information:
▪ Tips on the significance and purpose of the work,
▪ relevant Work Cards i.e. those Work Cards which contain required or
useful information,
▪ the required tools and auxiliary equipment,
▪ possible supplementary details /technical data and
▪ the individual work 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 Cards, top right in the header, consists of the
three-digit sub-assembly number (or a neutral digit group) and a sequential
number. Example: 021.02
How are the required Work The Work Cards are listed in the directories of sections 2 and 3. The direc-
Cards found? tory in section 2 contains the Work Cards summarised according to the sub-
jects / keywords, the directory in section 3 contains instructions sorted
according to the sub-assembly system of the engine.
The sub-assembly overview ensures access to the filing system of the direc-
tories in section 3. Through illustrative / graphical representations of the
engine, as well as a tabular overview, it leads to the sub-assembly numbers,
according to which the Work Cards are sorted.
Safety Instructions Dangers, error sources, technical requirements and supplementary informa-
tion are highlighted by notes. While doing so, the following symbols are used,
depending upon the importance:
Imminent danger
For directly imminent dangers! Possible consequences: Death or
severe injury, total property destruction!
Source of error
Introduction
Additional information
For application tips and supplementary information.
Clearances and tolerances, Clearances and tolerances, temperatures and pressures are listed in Volume
temperatures and pressures 010.005 Engine - Operating Instructions in section 2.5.
The Work Cards 000.29 and 000.30 together with 000.31 contain the values
for tightening the bolted connections and the 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 Instructions or Volume 010.005
Engine - Spare Parts Catalogue.
Introduction
General
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Introduction
Tools/aids required
Tools/Aids The section Tools/aids required at the start of the work cards contains a list
of the tools/aids required to carry out the maintenance work described. See
example in following table.
Quantity Designation Number Status
1 Removal and mounting device 322.056 Option
2 Bracket 322.056-1 Option
1 Strip 322.056-4 Option
4 Shackle A0.6 002.452 Standard
1 Open-end wrench and ring spanner (set) -- Standard
1 Hexagon screwdriver (set) -- Standard
1 Lifting tackle with rope -- Inventory
Table 1: Example: list of tools/aids required
Status/Availability In addition to the required quantity, designation and tool number, the table
also contains information on the status/availability of the tools listed. The fol-
lowing terms are used for this:
▪ Inventory: describes a tool/aid that is not included in the standard scope
of supply. We assume that tools/aids of this kind are basically available.
▪ Option: describes a tool/aid that is not included in the standard scope of
supply. Tools of this kind can be delivered by MAN Diesel & Turbo SE if
required.
▪ Standard: refers to a tool/aid that is included as standard in the scope of
supply for the engine installation, or standard workshop equipment spec-
ification.
Basic tool The basic tool which is identified with the "Standard" status is not included in
the standard scope of supply of MAN Diesel & Turbo SE. The scope of sup-
ply can be extended to include the basic tool if requested. The constituent
parts of the basic tool are listed in the table below.
Introduction
General
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Introduction
Ratchet DIN 3122C - 12.5 001.521
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Introduction
Locking ring pliers DIN 5254A - 10-25 002.121
Locking ring pliers DIN 5254A - 19-60 002.122
Gripping pliers with slip joint DIN 5231 D-L - 240 002.198
Introduction
General
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1 Introduction
2 Work Cards, Classified by Subjects
3 Work Cards, classified into sub-assem-
blies
4 Appendix
Summary
Keep the operating media systems free from impurities and residue, prevent
operating problems / damage.
Flush the operating media systems before commissioning, clean individual
parts before installation. This includes the systems for lubricating oil, fuel,
cooling water and compressed air and, depending on the system:
Flush system(s) (Step 1),
flush system(s) (Step 2),
drain system(s) and
clean components.
Safety requirements
▪ Operating media systems closed/depressurised
▪ Engine secured against starting
▪ Engine shut down
Severe bearing damage can arise by dirt particles entering the engine!
Work Cards, Classified by Subjects
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 so it requires no
preheating.
reduced to a minimum, i.e. until the flushing intervals have reduced to maxi-
mum 1 flushing per hour for automatic filters without continuous flushing and,
in the case of automatic filters with continuous flushing, the displayed differ-
ential pressure has reached a minimum.
The minimum flushing duration of 24 hours must, however, be maintained.
The inserts with filter candles are to be installed in the automatic filter (if they
General
2010-03-02 - de
have been removed), the slide valve for the bypass pipe is to be closed.
activated contamination display can lead to problems in the lube oil supply.
Therefore, when the differential pressure alarm is triggered, increased atten-
tion 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 manu-
Operating media systems/Pipes
facturer's instructions.
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 plant. The filter housing remains in the engine. After this there will be
no further filtering effect from this running in filter. A corresponding note on
the filter housing points this out.
In the case of constructional changes to the lube oil system, or for other rea-
sons that require flushing of the lube oil system, the filter insert must be refit-
ted until the flushing process is complete.
tem.
Perform the flushing operation as described under point 1.3.1. Based on
past experience, a period of 24 hours must be allowed for flushing.
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Once the second flushing operation is complete, which takes roughly 6 hours
according to experience, open the shut-off valves of the fuel delivery pumps.
pressure and control pipes must be free of flammable media and slag, scale
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and rust.
High noise levels when blowing by! Always use ear protection!
Operating media systems/Pipes
The air pipes are cleaned by blowing by 3 or 4 times with compressed air at
a pressure of 30 bar in the starting air tank.
In order to do this, separate the installation-side pipe line from the main start-
ing valve and attach the pipe line securely to prevent deformation when
blowing. Close the open engine entry point. Also remove the control air pipe
before the engine. The blowing is activated by opening the slide-valve on the
connecting tank.
After the cleaning process, all the pipes that have been removed must be
reconnected.
High noise levels when blowing by! Always use ear protection!
1. Remove the starting pipe in front of the first cylinder and check for flam-
mable media in both directions.
2. Remove the starting valves and blow the air passage out in the direction
of the open pipe.
3. Create a connection for compressed air behind the main starting valve
and slowly begin blowing by the pipe/spaces towards the cylinder for an
extended period (several air cylinder's worth).
4. Leave open for 24 hours in order to allow the solvent residues to evapo-
rate.
5. Fit the starting valves and return to the initial state.
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Summary
Remove contamination/residue from operating fluid systems, ensure/re-
establish operating reliability.
Cooling water systems containing deposits or contamination prevent effec-
tive cooling of parts. Contamination and deposits must be regularly elimina-
ted.
This comprises the following:
Cleaning the system and, if required,
removal of limescale deposits,
flushing the system.
Cleaning
The cooling water 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 carried out by a specialist.
Oil sludge Oil sludge from lubricating oil that has entered the cooling system or a high
concentration of rust inhibitors 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
Work Cards, Classified by Subjects
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 slush-
ing oil concentration is too low. A thin lime scale layer can be left on the sur-
face as experience has shown that this protects against corrosion. If how-
ever, the thickness of limescale deposits exceeds 0.5 mm, this can obstruct
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
velocity is low.
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Products that remove limescale deposits are generally suitable for removing
rust. Suitable cleaning agents are listed alphabetically in the table entitled
Operating media systems/Pipes
"Cleaning agents for removing lime scale and rust deposits". Products by
other manufacturers can be used providing they have similar properties. The
manufacturer's instructions for use must be strictly observed. Prior to clean-
ing, check whether the cleaning agent is suitable for the materials to be
cleaned. The products listed in the table entitled "Cleaning agents for remov-
ing lime scale 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% Approx. 4 h at 50 – 60 °C
Table 2: Cleaning agents for removing limescale and rust deposits
In emergencies only Hydrochloric acid diluted in water or aminosulfonic 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 appli-
cation:
▪ Stainless steel heat exchangers must never be treated using diluted
hydrochloric acid.
▪ Cooling systems containing non-ferrous metals (aluminium, red bronze,
brass, etc.) must be treated with deactivated aminosulfonic acid. This
acid should be added to water in a concentration of 3 - 5 %. The tem-
perature 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 once the system has been neutral-
ised and flushed. This residual acid promotes pitting. We therefore rec-
ommend 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
absolutely 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
Work Cards, Classified by Subjects
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Only carry out the cleaning operation once the engine has
Pipes
Summary
Insert/replace components, process and install professionally. Pipes must be
replaced/supplemented if necessary. The materials must, therefore, be
selected according to the requirements, and must be properly processed.
This includes: Selection of suitable materials, proper processing and proper
installation.
Preliminary remarks
If 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.
Instructions
Pipe Dimensions/Materials As replacements for pipes on the engine or the operating device, seamless
mild-steel pipes are to be used, in accordance with DIN 2391, or seamless
copper pipes in accordance with DIN 1754, made from St 35 GZF in accord-
ance with DIN 1629 and C-Cu F 25 and/or F 30 in accordance with DIN 17
671 and/or stainless steel pipes made from X6 CR Ni Ti 1810 in accordance
with DIN 2462. Normally pipes of the same dimensions are refitted to the
engine.
Production Pipes with a small diameter can be cold-bent using commercial pipe bending
devices. When using solderless pipe unions in accordance with DIN 2353,
heat treatment can, in most cases, be avoided (see Work Card 000.17).
For air pipes in the pneumatic operating device or in the starting system, only
stainless products may be used, i.e. chromated, galvanised or brass
screwed fittings. Particular attention has to be paid to the thread, since,
depending upon the location, both metric and Whitworth threads, in both
cylindrical and conical form can be present.
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
Work Cards, Classified by Subjects
pipes must be acidified, leached and washed afterwards (see Work Card
000.16).
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 oper-
ation. Operational malfunction caused by damage to the bearings could
General
flange connections are to be used, whereby their number and location are to
be selected in such a way 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.
Operating media systems/Pipes
Both with gas welding and with TIG welded joints, the tack and finished
welding 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
result in the formation of cracks.
Work Cards, Classified by Subjects
General
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Pipes
Summary
Keep operating media systems free from contamination and residues,
ensure/restore operating safety. Pipes that are replaced or added must, after
manufacture/machining, be mechanically or chemically cleaned, and pre-
served if required.
Depending on the actual situation, this includes: Mechanical cleaning of the
components, chemical cleaning of the components, a pressure test and
preservation.
Preliminary remark
All pipes which are attached as a replacement on the engine, are to be
cleaned mechanically or chemically after manufacture. If a longer period ari-
ses between cleaning and fitting (spare pipes), the pipes must be preserved
and sealed at the ends. Sealing plugs or plastic caps in conspicuous colours
are ideal for this to ensure that they are not overlooked.
Normally, mechanical cleaning is performed on cooling water, heating,
exhaust gas and intake air system pipe lines. Mechanical and chemical
cleaning is performed on lube oil, fuel, compressed air, gas, steam and water
condensate system piping. Isolating and regulating units, as well as other
devices in the individual systems may only be fitted after the cleaning proc-
ess.
For pipes filled with sand for hot-bending, only completely dry and fine-grain
sand may be used. With damp sand there is a danger of accidents caused
by steam formation. All pipe systems must undergo a compression test,
either in sections, or as a whole system. The entire lube oil, fuel and com-
pressed air system must be thoroughly rinsed before commissioning the
engine installation.
Mechanical Cleaning
Scale and weld splatter is to be removed carefully from the welded joints,
using a chisel, file or grinding wheel. The whole pipe must be tapped with a
Work Cards, Classified by Subjects
hammer and blown through with compressed air, as far as possible at the
same time, so that even the smallest particles (of sand for warm-bending) are
removed.
All pipe connections are to be blocked off until assembly.
For pipes, which are cleaned mechanically and chemically, an acid bath is
required. The acid bath device essentially consists of:
▪ a hydrochloric acid bath for steel pipes,
▪ a water bath for washing the acid off,
▪ an alkaline bath for neutralising and phosphatising,
▪ a sulphuric acid bath for copper pipes.
With the hydrochloric acid and sulphuric acid bath, the rising vapour must be
General
extracted using fans and dispersed via scrubbers. The vapour from the alka-
2007-10-25 - de
line bath must also be directed outside using a fan. The regional protection
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.
Operating media systems/Pipes
2007-10-25 - de
Preservation of Pipes
When stored for a short period indoors and/or in dry surroundings, phospha-
tisation and an oil film are sufficient for corrosion protection. Also during long-
term storage for service, phosphating before the actual preservation with
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slushing oil, lacquer or grease offers a good basic preservation. Pipe ends
and connection points are to be sealed with coloured plastic caps. Plastic
caps in striking colours have the advantage that they are easier to recognise
when fitting the pipes to the engine. They must be removed again when fit-
Operating media systems/Pipes
ting.
Work Cards, Classified by Subjects
General
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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
Quantity Designation Number Status
1 Tools, Basic Scope 009.229 Option
1 Pipe cutter - Inventory
1 Counterbore - Inventory
1 Machine oil - Inventory
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
internal 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
(4) well. Then slide the nut and ring over the pipe end as shown. If the
Work Cards, Classified by Subjects
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
tightening 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.
4. Pipes of smaller outside diameter can be fixed in screwed connections
General
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
approx. fifteen fold length of the width across flats (possibly extended by
using a pipe). Otherwise proceed as above. The final tightening is easier
Operating media systems/Pipes
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.
Work Cards, Classified by Subjects
Figure 1: Required tools - counterbore cutter, pipe cutter and pipe bending device
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7 Mark
Figure 3: Assembly of pipe unions. Assembly on site - on the left, pre-assembly in the
vice - on the right
General
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Additional information
The straight pipe end extending into the screw connection must have a mini-
mum 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).
2008-10-28 - de
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 connec-
tions.
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
connections.
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
tightening 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
Work Cards, Classified by Subjects
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-
hand. Ensure that the pipe end is shortened by the length of the nozzle col-
lar.
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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).
2008-10-28 - de
Lubricating oil
Summary
Collating and assessing operating media parameters, maintaining the consis-
tency within the permitted range, avoiding/reducing damaging effects. Lubri-
cating 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
media.
Oil Evaluation
Spot test/oil analysis The condition of the used oil in the engine must be constantly monitored. At
which intervals a spot test should be prepared on filter paper, or an oil sam-
ple is to be taken for examination in a laboratory set up for the purpose (it
would be best to consult the customer service of the supplier in this regard)
is given in the servicing schedule. The oil sample must be taken after the fil-
ter, while the engine is running. This ensures that the result will be represen-
tative for the oil in the engine.
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.
We recommend obtaining a suitable test kit for the routine local examination
of the operating media. MAN SE has developed a test case together with the
company Mar-Tec, which contains easy-to-operate devices. This enables the
bunkered heavy fuel and the parameters required for treatment, and the con-
dition of the waste lube oil, to be determined with sufficient accuracy. Sup-
porting documents can be obtained from Mar-Tec., Warnckesweg 6, 22453
Hamburg.
In general, the following values are sufficient for the routine examination of
used oil:
Characteristic value Limit value Measurement method
Viscosity at 40°C mm2/s > 110 ISO 3104
< 220
Work Cards, Classified by Subjects
Colour
2007-10-25 - de
sive black colouring of the oil, even at lower concentrations. The total con-
tamination of the lube oils can be ascertained, amongst others, by using DIN
Operating media/Auxiliary agents
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 vis-
cosity 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
approximately 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
evaporate 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 pro-
motes, amongst other things, corrosion of the polished running gear compo-
nents 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 hydrody-
namic 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
Work Cards, Classified by Subjects
2007-10-25 - de
the time period specified by the diesel engine manufacturer with the corre-
sponding approximate value.
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 lubri-
cant 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.
Lubricating oil/Fuel
Summary
Collating and assessing operating media parameters, maintaining the consis-
tency 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.
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 dark colour. If the edge has a radial appearance, this indicates that
the lubricating oil contains water or fuel.
The oil samples for the spot tests must be taken from the oil circuit at the
specified intervals (also see maintenance schedule) and at the same point
when 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
2009-03-26 - de
Figure 1: Spot tests of doped lubricating oils - Sample 1: slightly contaminated - Sample 4: analysis required - Sample
5: oil change required
2009-03-26 - de
Cooling water
Summary
Acquire and check typical values of the service media to prevent or limit
damage.
The fresh water used to fill the cooling water circuits must satisfy the specifi-
cations. The cooling water 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 concentration of the rust
inhibitor.
Tools/equipment required
Equipment used to check the The following can be used:
quality of fresh water ▪ The MAN Diesel & Turbo 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 Diesel & Turbo 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.
Chemical additives according to the quality specifications in Volume 010.005 Engine - Operating Instruc-
tions, Chapter 3, Page 3.3.7
Anti-freeze according to the quality specifications in Volume 010.005 Engine - Operating Instruc-
tions, Chapter 3, Page 3.3.7
Table 2: Concentration of cooling water additives
Checking the concentration The concentration should be checked every week and/or in accordance with
of chemical additives the maintenance schedule using the testing instruments and reagents from
the relevant supplier and corresponding instructions.
Slushing oil containing chemical additives only provides effective protection if
the specifications regarding concentration are precisely complied with. This is
why the concentrations recommended by MAN Diesel & Turbo (quality speci-
fications in Volume 010.005 Engine – Operating Instructions, Chapter 3,
Page 3.3.7) must be complied with in all cases. These recommended con-
centrations may not be the same as the manufacturer's specifications.
Checking the concentration The concentration must be checked in accordance with the manufacturer's
of anti-freeze instructions or this work can be outsourced to a suitable laboratory. If in
doubt, consult MAN Diesel & Turbo.
Test We test the cooling water in our laboratory for our customers. In order to
carry out the test, we need a representative sample of roughly 0.5 litres.
Work Cards, Classified by Subjects
General
2010-02-09 - de
Engine or components
Summary
Adopt measures to counteract corrosion, carry out/repeat protective meas-
ures.
Corrosion protection and preservation measures are adopted with specific
targets, not only with regard to a suitable slushing oil, but also the type of
application and the intervals for renewal inspection.
This includes:
Selection of a suitable slushing oil,
anti-corrosion measures for new engines and spare parts and
preservation of engines and engine components in the event of stoppage.
Corrosion Protection
Most corrosion on polished metal surfaces is caused by the effects of the
weather, the type and extent of which varies depending on the climate (conti-
nental, industrial, oceanic, tropical climate). Corrosion which originates, for
example, in pipes, fittings and heat exchangers through contact with water
remaining in the system or due to air humidity can be overlooked and first
becomes apparent when a fault occurs. The application of a covering coat
on the metal surface is the most common means of preservation. The pres-
ervative must have a thick continuous layer which adheres to the surface
well, displaces water and is not affected by corrosive media.
Protection for a limited Even the best preservation provides protection for a limited period only. A
period check is absolutely necessary at stipulated time intervals, so that the preser-
vation treatment can be repeated in good time.
The addition of vapour-phase anti-corrosion oil (VCI) has proved to be effec-
tive for internal preservation. Owing to their properties, these oils continu-
ously deliver small quantities of gaseous inhibitors, so that a vapour-phase
develops in a closed space that provides additional preservation if required.
Nevertheless, it is important that the crankcase is completely closed off and
that the preserved engine, or the engine's individual parts, are stored in a
dry, well-ventilated room where the temperature is regulated. Work Cards, Classified by Subjects
Rust inhibitor
Depending on the intended purpose and the existing conditions, there are
various different slushing oils which can be classified as follows:
1. Slushing oil with added solvent
This is a mineral oil based wax or oil to which, for example, white spirit is
added as a solvent, and which is applied, without heating, to the metal sur-
face to be protected by immersing, spraying or brushing. After the solvent
has evaporated, a protective layer is left behind which can be wiped down or
washed off. If the inner preservation of the engine is carried out using this,
cleaning prior to commissioning is not required if the protective coating is
dissolved by the lubricating oil during operation. These protective agents are
also suitable for individual engine parts and the external preservation of com-
General
2010-07-07 - de
plete engines.
2. Anti-corrosion grease
This protective grease is applied using a paintbrush, or is rubbed onto the
metal surface. If the grease is oil-soluble and was only applied sparingly, the
protective layer can be left in the preserved inner parts when commissioning
the engine, provided that the engine was closed off and no dust or dirt has
settled inside.
The external or individual parts of the engine preserved with grease must
always be cleaned before commissioning. This can be easily carried out by
washing with an oil-dissolving liquid (e.g. diesel fuel). Nevertheless, you must
ensure that the washing liquid does not penetrate the engine and mix with
the lubricating oil.
3. Anti-Corrosion Oils
These protective oils are mineral oils with corrosion inhibiting substances
which are suitable for spraying or painting onto individual engine parts or, if
the engine is assembled, for preserving the internal parts. It is also possible
to operate the thoroughly cleaned engine with the oil for a short time, which
also provides good preservation of the oil system.
4. Anti-Corrosion coating wax, vapour-phase slushing oil or paper are other
products with which individual parts can be preserved.
2010-07-07 - de
Turbocharger - preservation
Turbocharger
The turbocharger must be cleaned on the turbine and compressor side
before shutting it down. In doing so, observe the instructions in the turbo-
charger documentation (see Volume 010.200 Turbocharger)
Work steps to be carried out A prerequisite for effective preservation is that all internal and external parts
prior to of the engine are thoroughly cleaned before treating with a protective agent.
Work Cards, Classified by Subjects
oil lines must be blown out. The oil pan, lubricating oil tank and lubricat-
2010-07-07 - de
ing oil service tank must be thoroughly cleaned. The lubricating oil sys-
tem must then be filled with anti-corrosion oil of the same viscosity as the
ble-free.
4. After shutting off the engine, likewise spray a small quantity of anti-corro-
sion oil (approx. 0.5l) into the main starter air pipe and control air pipe
5. After stopping the system, all pressure gauges must indicate zero. The
engine is to be secured against unintentional turning of the running gear.
The turning gear is to be engaged (if present).
6. Preservation of the coolant areas is not necessary if an anti-corrosion oil
has been added to the coolant during operation. If a chemical additive
has been used, the coolant must be changed and an anti-corrosion oil at
approx. 3-5% concentration is to be added and the engine to be oper-
ated with it. If the engine is out of service for a prolonged period, or if
there is a danger of frost, the coolant must be fully drained from the
engine, turbocharger and the coolers of the individual circuits and you
must ensure that the drain cocks remain constantly open with the engine
switched off. When draining the coolant, the coolant compartment in the
coolant pump must also be drained. The injection valves must be
removed and drained separately.
7. All external polished engine parts must be coated or sprayed with an
anti-corrosion agent. This applies in particular to the control linkage and
control rods of the injection pumps. The crankshaft exit from the cylinder
crankcase is to be closed off with grease.
oil and coolant are drained off. All engine parts must also be carefully
cleaned.
8. Spray out the crankcase with an anti-corrosion agent (e.g. Fuchs Anti-
corit 6120-42 DFV or Valvoline Tectyl 51111). In addition, preserve the
camshaft with an anti-corrosion agent that leaves a waxy layer (e.g. Val-
voline Tectyl 542). In addition, add 5 - 6 litres of a VCI oil to the crank-
case.
9. The silencer is to be covered with foil and the exhaust gas pipe sealed to
avoid a draught through the engine.
10. The preservation must be renewed every 6 months.
General
2010-07-07 - de
storage
2010-07-07 - de
Compatibility with fuel/ Fuel and lubricating oil Fuel and lubricating oil Insoluble in fuel and lubricat-
oil ing oil
Anti-corrosion agent with thixo- Anti-corrosion agent, soft waxy Anti-corrosion agent, hard waxy
tropic properties (oily protective film film
film with low flow characteristics)
Removability of coat- Same as anti-corrosion agent Diesel fuel and petroleum Same as anti-corrosion agent
ing (a) (e)
Area of application Turbocharger assembly, inte- Internal machined surfaces in External machined surfaces,
and comments rior surfaces and bores, verti- fuel and lubricating oil sys- tie rods and tools. The coat-
cal machined surfaces, pol- tem. Contains solvents! A ing must be removed before
ished screws, etc. component must therefore initial operation.
not be packaged, insulated or
have a second coating
applied until the solvent has
been fully degassed.
Preferred anti-corro- Bantleon-Cortec VCI 369 Esso-Rust-Ban 395 Esso-Rust-Ban 397
sion agent Fuchs-Anticorit 6120-42E Shell-Ensis Fluid H Fuchs-Anticorit BW 366
(65 cSt/20°C) Valvoline Tectyl 502 C Valvoline Tectyl 846
(solvent free)
Valvoline Tectyl 542
Fuchs-Anticorit 15N
(50 cSt/20°C)
Esso-Rust-Ban 391
(6.5 cSt/20°C)
Table 2: Recommended anti-corrosion agents (Part 2)
Removability of coat- Same as anti-corrosion agent Same as anti-corrosion agent Stripping agent
ing (e) (e), cloth
General
2010-07-07 - de
2010-07-07 - de
Loctite Products
Summary
Use of auxiliary equipment, proper processing and mounting. Loctite is a liq-
uid plastic which hardens into a tough layer between close-fitting metal parts.
Loctite products can be used for fixing, sealing and adhesive purposes.
Selection according to Tables 1 to 3.
The work/work steps include: Proper assembly, disassembly and reassem-
bly.
Preliminary remarks
The filling material LOCTITE is a liquid plastic which hardens automatically
between close-fitting metal parts to form a tough layer, anchors itself in the
machining grooves and considerably increases the surface contact of two
parts. Versions of varying strength are to be used for gaps of different sizes.
According to specification, LOCTITE products can be used for fastening,
sealing and glueing.
With bolted connections, which are tightened under torque control, LOCTITE
222 and 243 are to be used if necessary, since the lubrication facility of both
these products corresponds to that of oil.
The curing time of LOCTITE can be shortened by using the activator T, or by
heating the joint. For recommended products see Tables 1, 2 and 3.
Loctite may not be stored for longer than approx. 1 year at ambient
temperature. Longer storage periods change the properties to the
point of becoming unusable. The expiry date must, therefore, be
Work Cards, Classified by Subjects
observed!
With interference fit assemblies and larger parts, both surfaces must
Operating media/Auxiliary agents
be coated thinly and evenly. With larger surfaces, the applied LOCTITE
can be spread using a clean paintbrush or a spatula. With blind holes
the bore is moistened to prevent the compressed air pressing away the
liquid LOCTITE product during assembly.
The bottle contents must not come into contact with metal parts until
being used!
2007-09-06 - de
Strength catego-
ries: *)
Compression shear 1)
N/mm2 20 - 35 5 - 13 10 - 25 4 - 14
strength
Breakaway torque 2)
Nm 20 - 45 9 - 25 25 - 55 5 - 13
max. continuing torque Nm -- -- 30 - 55 --
Hardening open waiting time
for steel max. hrs. 24 24 24 24
for non-ferrous max. min. 5 1 60 1
metal
Handling Min. 60 - 120 15 - 30 120 30
strength
General
2007-09-06 - de
strength
Special properties DVGW BAM
approval approval
Table 2: Loctite Products for Sealing Threads and Surfaces
for materials
Special properties difficult to
bond
e.g. Vitron
Table 3: Loctite Products for Bonding
1)
Tensile strength N/mm2, 2) Tensile shear strength N/mm2, 3) with activator 7471
General
2007-09-06 - de
Machine Elements
001 Operating media systems/Pipes
002 Operating media/Auxiliary agents
003 Machine Elements
004 Hydraulic tensioners/High-pressure pump
005 Operating values/Operating results
Galvanised Bearings
Machine Elements
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 run-
ning 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.
General
1 Anti-corrosion layer
2 Running layer
3 Nickel dam
4 Bearing metal
5 Steel support shell
The soft running layer has better running in and emergency running proper-
ties 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, bear-
ings 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 fil-
tered and separated. This means that cleaning the filters and separators, and
checking the oil, are very important.
Damaged bearing shells (upper or lower shell) can be replaced individually or
in pairs.
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
General
2008-10-28 - de
Undersized bearings (with smaller diameter) ready for installation can be sup-
plied for reworked crank pins.
Machine Elements
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.
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
Work Cards, Classified by Subjects
2008-10-28 - de
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
Machine Elements
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 evi-
dent.
Mirror effect on both edges of the bearing
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
General
2008-10-28 - de
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 loa-
Machine Elements
ded zone.
"Bark Beetle"
smoothed.
Spallings on the bearing metal layer
If generator installations are not sufficiently earthed, this can lead to stray
electrical 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
General
2008-10-28 - de
Machine Elements
material 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
reworked.
Cold shuts on the bearing shell joint
Bearing Spread
General
2008-10-28 - de
D Bearing diameter
S Spread
2008-10-28 - de
Machine Elements
assessing
Summary
Carry out the work in good time in accordance with the maintenance sched-
ule; check the components’ quality/wear condition. The bearing shells
(bimetal 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.
The work/work steps include: Measuring of components and assessing sur-
face/wear condition.
General
1 Bearing metal
2 Al - Binding layer
3 Steel support shell
The wall thickness (A) must always be measured in the area with the
main load or perpendicularly to the joint face.
2008-10-28 - de
Machine Elements
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.
1. 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).
Assessing: The bearing cannot continue to be used.
The loaded area of the bearing shell shows signs of bearing metal spallings
caused by fatigue of the sliding layer (see figure 5).
Assessing: The bearing cannot continue to be used.
General
2008-10-28 - de
Elastomer Seals
Machine Elements
storage, cleaning and fitting
Summary
Insert/replace components, process and install professionally. Elastomer
seals (rubber products) are to be stored properly and replaced during over-
haul 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.
5. Rubber items should be protected from direct sunlight and strong artifi-
cial light which has a high UV content. The effects of ozone are particu-
larly damaging. You must therefore ensure that the storage location is
not close to fluorescent tubes or other light sources having high ultra-vio-
let radiation. Because of the effects of ozone, rubber items should not be
stored close to electrical installations, engines and generators.
6. Rubber items should not be stored in the same storage room as sol-
vents, fuels, anti-seize agents, slushing oils, chemicals, acids, disinfec-
tants and similar substances.
7. Rubber items must be tension-free, i.e. stored without tension, compres-
sion or deformation of any kind (e.g. O-ring seals should not be stored
hanging on hooks, since they would be in danger of being permanently
General
tant for parts which have different colours. Also avoid contact with cop-
per 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.
Observe points 6-7.
10. Newly delivered rubber items should be stored separately from those
already in storage so that the oldest are used first.
In the event of fire / heating above 315 °C of FKM fluoro rubber (Trade
names Viton, Fluorel, Techoflon, Dai-el) poisonous fumes are pro-
duced.
Hydrogen fluoride vapour, in the presence of water, produces fluorhy-
dric acid (hydrofluoric acid) which causes serious chemical burns
which are difficult to heal.
When extinguishing fires, the appropriate breathing apparatus, face
masks and protective clothing must be used.
Observe appropriate disposal methods.
Cleaning
Rubber items are cleaned in warm soapy water and dried at room tempera-
ture. If necessary, seals which have been stored for a long period can be
cleaned in a 1.5% sodium bicarbonate solution. Any cleaning solution resi-
due 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
Work Cards, Classified by Subjects
Basic principles that apply in You must exercise particular care when installing rubber products. Observe
general the following points in particular when carrying out the installation.
O-ring seals ▪ Sealing rings can be expanded briefly by 30% of their internal diameter at
the most during installation.
▪ Sealing rings must not be twisted when installing them (particularly
applies for rings with large diameters and small cross-sections). Some
sealing rings have a line running round their circumference which must
be continuously visible.
▪ Sharp edges, threads, slots, etc. must not scrape over sealing rings.
Cover sharp edges if necessary.
▪ Sealing rings must not come into contact with corrosion-inhibiting wax
General
when other components pass over them. Cylinder liners must be free of
2010-04-07 - de
corrosion-inhibiting wax in the area where the sealing rings are installed.
The solvent used for cleaning must be allowed to dry out completely.
▪ The installation spaces of the sealing rings must be coated with a suita-
ble anti-seize agent.
Machine Elements
Radial sealing rings The sealing lips of radial shaft sealing rings must always be facing towards
the medium being sealed off.
Anti-seize agent Sealing rings and sealing ring grooves must be wetted with engine lubricating
oil.
Threaded inserts
Machine Elements
use
Summary
Insert/replace components, process and install professionally. Threaded
inserts are used for manufacturing lock-proof threads in components made
of grey cast iron or alloy. Damaged threads can be repaired.
The work/work steps include: Proper assembly and, if necessary, disassem-
bly.
Tools/aids required
Conventional twist drills, diameter corresponding to the required threaded
insert and the according to the manufacture.
Also by the manufacturer of the threaded inserts:
▪ Special thread drill bit,
▪ Screwing-in tool, if necessary, boring tool,
▪ Pin breaker or punch.
▪ Standard tools
Preliminary remarks
Threaded inserts serve, for example, for making wear-resistant threads in
components made from grey cast iron or alloy, etc. On the other hand, a
damaged thread bore can be repaired such that the same screw size can
continue to be used. In order to do so, the old thread must be drilled out, a
new thread must be cut and a suitable threaded insert must be screwed in.
Threaded inserts are available in two designs: Type A - standard version
(non-locking) and type B - self-locking version (one thread hexagonally sha-
ped). See the following figure.
A ∅ of threaded insert
Machine Elements
C Carrier pin
H Screwing-in tool
2008-10-28 - de
Machine Elements
L Pin breaker/punch
M Boring tool
Machine Elements
Tightening torques (partial image)
Summary
Provide torque values for important bolted connections, ensure operational
safety. Bolted connections, which are tightened by means of hydraulic ten-
sioners according to torque or torsion angle, must be tightened or untight-
ened in accordance with the specified values.
Work Cards 000.29 and 000.30 contain the necessary information.
Explanations
The illustrations in Work Card 000.29 serve for identification purposes con-
cerning the position and proximity of the parts to be connected. The illustra-
tions have identification numbers, for example 020-1, which are listed in
numerical order in Work Card 000.30. The identification numbers also indi-
cate the tightening torques and the corresponding Work Cards.
2007-07-17 - de
Machine Elements
Work Cards, Classified by Subjects
V32/40
2007-07-17 - de
2007-07-17 - de
Machine Elements
Tightening torques (table)
Summary
Provide torque values for important bolted connections, ensure operational
safety. Bolted connections, which are tightened by means of hydraulic ten-
sioners according to torque or torsion angle, must be tightened or untight-
ened in accordance with the specified values.
Work Cards 000.29 and 000.30 contain the necessary information.
2 (12)
V32/40
000.30
Tightening torques
6632 000.30-06 EN
MAN Diesel & Turbo
2010-03-05 - de
2010-03-05 - de
6632 000.30-06 EN
Work Cards, Classified by Subjects Machine Elements
V32/40
3 (12)
000.30
Work Cards, Classified by Subjects Machine Elements
4 (12)
V32/40
000.30
6632 000.30-06 EN
MAN Diesel & Turbo
2010-03-05 - de
2010-03-05 - de
6632 000.30-06 EN
Work Cards, Classified by Subjects Machine Elements
V32/40
5 (12)
000.30
Work Cards, Classified by Subjects Machine Elements
6 (12)
V32/40
000.30
6632 000.30-06 EN
MAN Diesel & Turbo
2010-03-05 - de
2010-03-05 - de
6632 000.30-06 EN
Work Cards, Classified by Subjects Machine Elements
V32/40
7 (12)
000.30
Work Cards, Classified by Subjects Machine Elements
8 (12)
V32/40
000.30
6632 000.30-06 EN
MAN Diesel & Turbo
2010-03-05 - de
2010-03-05 - de
6632 000.30-06 EN
Work Cards, Classified by Subjects Machine Elements
V32/40
9 (12)
000.30
Work Cards, Classified by Subjects Machine Elements
10 (12)
V32/40
000.30
6632 000.30-06 EN
MAN Diesel & Turbo
2010-03-05 - de
2010-03-05 - de
6632 000.30-06 EN
Work Cards, Classified by Subjects Machine Elements
V32/40
11 (12)
000.30
Work Cards, Classified by Subjects Machine Elements
12 (12)
V32/40
000.30
6632 000.30-06 EN
MAN Diesel & Turbo
2010-03-05 - de
MAN Diesel & Turbo 000.31
Machine Elements
Tightening torques (turning moments)
Summary
Provide tightening torques for important bolted connections, ensure opera-
tional safety. Bolted connections should be tightened using a torque wrench
if at all possible. For especially important connections, the values are speci-
fied in Work Card 000.30. Approximate values for other bolts are stated here.
Work Cards 000.29 and 000.30 contain the necessary information.
Tightening Torques
Tightening of bolted connec- If other bolted connections other than those listed in Work Card 000.30 are
tions according to torque tightened using torque wrenches, approximate torque values can be taken
from Table 2. The following must be observed when doing so:
▪ Apart from the applied tightening torque, the clamping force of a
screwed connection depends on the anti-seize agent used, the surface
quality of the base and the thread and the material combination. It is
therefore essential that these conditions are fulfilled in their entirety.
▪ The tightening torques for the various threads can be taken from Table 2,
depending on the coefficient of friction μ, i.e. depending on the selected
anti-seize agent. The torque values apply to a screw material of strength
category 8.8 and in utilisation of approx. 70 % of the yield point. Conver-
sion factors must be used for other strength classes, by which the tight-
ening torque taken from the table must be multiplied. The strength class
is stamped on the screw 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 anti-seize agent containing molybdenum disulphide (MoS2)
Optimoly-Paste White T)
μ = 0.14 for surfaces without post-treatment, slightly oiled
or lubricated using Loctite
(see Work Card 000.19)
M8 17 25 M 27 700 1020
M 12 60 85 M 30 950 1380
M 14 95 135 M 30x2 1015 1540
M 14x1.5 100 145 M 33 1270 1870
M 16 140 205 M 33x2 1350 2060
M 16x1.5 150 220 M 36 1640 2400
M 18 200 280 M 36x3 1710 2550
M 18x1.5 215 320 M 39 2115 3120
M 18x2 205 300 M 39x3 2190 3300
M 20 275 400 M 42 2630 3860
M 20x1.5 295 450 M 42x3 2760 4170
M 20x2 285 425 M 45 3260 4820
M 22 370 540 M 45x3 3415 5180
M 22x1.5 395 595 M 48 3950 5820
M 22x2 380 565 M 48x3 4185 6370
Table 2: Tightening torques for bolts of strength class 8.8
Work Cards, Classified by Subjects
General
2007-08-29 - de
Machine Elements
General remarks
Summary
Impart the necessary knowledge, ensure the operational safety of bolted
connections. Different methods of tightening bolted connections must be
used depending on the purpose of the connection and its significance. The
following are used: Tightening without specification, tightening to torque,
tightening to torsion angle, tightening to length change, tightening with
hydraulic tensioning tools.
Work Cards 000.29 and 000.30 contain the necessary information.
General remarks
Tightening with standard Different methods of tightening bolted connections are used depending on
tools the purpose of the connection and its significance. When there are no speci-
fications for the tightening of screwed connections of average significance,
use normal ring spanners, socket spanneres or open-jaw wrenches without
any extensions.
Self-locking hexagon nuts must only be used once! After use for
assembly, they must be replaced by new self-locking hexagon nuts!
Tightening to torque Bolted connections for which a specific tightening torque is specified in Work
Cards 000.29 and 000.30 must be tightened using a torque wrench. The
specified anti-seize agent must be adhered to during fitting, since different
forces are exerted in the screwed connection at the same torque value,
depending on the lubricant used. The manufacturer's specifications are deci-
Work Cards, Classified by Subjects
sive for the pre-treatment of the bolted connection and for the application of
the anti-seize agent.
If torque wrenches are also used to release bolted connections, it must be
ensured that the maximum torque capacity of the wrench is not exceeded
(risk of damage). Extension pipes must not be used under any circumstan-
ces. Torque wrenches must also be regularly checked for correct read-out/
setting.
If other bolted connections other than those listed in Work Card 000.30 are
tightened with torque wrenches, approximate torque values can be taken
from Work Card 000.31.
Tightening to torsion angle Bolted connections for the tightening of which a specific torsion angle is
or torque and torsion angle stipulated, must firstly be tightened with a torque wrench to the stated torque
General
or with an open-jaw spanner, ring spanner or socket spanner until the nut or
2007-03-26 - de
bolt fits tightly. Secondly, the nut or bolt must continue to be tightened by
the stipulated torsion angle.
Tightening to the elongation The procedure in which the screwed connections were primarily, or exclu-
sively, tightened by reference to the elongation of the bolt/pressing of the
Machine Elements
of the bolt
parts to be tensioned has been discarded in favour of other methods. Today,
the change in length/pressing is only measured as a checking dimension, in
addition to tightening with hydraulic tensioners.
Disadvantages of the previ- The following disadvantages of tightening bolted connections with ring span-
ously stated methods ners, open-jaw spanners or socket spanners or with torque wrenches must
be stated:
▪ Extremely high lateral forces are introduced into the connection
▪ Effective pretension depends on the anti-seize agents used and/or the
frictional conditions
▪ These procedures can no longer be applied to bolted connections which
have larger nominal diameters
Tightening with hydraulic The disadvantages listed above are not applicable to the tightening of bolted
tensioners connections using hydraulic tensioners. The procedure can even be applied
to the largest of bolts, with a high degree of reliability. Screws, bolts or axes
are hydraulically extended and, after tightening or releasing the nuts, they are
detensioned. See Work Cards "Hydraulic tensioner - Use" and safety regula-
tions.
Work Cards, Classified by Subjects
General
2007-03-26 - de
Surface Test By
Machine Elements
Penetration methods
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 test-
ing, inspecting parts/components.
Tools/aids required
Quantity Designation Number Status
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, pro-
vided 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 direc-
tion as well as independently 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
Work Cards, Classified by Subjects
removed. This is necessary so that the penetrant can fully wet the surface
2008-10-28 - de
removed. In doing so, you must ensure that the penetrant remains in position
2008-10-28 - de
in any faults that are detected. The cleaning method depends on the pene-
trant used.
Machine Elements
1 water soaked, non-fraying cloth 3 Rinsing with water
or sponge
2 Cleaning with a brush 4 Special cleaning agents (compat-
ible with the penetrant)
Figure 3: Intermediate cleaning options
Machine Elements
1 Cold cracks 6 Cluster porosity
2 Hot cracks 7 Spongy structure
3 Grinding cracks 8 Porosity (heavy bleeding)
4 Cracks (heavy bleeding) 9 Stress corrosion cracking
5 Porosity
Figure 7: Fault indications
2008-10-28 - de
Machine Elements
Figure 10: Testing Chemicals of Various Manufacturers (Special Cleaning Agents/
Penetrants/Developers Respectively)
Surface Test By
Machine Elements
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 test-
ing, inspecting parts/components.
Tools/aids required
Quantity Designation Number Status
1 Yoke magnetising equipment - Inventory
1 Permanent magnetisation device - Inventory
1 UV light source - Inventory
1 Magnetic powder (dry) - Inventory
1 Magnetic powder (in suspension) - Inventory
1 Special cleaning agent - Inventory
1 Special paint - 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 floo-
ded by a magnetic field. These go beyond the component surface. The pres-
ence of a magnetic discontinuity or a leakage field is verified by the applica-
tion 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.
Work Cards, Classified by Subjects
Figure 2: Permanent magnet with special paint and magnetic powder in spray cans
(by Helling)
Yoke magnetisation
General
2008-10-28 - de
Machine Elements
Figure 3: 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
(transverse to the field direction). It is therefore necessary to perform the test
a second time in a transverse direction (see figure 4/B and 4/C).
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 below the surface are indicated inaccurately, becoming increasingly
obscure the deeper they are. The magnetic powder test is therefore mainly
used for detecting surface faults or faults near the surface.
Figure 5: Bead formation in the magnetic powder due to magnetic leakage fields
Dry process In the dry process, the magnetic powder is sprinkled onto the component
surface 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 sur-
face 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 parti-
cle suspensions. The particles "swim" to the faults. This, however, assumes
the constant movement of the carrying agent in order to prevent the mag-
netic 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-fluo-
rescent 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
surface 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 component surface to be tested.
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
reliably detected using the wet process with less concentrated magnetic par-
ticle suspensions and a smaller grain size.
General
2008-10-28 - de
Finally, the test area is examined for powder accumulation and the possible
fault indications are evaluated, marked and fixed if necessary. Depending on
Machine Elements
the use of the component, test agent residues are removed and the compo-
nent is demagnetised.
Demagnetisation
After magnetisation, residual magnetism remains in the test object, which
can lead to malfunctions, depending on the use of the component. To
demagnetise, the component is subjected to an alternating magnetic field of
decreasing 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.
General
2008-10-28 - de
Machine Elements
the use of load carrying equipment/slings
Summary
Impart the necessary knowledge, ensure safe use (of load carrying equip-
ment).
In order to use the load carrying equipment/slings in a safe manner the regu-
lations for use must be observed.
The following must be observed:
Danger of accidents,
Safety regulations and
Maintenance regulations.
Preliminary remarks
The following must be observed in order to use the load carrying equipment/
slings safely:
▪ the regulations for use,
▪ the maintenance regulations and
▪ the safety regulations
Safety Regulations
▪ Observe the Work Cards and safety regulations.
▪ Remove dirt from the contact faces of engine parts or load carrying
equipment, check the thread and clean if necessary.
▪ Only use tools in perfect working order. Overhaul or replace faulty/doubt-
ful components.
▪ Use the stipulated tensioning values and lubricants.
Work Cards, Classified by Subjects
inspection, inspection for damage and wear and magnetic crack test of
all the components of the fixtures) at regular intervals (approx. every 50
loading cycles). This must be recorded in the operating records in writ-
ing!
2008-09-15 - de
Warranty and liability Our "General terms and conditions of sale" apply as a basic rule. These are
available to the operator following contract conclusion at the latest. Warranty
Machine Elements
and liability claims are dealt with exclusively according to the provisions aris-
ing from the contractual agreement between MAN Diesel & Turbo and the
user and/or customer. Warranty and liability claims made in the event of
physical injury or damage to property will not be recognised if they are for
one or several of the following reasons:
▪ Use of the load carrying equipment/sling gear for any other purpose
other than that for which it was intended
▪ Incorrect assembly, commissioning, operation and maintenance of the
load carrying equipment/sling gear
▪ Operation of load carrying equipment with defective safety equipment,
and also when components, safety devices and guards have not been
properly installed or are not working correctly
▪ Non-compliance with the information on transport, storage, assembly,
commissioning, operation, maintenance and setting up of load carrying
equipment/sling gear contained in the Operating Instructions
▪ Constructional changes to the load carrying equipment/sling gear made
without authorisation
▪ Insufficient monitoring and inspection of load carrying equipment and
components that are subject to wear
▪ Repairs that have been incorrectly carried out
▪ Non-compliance with the maximum allowable service life of load carrying
equipment/sling gear
▪ Disasters due to extraneous causes or force majeure
Organisational measures In addition to the Operating Instructions, generally applicable rules and other
mandatory regulations for accident protection and environmental protection
must be observed and communicated!
Examples of these kind of obligations on the part of the operator are:
▪ Ensure availability/use of personal protective equipment
▪ All existing load carrying equipment/sling gear must be regularly
checked.
▪ Personnel who are authorised to work with the load carrying equipment/
sling gear must receive instruction regarding use of the Operating
Instructions and the safety information contained therein.
Work Cards, Classified by Subjects
Safety equipment Before using load carrying equipment/sling gear, make sure that all safety
equipment is properly attached and functional.
Informal safety measures The Operating Instructions must always kept with the load carrying equip-
ment/sling gear.
In addition to the Operating Instructions, the generally applicable rules as well
as the local accident prevention and environmental protection regulations
must be made available and observed.
Instruction of personnel Work on the load carrying equipment/sling gear may only be carried out by
personnel who have received training and instruction in its use. It must be
clearly defined which personnel are responsible for operation, for carrying out
modifications and for carrying out maintenance. Personnel who are training
General
on the job may only work with the load carrying equipment/sling gear under
2008-09-15 - de
Safety measures to be taken Before using load carrying equipment/sling gear, make sure that this will not
put anyone in danger. Check the load carrying equipment at least once every
Machine Elements
Damaged components
Load carrying equipment must always be cleaned and checked for
damage after use.
Damaged and worn load carrying equipment or components must not
be used under any circumstances whatsoever and must be replaced
immediately.
Maintenance and repairs, ▪ Carry out prescribed adjustment, maintenance and inspection work on
troubleshooting time.
▪ Secure load carrying equipment/sling gear or lifting tackle to prevent it
from starting up or moving accidentally.
Constructional changes to ▪ If the load carrying equipment/sling gear is not in perfect condition,
General
2008-09-15 - de
load carrying equipment/ replace it immediately! Only use genuine spare and wear parts! It cannot
sling gear be guaranteed that parts procured from other sources are designed and
manufactured to meet the specific loading and safety requirements.
Machine Elements
▪ All conversion measures require the written consent of MAN Diesel &
Turbo SE.
Summary
Impart the necessary knowledge, ensure safe use (of high-pressure tools).
Hydraulic tensioners, high-pressure hose and the high-pressure pump are
tools that can be used safely, despite high-pressures, if the instructions for
use are observed.
The following are to be observed: Accident hazards, safety regulations and
maintenance instructions.
Preliminary remarks
Hydraulic tensioners, high-pressure hoses and the high-pressure pump are
tools which can be used safely without malfunctioning, despite high operat-
ing pressures, if the following instructions are observed.
▪ Instructions for use
▪ Instructions for repair
▪ Safety Regulations
Safety Regulations
▪ Observe work cards and safety regulations.
▪ Remove dirt from contact faces of engine parts or tools, check thread
and clean as necessary.
▪ Only use tools that are in proper working order. Overhaul or replace parts
which are defective or may not be working properly.
▪ Use prescribed tightening values and lubricants.
▪ Use low-viscosity slushing oil as hydraulic fluid (not lubricating oil or fuel).
▪ Once the hose coupling has engaged, screw on the locking ring (knurled
threaded ring) up to the stop.
▪ Seal the hose couplings that are not connected to a hose with blind
plugs.
Work Cards, Classified by Subjects
▪ Put on safety goggles.
▪ Keep persons clear of the extension range of the bolts or axes of the
press.
▪ Keep as much distance as possible from presses and high-pressure
pipes.
▪ Raise the pressure control valve slowly, without exceeding the specified
pressure.
▪ Avoid heavy impacts on bolts, nuts and presses that are under load.
▪ Do not bend high-pressure pipes, minimum bending diameter 400 mm.
▪ Following each tightening operation, make sure the piston returns to its
original position. This is described in the work cards for the hydraulic ten-
General
sioners.
2007-07-19 - de
▪ When checking bolts that have been hydraulically tightened, the release
pressure must not by more than 7% below or more than 5% above the
Hydraulic tensioners/High-pressure pump
Obligations and liability ▪ Knowledge of the fundamental safety information and safety regulations
is a fundamental prerequisite for working safely with hydraulic tensioners
without problems.
▪ All persons working with the hydraulic tensioner must comply with these
Operating Instructions, particularly the safety information.
▪ The applicable rules and regulations at the place of use governing the
prevention of accidents must also be observed.
Hazards associated with Although the hydraulic tensioner is constructed in accordance with the latest
handling the hydraulic ten- technical standards and generally recognised safety regulations, it can still
sioner pose a danger to life and limb of the user or others, or could be damaged or
cause other material assets to be damaged when in use. Only use the
General
hydraulic tensioner:
2007-07-19 - de
Once 2500 loading cycles have elapsed, the hydraulic tensioner must
be taken out of service and replaced with a new one! A tally of the
loading cycles must be kept in the operating records!
Warranty and liability Our "General terms and conditions of sale" apply as a basic rule. These are
available to the operator following contract conclusion at the latest. Warranty
and liability claims made in the event of physical injury or damage to property
will not be recognised if they are for one or several of the following reasons:
▪ Use of the hydraulic tensioner for any purpose other than for which it was
intended
▪ Incorrect assembly, commissioning, operation and maintenance of the
hydraulic tensioner
▪ Operation of the hydraulic tensioner with defective safety equipment, and
also when components, safety devices and guards have not been prop-
erly installed or are not working correctly
▪ Non-compliance with the information on transport, storage, assembly,
commissioning, operation, maintenance and setting up the hydraulic ten-
sioner contained in the Operating Instructions
▪ Unauthorised constructional changes to the hydraulic tensioner
▪ Unauthorised changes to the operating pressure
▪ Insufficient monitoring of the hydraulic tensioner and components that
are subject to wear
Work Cards, Classified by Subjects
▪ Repairs that have been incorrectly carried out
▪ Non-compliance with the maximum number of loading cycles the
hydraulic tensioner is allowed to perform
▪ Disasters due to extraneous causes or force majeure
Intended use The purpose of the hydraulic tensioner is to tighten and release the clamping
screw connections on the Diesel engine specified by MAN Diesel & Turbo
SE, Augsburg. This is done using a high operating pressure or tightening
pressure which is specified for the bolt connections and corresponding limits.
Improper use Use for any purpose other than that specified above is prohibited. Hazards
may arise as a result of improper use.
Examples of improper use are:
General
Organisational measures In addition to the Operating Instructions, generally applicable rules and other
mandatory regulations for accident protection and environmental protection
Hydraulic tensioners/High-pressure pump
Particular dangers Period for which hydraulic hose lines and seals can be used
▪ Observe the information provided by the hose manufacturer regarding
the period of use!
Hose line connections
▪ Hose connections must be checked prior to operation.
▪ The connections must have snapped into place and must be locked.
General
2007-07-19 - de
▪ Hose lines may only be uncoupled once the hydraulic system is at zero
pressure.
▪ Check all lines, hoses and threaded unions regularly for leaks and visible
signs of damage! Repair damage immediately! Oil that spurts out can
Hydraulic tensioners/High-pressure pump
2007-07-19 - de
High-pressure pump
Summary
Impart the necessary knowledge, ensure adequate application. The high-
pressure pump produces the pressure required for tightening and releasing
the large bolted connections using the hydraulic tensioner. It is driven by
compressed air and produces pressures up to 1,500 bar at low delivery
rates.
Information is imparted concerning: Technical data, commissioning, shut-
down, maintenance and behaviour in the case of failures.
Tools/aids required
Quantity Designation Number Status
1 High-pressure pump 009.342 Standard
1 Tools, Basic Scope 009.229 Option
1 Slushing oil (viscosity 6-16 mm²/s) - Inventory
Technical data
Designation Information
Pressure range 0 - 1500 bar
Test pressure 1500 bar
Compressed air connection 7 - 15 bar
Oil filling 5 Liter
Quality Korrosionsschutzöl
Dimensions 431x317x405 mm
Weight 30,5 kg
Structure/Mode of action
Work Cards, Classified by Subjects
For tightening and releasing large bolted connections the following is nee-
ded:
▪ high-pressure pump,
▪ specific pressure resistant hose lines and
▪ hydraulic tensioners, if necessary with resetting devices.
The high-pressure pump feeds a relatively small volume of liquid (if required,
at a pressure of up to 1,500 bar) through the pluggable hose pipes to one or
more tensioners.
If the piston of the hydraulic tensioner is screwed onto the thread of the
screw, the liquid raises the piston in the casing and extends the screw, whilst
General
both sides and is equipped with pistons of smaller diameter on both sides
which draw in hydraulic oil from the surrounding reservoir, or which feed it 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 pilot valve,
and the pumping and suction action is repeated. The effective pressure of
the air is normally reduced in order to produce a pressure of 1500 bar on the
hydraulic side. An outlet pressure of 1500 bar must not be exceeded.
Commissioning
Work steps 1. Check oil level indicator (5) in the high-pressure pump, open oil filler neck
(1) and add slushing oil if necessary.
When adding slushing oil, pour oil through the basket strainer, since
malfunctions can be caused by foreign material.
the hose connections (4) which are not in use with a blind plug (lock the
sliding sleeve of coupling with the stop ring).
8. Put shut-off valve (A) to position I / OPERATION- High-pressure pump
starts.
9. Close relief valve (B) (clockwise).
10. Gradually turn the pressure-regulating valve (C) for compressed air in a
2007-04-25 - de
clockwise direction until the desired pressure is indicated on the oil pres-
sure gauge (3) (there is a delay depending on the size of the hydraulic
tensioner).
Shutdown
Work steps 1. Set shut-off valve (A) to position II / OUT OF SERVICE, thus venting the
air system of the high-pressure pump.
2. Open vent valve (B) in order to make the oil side of the high-pressure
pump pressure-free (oil pressure gauge (3) will fall to zero). The pressure
reduction in the high-pressure hose will take place more slowly. After the
pressure release, the high-pressure hose has to remain connected to the
high-pressure pump with the relief valve open for approx. 3 minutes.
Otherwise an internal pressure may remain which will block the hose
coupling (See Work Card 009.05 for troubleshooting).
3. Release the quick-acting coupling on the high-pressure hose.
When more screw connections are tensioned one after the other at the
same pressure, the pressure regulating valve (C) remains at the set
value. Re-adjustments are not necessary.
4. Drain slushing oil from the hydraulic tensioner while the high-pressure
hose is still connected to hose coupling (4) (See Work Card for each
hydraulic tensioner for a description of this procedure).
5. Disconnect high-pressure hose.
Work Cards, Classified by Subjects
Maintenance
The components and connections of the high-pressure pump have to be
checked regularly for leakage and overhauled if necessary. The set of wear
parts (2) for the high-pressure pump and pressure regulating valve (C) is fixed
behind the side plate.
Check the oil level on the oil level indicator (5) and add oil if necessary prior to
every start. Never run high-pressure pump without oil, to avoid air being
sucked in. Drain oil once a year and fill with new slushing oil. Clean the oil
chamber when changing oil.
To drain water from the compressed air filter at the compressed air regulator
(C) remove the side plate and screw in the screw plug by a few turns, so that
General
water can drain out. Tighten locking bolt afterwards. See manufacturer's
2007-04-25 - de
manual.
2007-04-25 - de
2007-04-25 - de
High-pressure hoses
Summary
Impart the necessary knowledge, ensure safe use (of high-pressure tools).
High-pressure hoses are required for connecting the hydraulic tensioners to
the high-pressure pump. They transmit high pressure.
Information is imparted concerning: Proper use/application and pressurising
the non-return valve.
Tools/aids required
Quantity Designation Number Status
1 High-pressure hose 009.330 Standard
1 High-pressure hose 009.306 Standard
1 High-pressure hose 009.305 Standard
1 High-pressure hose 009.304 Standard
1 Opener 009.026 Standard
Make-up
For the connection of the high-pressure pump with hydraulic tensioner, spe-
cial pressure-resistant hose pipes are used. They consist of a steel wire-brai-
ded plastic interior hose and an external protective hose, which will catch the
emerging fluid jet in the case of leakage.
Permitted operating pressure:
with constant load 1500 bar
with sudden load 900 bar
Minimum burst pressure 3,300 bar
Use
Work Cards, Classified by Subjects
For the connection of the high pressure pump there are quick-acting cou-
plings on both sides, which have to be secured with an additional threaded
ring against unintentional loosening. After the coupling is engaged, the corru-
gated threaded ring must be screwed up to the stop.
Opening the check valve After the use of high pressure hoses, i.e. after switching off the high pressure
General
pump and opening the release valve, the hoses must remain connected for
2009-07-06 - de
re-connected to the coupling. In this case, open the check valve with the
opener (009.026) (see Fig. 2). Other tools must not be used, since damage
Hydraulic tensioners/High-pressure pump
could occur.
The high pressure hoses are equipped with check valves on both sides. This
stops them from leaking when in storage.
2009-07-06 - de
Hydraulic tensioner
Summary
Impart the necessary knowledge, ensure proper use.
Hydraulic tensioners are used for extending bolts with regard to the compo-
nents to be connected. In this condition, nuts can be tightened or loosened
without applying force.
The work/work steps include:
loosening,
tightening and
resetting the piston.
Tools/aids required
Quantity Designation Number Status
1 Hydraulic tensioner 009.096 Standard
1 Hydraulic tensioner 009.097 Standard
1 High-pressure pump 009.342 Standard
1 Hydraulic hand pump 009.320 Standard
1 High-pressure hose 009.304 Standard
1 High-pressure hose 009.305 Standard
1 High-pressure hose 009.306 Standard
1 High-pressure hose 009.330 Standard
1 Resetting device 009.092 Standard
1 Open-jaw wrench 24x27 000.606 Standard
1 Tommy bar, 10 000.263 Standard
1 Tommy bar, 6 000.261 Standard
Technical data
Designation Information
Tool number 009.096/009.097
Effective piston area 72,72 cm²
Effective stroke 11 mm
Nominal pressure 1200 bar
2007-10-25 - de
32/40
Preliminary remarks
The piston and the casing of the tensioner, supplemented by thrust pieces
and adapter pieces, extend the bolts with respect to the components to be
connected. This happens by pressing hydraulic fluid from the high-pressure
pump/hydraulic hand pump under the piston. When the pressure is high
enough, the bolt nut is accessible and can be releaseed or adjusted accord-
ing to specifications.
Hydraulic tensioners and high-pressure hoses must be completely filled with
hydraulic oil prior to use. They must be bled if necessary.
Check for leakage occasionally. See Work Card 009.02.
The high-pressure hoses are equipped with non-return valves on both sides.
They cannot, therefore, run dry.
A requirement for correct tightening of the bolted connection is a pressure
gauge with a display in perfect working order. In case of doubt compare the
pressure gauge with a comparison pressure gauge.
For instructions for re-setting the tensioner see Work Sequence 3.
Tensioners Single tensioners are used separately or in combination with others.
Tandem tensioners are always used as a unit.
Work Cards, Classified by Subjects
1 Piston 5 Bolt
2 Casing 6 Tommy bar
3 Thrust piece 7 Hose connection
4 Nut A Gap dimension for releasing the
bolted connection
Figure 1: Single tensioner, not self-resetting. Shown on the left for tensioning, on the
right for releasing
Tightening Before tightening the screwed connection, the nut must be tightened hand-
tight. The piston of the tensioner must be screwed on such that the casing
and the thrust pad are blocked.
2007-10-25 - de
32/40
Releasing To untighten the screwed connection, its piston must be turned back by a
specified angle from the manually tightened position. Otherwise there is a
Before fitting the tensioners ensure that the pistons are completely
retracted. If the piston is not fully retracted there is a danger that
hydraulic oil may suddenly be discharged.
4. After fitting the tensioner turn back the piston by the turn-back angle
stipulated for the individual bolted connection (see Work Card 000.30).
This results in the associated gap dimension A, to be measured on or
under the thrust piece.
5. Connect the high-pressure hose to the tensioner and high-pressure
pump/hydraulic hand pump.
6. Start high-pressure pump or hydraulic hand pump (see Work Card
009.03).
7. Close gap (A).
8. Pump the tensioner until the nut (4) can be released.
9. Turn nut back with tommy bar through the cut-out in the thrust piece
Work Cards, Classified by Subjects
(turn-back angle see Work Card 000.30).
10. Release pressure, disconnect high-pressure hose from the tensioner and
high-pressure pump/hydraulic hand pump.
11. Remove tensioner and remove thrust piece.
6. Tighten stud (5) with specified pressure (see Work Card 000.30).
Hydraulic tensioners/High-pressure pump
7. Tighten nut (4) with tommy bar through the cut-out in the thrust piece
until it is in contact.
8. Release pressure, disconnect high-pressure hose from the tensioner and
high-pressure pump/hydraulic hand pump.
9. Remove tensioner and remove thrust piece.
Hydraulic tensioner
Summary
Impart the necessary knowledge, ensure the correct execution of the work.
Hydraulic tensioners must be completely filled with hydraulic fluid when used.
They must be bled, if necessary, and checked for leakage occasionally. If
they leak, the sealing rings must be replaced.
The work/work steps include:
bleeding,
checking tightness,
disassembling and assembling and
replacing sealing rings/sealing elements.
Tools/aids required
Quantity Designation Number Status
1 Hydraulic tensioner 009.097 Standard
1 Piston 009.097-1 Standard
1 Casing 009.097-12 Standard
1 Hydraulic tensioner 009.096 Standard
1 Piston 009.096-1 Standard
1 Casing 009.096-12 Standard
1 Hydraulic nipple 009.096-20 Standard
1 Threaded piece 009.096-21 Standard
1 Sealing ring 009.096-22 Standard
1 O-ring seal 009.096-26 Standard
1 Backing ring 009.096-27 Standard
1 O-ring seal 009.096-30 Standard
1 Backing ring 009.096-31 Standard
1 High-pressure pump 009.342 Standard
Work Cards, Classified by Subjects
009.01
Preliminary remarks
Hydraulic tensioners must be completely filled with hydraulic fluid before they
are used, as is the case with high-pressure pipes. It may be necessary to
bleed them. A leak test should occasionally be carried out. Non-return valves
are fitted at both ends of the high-pressure pipes which means they cannot
run dry.
The hydraulic tensioner must be dismantled if the O-ring seals/backing rings
need to be replaced or if there is damage. All O-ring seals and backing rings
should be replaced as a matter of course if the hydraulic tensioner is disman-
tled. As high working pressures and critical tolerances and areas are
involved, further interventions/repairs are not recommended. Instead, we rec-
ommend you have the device overhauled by MAN Diesel & Turbo SE or an
authorised Service Centre, if necessary.
Bleeding 1. Arrange the tensioner so that the hydraulic nipple (20) points upwards.
2. Connect high pressure pump or hydraulic hand pump and high pressure
hose.
3. Press the tensioner apart by approx. 10 mm (not more!).
4. Reduce pressure to "0" and uncouple the high-pressure hose.
5. Fit the resetting device (009.092) (see Work Card 009.01). Push open the
non-return valve in the hydraulic nipple (20) with the push-open device
(see Work Card 009.05 for handling instructions).
32/40;V32/40PGI
6. Hold the tensioner in such a way that the high-pressure nipple points
upwards and depress the piston with the resetting device until the
hydraulic fluid comes out without any bubbles.
7. Remove the push-open device and the resetting device.
2007-10-24 - de
Leakage checking 1. Mount tensioner on a readily accessible bolt for occasional leakage
checking. Connect high-pressure hose.
1 Piston 12 Casing
Figure 2: Dismantling the tensioner (pushing the piston out)
Work Cards, Classified by Subjects
32/40;V32/40PGI
Hydraulic tensioner
Summary
Impart the necessary knowledge, ensure proper use.
Hydraulic tensioners are used for extending bolts with regard to the compo-
nents to be connected. In this condition, nuts can be tightened or loosened
without applying force. The piston is pressed back into the initial position by
the cup springs.
The work/work steps include:
loosening,
tightening and
resetting the piston.
Tools/aids required
Quantity Designation Number Status
1 Hydraulic tensioner 009.346 Standard
1 Hydraulic tensioner 009.347 Standard
1 High-pressure pump 009.342 Standard
1 Hydraulic hand pump 009.320 Standard
1 High-pressure hose 009.306 Standard
1 Open-jaw wrench 55 000.570 Standard
1 Tommy bar, 10 000.263 Standard
Technical data
Work Cards, Classified by Subjects
Designation Information
Nominal pressure 1000 bar
Test pressure 1100 bar
32/40;L32/44CR;V32/40PGI
Preliminary remarks
The piston and the casing of the tensioner, supplemented by thrust pieces
2007-10-24 - de
and adapter pieces, extend the bolts with respect to the components to be
connected. This happens when hydraulic fluid from the high-pressure pump
or hydraulic hand pump is pressed under the piston. When the pressure is
high enough, the bolt nut is accessible and can be releaseed or adjusted
Hydraulic tensioners/High-pressure pump
according to specifications.
1 Tensioner
2 Cup spring
3 Tension nut
4 Tommy bar
5 Thrust piece
6 Nut
7 Bolt
A Gap dimension for releasing the
bolted connection
B Hole for tommy bar
X Releasing
Y Tightening
10. Turn nut back with tommy bar through the cut-out in the thrust piece
(turn-back angle see Work Card 000.30).
11. Release pressure, disconnect high-pressure hose from the tensioner and
high-pressure pump or hydraulic hand pump.
12. Remove tensioner and remove thrust piece.
until it is in contact.
2007-10-24 - de
Hydraulic tensioner
Summary
Impart the necessary knowledge, ensure the correct execution of the work.
Hydraulic tensioners must be completely filled with hydraulic fluid when used.
They must be bled, if necessary, and checked for leakage occasionally. If
they leak, the sealing rings must be replaced.
The work/work steps include:
venting,
checking tightness,
disassembling and assembling and
replacing sealing rings/sealing elements.
Tools/aids required
Quantity Designation Number Status
1 Hydraulic tensioner 009.347 Standard
1 Hydraulic tensioner 009.346 Standard
1 Hydraulic nipple 009.346-1 Standard
1 Sealing ring 009.346-2 Standard
1 Threaded piece 009.346-3 Standard
1 Sealing ring 009.346-4 Standard
3 Cup spring 009.346-10 Standard
1 Closing cap 009.346-13 Standard
1 Nut 009.346-16 Standard
1 Piston 009.346-17 Standard
1 Piston 009.346-18 Standard
1 Backing ring 009.346-19 Standard
1 Sealing ring (Round) 009.346-20 Standard
1 Casing 009.346-21 Standard
Work Cards, Classified by Subjects
Preliminary remarks
1 Hydraulic nipple
2 Seal
3 Threaded piece
4 Seal
5 Nut
6 Piston
7 Piston
8 Backing ring
9 O-ring seal
10 Casing
11 O-ring seal
12 Backing ring
13 Cup spring
14 Casing
15 Closing cap
repairs are not recommended. Instead, we recommend you have the device
overhauled by MAN Diesel & Turbo SE or an authorised Service Centre, if
necessary.
Bleeding 1. Hydraulic nipple (1) must point upwards when mounting tensioner with
tension nut.
2. Connect high-pressure pump or hydraulic hand pump and high-pressure
hose.
3. Expand or pump open (in disassembled condition) tensioner approx. 3
mm (not more).
2007-03-26 - de
4. Release pressure again. When resetting the piston by the cup springs,
existing air escapes through the high-pressure hose.
5. Disconnect high-pressure hose and bleed hose with opener (009.026).
Leakage checking 1. Mount tensioner on a readily accessible bolt for occasional leakage
checking. Connect high-pressure hose.
2. Inflate hydraulic tensioner with the recommended tension pressure for
that bolt. No leakage should appear for the next 5 minutes.
3. Release pressure, uncouple high-pressure pump or hydraulic hand pump
and high-pressure hose. Remove tensioner.
(13) in the correct sequence (see figure). Screw in nut (M30 x 2/M33 x 2) with
single-ended open-jaw spanner (000.570) up to the stop, while counter-
holding the piston (6) with a hexagon screwdriver (000.299).
The cup springs (13) have to be compressed a little to enable the ten-
sion nut to rest on the piston.
2007-03-26 - de
Hydraulic tensioner has to be bled after assembly and checked for leakage
(see work sequence 1).
Hydraulic tensioners/High-pressure pump
Ensure that the sealing elements are positioned correctly. Always place
O-ring seals on the pressure side, hollow in the backing ring faces the
O-ring seal
Work Cards, Classified by Subjects
32/40;L32/44CR;L32/40CR
2007-03-26 - de
Summary
It is important to use the right torque to tighten and untighten the screwed
connections and ensure correct performance of the work.
The measuring device serves the purpose of determining the bolt elongation
for comparison with a reference value. This should ensure that particularly
important screws are tightened correctly by using hydraulic tensioners.
The work/work steps include:
correct use/application and
measuring of the elongation.
Tools/aids required
Quantity Designation Number Status
1 Measuring device 009.121 Standard
1 Magnetic prism with support 009.121-1 Standard
1 Guide piece 009.121-3 Standard
1 Clamping piece 009.121-5 Standard
1 Dial gauge 009.121-8 Standard
1 High-pressure pump 009.342 Standard
1 Hydraulic hand pump 009.320 Standard
1 High-pressure hose 009.306 Standard
1 Hydraulic tensioner 009.096 Standard
1 Hydraulic tensioner 009.097 Standard
1 Hydraulic tensioner 009.346 Standard
Preliminary remarks
The bolt elongation is to be measured for comparison with a reference value
in the case of bolted connections of primary significance. This is to ensure
that the required pretension is actually present in the form of the elongation
of the bolt and compressing of the parts to be tightened. This is not guaran-
teed if the tensioner is blocked or the tension pressure is partly or fully dissi-
32/40;V32/40PGI
pated by friction.
2007-10-24 - de
Bolts must be tightened with the required oil pressure, not according
Work Cards, Classified by Subjects
6. If deviation from the target value is too great repeat the process, other-
wise check tensioner, bolted connection and pressure gauge.
7. Reduce pressure to "0". Remove tensioner.
32/40;V32/40PGI
2007-10-24 - de
Summary
Collate and assess operational data, detect problems on (influencing) sub-
assemblies /systems.
Ignition and compression pressures are important measures for the mechani-
cal loading of the engine. They are closely connected to important operating
data and allow conclusions as to the condition of components and systems
to be drawn.
The work/work steps include:
Recording pressures,
Collating operational data and
Assessing results.
Tools/aids required
Quantity Designation Number Status
1 Ignition measuring instrument by 419.019 Option
Baewert, Type 250E
1 Protective gloves - Inventory
Preliminary remarks
Ignition pressures are an important benchmark for the mechanical loading of
the engine. They are closely connected to important operating data and
allow conclusions as to the condition of components and systems to be
drawn. They must be determined with an indicator (pressure gauge) at regu-
lar intervals, in accordance with the maintenance schedule. When evaluating,
Work Cards, Classified by Subjects
both the absolute values and the differences from cylinder to cylinder are
important.
The calibration interval for the ignition pressure measuring device should be
one year.
2010-03-02 - de
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
assessment 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
Quantity Designation Number Status
1 Digital pressure gauge "Digima- 009.090 Option
Premo"
1 Storage bag 009.090-1 Option
1 9V battery 009.090-2 Option
1 Plug-in charger 009.090-3 Option
1 PVC 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 - Inventory
PVC hose
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 rec-
Work Cards, Classified by Subjects
ommended cleaning intervals in the maintenance schedule, the measure-
ment 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.
General
2007-11-15 - de
2007-11-15 - de
Safety Instructions
Maximum pressure on the device 14 bar.
Only dry gases are allowed to be admitted at connection p1 and only gases
and fluids which do not attack polyester, silicone and silicon are allowed on
connection p2. On connection p1 you may only use a measuring hose with a
water repellent filter.
Differential pressure measurements normally p2 > p1. If p2 < p1 the sign of
Work Cards, Classified by Subjects
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-blocking.
engine side.
2. Connect PVC hoses with filter to measuring points A and B. The locking
rings of the hose couplings must engage.
4. Press "On" push-button. Read off the measured value of the display.
5. Pulsating pressures lead to unstable indications. In this case press the
push-button "attenuation". Indication at "D" will be visible in area 3.
6. Turn off measuring device. Remove measuring hoses from the measur-
ing points (lift locking ring to do so).
7. Compare measured value with reference value and evaluate. The differ-
ential pressure in the as-new condition can be taken from the engine
acceptance test record. The charge air cooler is, at the latest, to be
cleaned when the differential pressure has reached the maximum value
(see manual section 2.5).
Additional information If the battery or accumulator voltage is too low a pre-warning "lo bat" will
appear in the indication field 9. The device can be used until the indication
starts to flash. From this point onwards incorrect measured values can
occur.
The recording instrument outputs 10a/10b provide a DC voltage of 1 mV/
digit (maximum 2 V) which is proportional to the measured value.
The zero-point setting can be carried out with the potentiometer 6a/6b when
the device is unloaded.
2007-11-15 - de
1 Introduction
2 Work Cards, Classified by Subjects
3 Work Cards, classified into sub-assem-
blies
4 Appendix
Sub-assembly overview
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
071 Dead centre indicator/Speed sensor
073 Crankcase cover/safety valve Work Cards, classified into sub-assemblies
100 Control device operating mechanism
101/102 Camshafts/Camshaft bearings
2010-08-06 - de
Sub-assembly overview
Sub-assembly overview
Sub-assembly overview - longitudinal and cross-section of the engine
2 (4)
V32/40
6632 3.1-03 EN
MAN Diesel & Turbo
2008-07-08 - de
MAN Diesel & Turbo 3.1
Sub-assembly overview
Overview of components - Designation
Sub-assembly Designation
Sub-assembly Designation
Sub-assembly overview
2008-07-08 - de
Foundations/Bearings
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
071 Dead centre indicator/Speed sensor
073 Crankcase cover/safety valve Work Cards, classified into sub-assemblies
100 Control device operating mechanism
101/102 Camshafts/Camshaft bearings
2010-08-06 - de
Foundations/Bearings
determining/checking
Summary
Checking alignment, detecting problems on (influencing) sub-assemblies/
systems, 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 instal-
lation and must be checked regularly.
This includes:
Checking the alignment,
recording measured values and
evaluating results.
Tools/aids required
Quantity Designation Number Status
2 Dial gauge - Inventory
1 Inside micrometer - Inventory
1 External micrometer - Inventory
Preliminary remarks
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 influ-
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.
The measured values are to be noted and recorded on a printed form (see
suggestion on the following page). The original measured values are to be
compared with the calculated given values, or with empirical values. If neces-
sary, the alignment must be corrected again. Later comparison of the values
allows conclusions to be drawn concerning time sequencing, the scope and
General
Foundations/Bearings
Engine Factory Ref. No.: Time:
The actual radial offset amounts to only half of the calculated difference
from the dial gauge indications (ΔA).
Remarks:
2007-07-23 - de
4 (4)
General
000.09
6682 000.09-01 EN
Signature:
MAN Diesel & Turbo
2007-07-23 - de
MAN Diesel & Turbo 012.01
Foundations/Bearings
Aligning engine on the foundations
Summary
Check alignment, Check sub-assemblies for consistency/wear, Detect prob-
lems with (influencing) components/systems.
Foundation bolts must be checked regularly for correct pretension, adapters
and stoppers to be checked for consistency and secure location.
This extends to:
Inspection of parts/components and
realign the engine.
Tools/aids required
Quantity Designation Number Status
1 Thrust piece 030.258 Standard
1 Nut 030.205 Standard
1 Guide tube 021.032 Standard
1 Hydraulic tensioner 009.346 Standard
1 High-pressure pump 009.342 Option
1 Hydraulic hand pump 009.320 Standard
1 High-pressure hose 009.306 Standard
Preliminary remarks
Included in the work specified in the service schedule is also the inspection
of the hydraulically tensioned foundation bolts for correct pretension as well
as the checking of the adapters and stoppers for firm seating. The pressure
required to loosen the nut is determined in this way. This is then compared
with the specified tensioning pressure. The foundation bolts are then re-tight-
ened with the specified tensioning pressure.
A further point in the maintenance schedule is the check of the crank web
deflection. If an impermissibly high value is detected by this control (espe-
cially at cylinder 1, or at cylinders A1/B1, see Work Card 000.10) and could
not be corrected through the alignment of the connecting shaft (generator),
the engine must be lifted from the foundation and realigned. See alignment
specifications in the foundation drawing.
Danger of death! During all work in the cylinder crankcase, close the
starter air cylinder, vent the starter pipe and engage the turning gear,
to prevent starting of the engine and rotation of the running gear! For
additional safety regulations, refer to Volume 010.005 Engine - Operat-
ing Instructions.
Work steps 1. Carefully clean cylinder crankcase and oil sump when overhauling and at
every oil change.
2. Examine cylinder crankcase from inside and outside for cracks.
1. Remove protective caps (9) and clean and degrease foundation bolts (12
or 13).
Foundations/Bearings
2. Check that nut (030.205) on tightening device (009.346) is screwed on
tight.
3. Place pressure piece (030.258) over foundation bolt and screw on tight-
ening device.
4. Rotate the tightening device back through 180°.
5. Connect high-pressure hose (009.306) to tightening device and high-
pressure pump or hydraulic hand pump.
6. Start the high-pressure pump or hydraulic hand pump (see Work Card
009.03) and close the gap between the pressure piece and tightening
device that arose when turning the tightening device backwards.
7. Pump the tightening device until the nut (10) can be released. Make a
note of the release pressure and compare it with the clamping pressure.
The pressure must lie max. 7% under or 5% over the tension pressure
(see Work Cards 000.30 and 000.33).
If there is plastic chocking, the tensioning value for the foundation bolts
must be specified by the manufacturer of the liner. The threads of the
When aligning take care with the coupled shaft and particularly with the
rib deflection of cylinder 1 or cylinders A1/B1 (coupling side). Check
with thickness gauges (000.454) whether the crankshaft rests on the
bottom bearing shells.
8. Determine the thickness of the fitting pieces and, if necessary, make new
fitting pieces.
Only one uniform material may be used for packers! A mixture of cast
resin and steel spacer plates is not allowed!
9. Install fitting pieces, check proper seating using the feeler gauge
(000.451).
10. Fit the foundation bolts (remember to install washer (17) with locating
screws!) and screw on nuts fingertight. Check bolt projection (A) = 79
mm.
11. Remove jacking screws and shims and store with the tool. Grease threa-
ded extraction hole and cover with protective caps.
12. Check that nut (030.205) is firmly screwed to the tightening device
Work Cards, classified into sub-assemblies
(009.346).
13. Place pressure piece (030.258) over the foundation bolt and screw on
the tightening device, for tightening sequence see Fig. 4 or 5.
14. Connect high-pressure hose (009.306) to tightening device and high-
pressure pump or hydraulic hand pump.
15. Start high-pressure pump or hydraulic hand pump (see Work Card
009.03) and tighten foundation bolt to specified clamping pressure (see
Work Card 000.30). Tighten nut fingertight using tommy bar (000.261).
If there is plastic chocking, the tensioning value for the foundation bolts
must be specified by the manufacturer of the liner. The threads of the
foundation bolts and the mating surfaces of the nuts must be free from
32/40;L32/44CR
16. Dump the pressure and detach the hydraulic tightening device.
2009-08-11 - de
17. Follow the above procedure to tighten the remaining foundation bolts
(points 13 to 16).
18. Check crank web deflection again and record in operating data logs (see
Work Card 000.10).
Foundations/Bearings
19. Grease the threads of the foundation bolts to protect against rust and
cover with protective caps.
11 Cylinder crankcase
14 Fitting piece
B6
Figure 4: Tightening sequence of the foundation bolts (V engine)
32/40;L32/44CR
2009-08-11 - de
Summary
Tightening and releasing important screwed connections with the correct val-
ues, ensure correct execution of work.
Crankshaft bearing bolts and cross tie rods
The work/work steps include:
determining pressure release and evaluating
tightening connection with target pressure.
Safety requirements
▪ Driving shaft secured against turning
▪ Engine secured against starting
Tools/aids required
Quantity Designation Number Status
2 Setting gauge 021.256 Standard
2 Tension screw 021.255 Standard
2 Thrust piece 021.254 Standard
2 Tension screw 021.253 Standard
2 Thrust piece 021.252 Standard
2 Intermediate ring 021.250 Standard
1 High-pressure pump 009.342 Standard
1 Hydraulic hand pump 009.320 Standard
4 High-pressure hose 009.306 Standard
009.01 009.03
Before installing the tensioning cylinder ensure that the pistons are
completely pressed in.
Make a note of the release pressure and compare it to the clamping pres-
sure.
1. Adjust high pressure pump to the specified tension pressure or activate
Work Cards, classified into sub-assemblies
2007-10-09 - de
Before installing the tensioning cylinder ensure that the pistons are
completely pressed in.
2007-10-09 - de
11. Make a note of the release pressure and compare it to the clamping
pressure.
Starting position Crankcase is opened, running gear is turned so that the main bearing cap is
easily accessible. Cross tie rod unloaded.
Note_Before untightening the main bearing bolts the cross tied rods
Cylinder crankcase/tie rod
must be untightened.
Work steps 1. Fit hydraulic tandem tensioners to both main bearing bolts (8) and
release the nuts (7).
(see Work Card 2, point 1 to 10)
2. Turn back both nuts (turn-back angle, see Work Card 000.30).
3. Release pressure and remove tandem tensioners.
4. Retract pistons of the tensioning cylinders (009.095) (see Work Card
009.01).
Work sequence 5 - Tightening the main bearing bolts and cross tie rods
Work steps 1. Tighten nuts (7) of the crankshaft bearing bolts (8) with tommy bar
(000.263) hand-tight.
2. Check that the gap in the separating joint between main bearing cap (3)
and cylinder crankcase (1) is the same on both sides (max. 1 mm).
3. Tighten nuts (5) of the cross tie rods (6) with tommy bar (000.262) hand-
tight.
4. Assemble the hydraulic tensioners on both cross tie rods, thereby tight-
ening the tension screws (021.253) hand-tight up to the stop.
Work Cards, classified into sub-assemblies
Before installing the tensioning cylinder ensure that the pistons are
completely pressed in.
Before installing the tensioning cylinder ensure that the pistons are
completely pressed in.
V32/40
7. Place the intermediate rings (021.250) over the tension screws on the
2007-10-09 - de
tensioning cylinder, insert the tommy bars through the holes in the inter-
mediate rings in the tension screws.
13. Set high-pressure pump or hydraulic hand pump in operation and tighten
cross tie rod with final pressure (see Work Card 000.30). Tighten both
nuts using the tommy bar, hand-tight.
11. Release pressure and remove tandem tensioners from the crankshaft
bearing bolts.
12. Close crankcase and place protection caps on the cross tie rods.
13. Retract pistons of all tensioning cylinders.
V32/40
2007-10-09 - de
Summary
Install/replace components, ensure proper use
, cylinder head bolts must be dismantled, if cylinder liners have to be disman-
tled at a low deinstallation height. Cylinder head bolts must also be disman-
tled if their sealing rings are damaged.
The work/work steps include:
removing components,
installing components.
Tools/aids required
Quantity Designation Number Status
1 Bolt extractor 009.089 Option
1 Ring nut 009.089-1 Option
1 Ring nut 009.089-2 Option
1 Tommy bar, 16 000.266 Standard
1 Ring spanner (cranked) 13x17 000.243 Standard
1 Grease (acid-free) - Inventory
Technical data
Starting position Bore and thread in the cylinder crankcase as well as the cylinder head bolts
well cleaned and degreased.
Working steps 1. Push new O-ring seals (2) and possibly renewed ring (3) over the thread
of the cylinder head bolts.
Cylinder crankcase/tie rod
2. Mount Bolt extractor (009.089) on the cylinder head bolt (1) (observe pro-
jection A = 53mm ).
3. Set cylinder head bolt in the bore, screw in and tighten with the tommy
bar (000.266), (see work card 000.30) hand-tight.
4. Remove bolt extractor.
5. Lubricate O-ring seals with acid-free grease.
6. Push O-ring seals and ring using suitable equipment in the bore, whilst
ensuring that the O-ring seals should not be twisted or damaged.
7. Mount the other cylinder head bolts in the same way.
8. Install cylinder head (see work card 055.02).
2009-09-10 - de
32/40;L32/44CR
2009-09-10 - de
Crankshaft/Coupling bolts
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
071 Dead centre indicator/Speed sensor
073 Crankcase cover/safety valve Work Cards, classified into sub-assemblies
100 Control device operating mechanism
101/102 Camshafts/Camshaft bearings
2010-08-06 - de
Crankshaft
Crankshaft/Coupling bolts
Measuring crankshaft deflection
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
regular intervals.
The work includes:
checking the alignment,
recording measured values and
evaluation of results.
Safety requirements
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Guide tube 021.032 Standard
32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;
1 Web deflection measurement unit 008.171 Option
(mechanical)
1 Thickness gauges 0.05-1 000.454 Standard
1 Felt-tip pen/marker pen - Inventory
Preliminary remark
The crank web deflection is the difference in the measured values between
two crank web positions offset by 180º. The crank web deflection indicates
the alignment of the main bearings and the bearing of the driven shaft. If the
2010-03-03 - de
Initial position
The initial position for the measurement of each crank is a position that
is closest possible to the left or right of the BDC and that allows the
measurement unit to be located.
Work Cards, classified into sub-assemblies
32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;
3. Check whether the crankshaft is lying on the lower bearing shells using
the feeler gauges (000.454).
Measuring points
The measuring points for the measurement with fitted running gears
are in the balance weights! Exception: Engine 58/64, the measuring
2010-03-03 - de
Crankshaft/Coupling bolts
If the engine is measured when it is hot, the measurement unit should
be placed in the crankcase approx. 15 minutes before measuring for
temperature adjustment.
6. Set the dial gauge approximately at the centre of the measuring range to
"0" as initial value.
7. Turn crankshaft in the normal rotation direction to the intended measur-
ing positions (from RBDC to RTDC - TDC - LTDC - LBDC for engine with
left-hand rotation, from LBDC to LTDC - RTDC - RBDC). At the positions
stated, read the value and direction of the dial gauge indication against
the initial value and enter the figures into a table (see table 1). Values are
positive (+) if the measured distance is larger, values are negative (-) if the
measured distance is smaller than the initial value of "0" (fig. 2, 3 and 4 /
table 1).
1 2 3 4 5 6 ...
Hand crank at 0 0 0 0 0 0 ...
RBDC1)
2010-03-03 - de
TDC
Hand crank at +1 +2 +4 +3 -3 -2 ...
LTDC
Hand crank at +2 0 +2 0 -1 -1 ...
LBDC1)
Table 1: Recording of measured values (example) - measured values in 1/100 mm
1)
Measurement with connecting rod removed = BDC
For comparison with the maximum permissible crank web deflection values,
the values of table 1 must be evaluated as stated in table 2. The vertical and
horizontal crank web deflection is determined (av and ah).
To obtain a value corresponding to the BDC position, a mean value of LBDC
and RBDC is calculated.
Example:
vertical av hand crank no. 6: av = (-3) - 0.5 ((-1) + 0) = -2.5
horizontal ah hand crank no. ah = (-1) - (-2) = +1
6:
Crank web deflection, with the corresponding algebraic sign, must not
Work Cards, classified into sub-assemblies
The absolute difference between the TDC values of adjacent cranks (calcula-
ted in table 3) must not exceed the absolute values of the permissible crank
web deflection.
51/60DF;V28/33D
Example:
TDC measured value between hand crank 5 +1 - (-3) = 4
and 6:
TDC measured value between hand crank 2 +3 - (+5) = -2, absolute difference = 2
2010-03-03 - de
and 3:
Crankshaft/Coupling bolts
type D CR CR L 48/60 V 48/60
B B
L 48/60 V 48/60
CR CR
L 51/60 V 51/60
DF DF
Crank web with cold ±15 ±142) ±182) ±182) ±18 ±23 ±26 ±23
deflection engine
with warm ±15 +14 +18 +18 ±18 ±23 ±26 ±23
engine -20 -25 -25
Measuring 320 460 540 550 505 580 580 560
point dis-
tance (A)
Table 4: Maximum permissible crank web deflection (differential values) with the running gear installed and correspond-
ing measuring point distances. Applies to all cranks of rigidly or resiliently mounted engines, except engine type 32/40
and 32/44 CR.1)2)
Crank web deflection in 1/100 mm, measuring point distances in mm
1)
The values specified are guide values only. The measured values must be tested and approved by MAN Diesel &
Turbo SE individually for new construction or for maintenance checking purposes. Attention: Different values with
tighter limits apply to newly installed engines!
2)
For hand crank no. 1 (on coupling side) for engines with resilient couplings of the type 32/40 the maximum values
of +14/-20 apply, for type 32/44 CR the maximum values of +18/-25 apply.
1 Crank web
2 Measuring range (centre punch)
3 Crank pin
A Measuring point distance
1 Crank web
3 Crank pin
Figure 3: Direction of deviation - measuring point distance relative to initial value "0" in
BDC or LBDC or RBDC (+ = increase, – = decrease)
TDC Top Dead Centre
LTD Left Top Dead Centre
C
RTD Right Top Dead Centre
C
51/60DF;V28/33D
Crankshaft/Coupling bolts
inspecting
Summary
Carry out the work in good time according to the maintenance schedule,
ensure the correct execution of the work/restore operational safety.
Bolted connections which are tightened with hydraulic tensioners must be
checked according to the maintenance schedule for correct tensioning.
The work/work steps include:
determining pressure release and evaluating
tightening connection with target pressure.
Safety requirements
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Thrust piece 030.243 Standard
2 Tensioning screw 021.251 Standard
2 Intermediate ring 021.250 Standard
1 High-pressure pump 009.342 Standard
1 Hydraulic hand pump 009.320 Standard
4 High-pressure hose 009.306 Standard
2 Hydraulic tensioner 009.097 Standard
2 Hydraulic tensioner 009.096 Standard
1 Tommy bar, 10 000.263 Standard
2007-07-17 - de
12. Reset the pistons of the tensioning cylinders (see Work Card 009.01).
Crankshaft/Coupling bolts
2 Balance weight
3 Nut
4 Stud
Crankshaft/Coupling bolts
closing
Summary
Ensure correct execution of work, enable emergency operation.
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.
The work/work steps include:
proper assembly
and if necessary
disassembly.
Safety requirements
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Locking device 020.050 Standard
1 Threaded rod 020.050-1 Standard
2 Sealing plug 020.050-5 Standard
1 Screwdriver 0.8x5.5 000.391 Standard
1 Ring spanner (cranked) 13x17 000.243 Standard
Preliminary remarks
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.
32/40
Figure 1: Close the oil bore in the crank pin (figure shows L32/40)
2007-05-10 - de
32/40
Crankshaft/Coupling bolts
removal and installation
Summary
Check assembly parts for state/wear condition; prevent operational prob-
lems/damage.
If the gearwheel on the crankshaft shows damage, then the gear rim is to be
replaced, i.e. renewed.
The work/work steps include:
removing components,
installing components.
Tools/aids required
Quantity Designation Number Status
1 Torque wrench 008.017 Standard
2 Shackle A0.6 002.452 Standard
1 Adapter 12.5x20 001.927 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Screwdriver insert 17x12.5 001.859 Standard
1 Socket spanner insert 30x12.5 001.759 Standard
1 Ratchet tool 001.521 Standard
2 Lifting eye bolt M12 000.142 Standard
2 Lifting tackle with rope - Inventory
4 Threaded rod M22/Dia22 - Inventory
2 Wood (to support underneath) - Inventory
1 Lubricant (containing molybdenum - Inventory
disulphide)
Technical data
Designation Information
Crankshaft gearwheel 66 kg
Preliminary remarks
It is recommended to have overhaul work on the camshaft drive on marine
V32/40
culty).
9. Detach shackle from lifting eye bolts and remove from ropes.
10. Lay ropes around the gearwheel lower part (25) and mount on the lifting
tackle.
11. Unscrew lower threaded rods.
12. Lift gearwheel lower part, replace wooden support for flat wooden sup-
port, lower gearwheel lower part onto this and pull out from under the
crankshaft.
Work Cards, classified into sub-assemblies
Only turn the running gear when the rocker arm casing is completely
removed, otherwise damage may be inflicted on the opened valves
through high running pistons (constrained motion between crankshaft
and camshaft(s) cancelled).
V32/40
2007-11-05 - de
Crankshaft/Coupling bolts
21 Flywheel 26 Parallel pin 29 Threaded rod
22 Crankshaft 27 Hexagon bolt 30 Wooden support
23 Crankshaft gearwheel 28 Rope
Figure 1: Arrangement of the crankshaft gearwheel (left)/crankshaft gearwheel pulled forwards to the outside of the
crankcase (right)
Before installing the gearwheel lower part pay attention to the position
Work Cards, classified into sub-assemblies
2007-11-05 - de
Crankshaft/Coupling bolts
23 Crankshaft gearwheel 35 Double spur wheel (intermediate
wheel)
33 Camshaft gearwheel 36 Injection camshaft gearwheel
34 Spur wheel (intermediate wheel) M Mark
Figure 4: Marks on the gearwheels
1. Screw in two threaded rods (29) through the gearwheel lower part in the
crankshaft.
2. Screw lifting eye bolts (000.142) into gearwheel upper part (24), fix ropes
with shackle (002.452) on the lifting eye bolts and suspend from the lift-
ing tackle.
3. Lift gear wheel upper part over the crankshaft and set on the gear wheel
lower part, thereby paying attention to the parallel pins/bores.
4. Apply MoS2-lubricant on threads and resting surface of the hexagon
socket bolts (32), screw in and tighten with the specified torque (see
Check that the marks (M) of the camshaft drive gearwheels coincide
(see figure 4).
10. Attach the main outer bearing and covering on the coupling side (see
Work Card 021.04 and 071.01).
Crankshaft/Coupling bolts
2007-11-05 - de
Coupling bolts
Crankshaft/Coupling bolts
inspecting
Summary
Carry out the work in due time according to the maintenance schedule,
ensure the operational safety of the bolted connections.
The coupling bolts must be checked at regular intervals. If you find loose
connections, the cause for this is to be investigated.
The work includes:
checking the bolted connections.
Tools/aids required
Quantity Designation Number Status
1 Tools, Basic Scope 009.229 Option
1 Lubricant (containing molybdenum - Inventory
disulphide)
Preliminary remarks
Controlling the coupling bolts for firm fitting also forms part of the specified
work in the maintenance schedule. If slack connections are detected the
cause must be ascertained (carelessness while tightening, overload,
amongst others).
2. When fitting the coupling (1) make sure that the thread and resting sur-
face of the hexagon bolts (10) are coated with MoS2 lubricant, are
screwed in position and tightened with the prescribed torque (see fly-
wheel arrangement drawing of the individual installation) and that there
2007-10-31 - de
32/40
are washers between the hexagon bolts and the coupling (11).
5 Casing 11 Washer
6 Oil pipe
* Shape and size of the coupling
and of the flywheel can differ
from the representation in the
illustration
Figure 1: Connection between crankshaft, flywheel and coupling
2007-10-31 - de
32/40
Balance weight
Crankshaft/Coupling bolts
removal and installation
Summary
Ensure correct execution of work, enable emergency operation.
Dismantling a balance weight is not customary maintenance work. This is
necessary only in special cases, e.g. emergency operation of the engine with
dismantled running gear.
The work/work steps include:
removing components,
installing components.
Safety requirements
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Wire rope 030.255 Option
2 Thrust piece 030.243 Standard
2 Tensioning screw 021.251 Standard
Technical data
Designation Information
Balance weight 145 kg
2007-10-09 - de
3. Place the thrust pieces (030.243) over the nuts (3) and screw the ten-
sioners (009.096) onto the studs (see figure 2).
Before fitting the tensioners ensure that the pistons are fully retracted.
Crankshaft/Coupling bolts
Once the tensioners have been fitted the crankshaft must not be
turned again.
2 Balance weight
4 Stud
Ensure that the clamping sleeve (5) and the parallel pin (6) remain in the
balance weight and do not stay in the crankshaft deflection (7).
Work Cards, classified into sub-assemblies
2007-10-09 - de
Crankshaft/Coupling bolts
Work sequence 2 - Installing the balance weight
Installing the balance weight is carried out in reverse order from the removal.
In doing so, observe the following points:
1. Check the position of the clamping sleeve (5) before installation.
2. Brush the threads of the studs (4) using MoS2 lubricant, screw them in
and tighten them using the specified tightening torque (see Work Card
000.30).
3. Screw on nuts (3) and tighten with tommy bar (000.263).
4. Check that the gap on the joint between crankshaft deflection (7) and
balance weight (2) is the same size on both sides.
5. Install measuring device (009.121) on the tensioner
(see Work Card 009.06)
6. Mount tensioners on both balance weight bolts.
7. Connect high-pressure hoses (009.306) to the tensioners and high-pres-
sure pump or hydraulic hand pump.
8. Start high-pressure pump or hydraulic hand pump (see Work Card
009.03) and tighten balance weight bolts with a pressure of 50 bar.
Reset measuring gauge to "zero".
9. Tighten balance weight bolts with specified final pressure (see Work Card
000.30) and tighten both nuts hand-tight. Release the pressure.
10. Tighten balance weight bolts with a pressure of 50 bar again. Read
screw elongation ΔL on the dial gauge and compare with the specified
value (see Work Card 000.30).
11. Release pressure and remove tensioners. Remove lifting eye bolts on the
Work Cards, classified into sub-assemblies
balance weight. V32/40
2007-10-09 - de
Summary
Carry out the work in good time according to the maintenance schedule,
ensure 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.
The work/work steps include:
dismantling the cross tie rods,
lowering the bearing cap,
checking the bearing shell and
restoring the starting position.
Safety requirements
▪ Driving shaft secured against turning
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Technical data
Designation Information
Main bearing cap 118 kg
Work sequence 1 - Lowering the main bearing cap - checking the lower crankshaft
bearing shell
Starting position The main bearing bolts and the cross tie rod are unloaded. Running gear is
turned so that the main bearing cap is easily accessible. The foot board (spe-
cial tool) is placed in the oil sump or the oil sump has been cleaned using an
appropriate agent. Temperature sensor removed (if fitted).
5 Cylinder crankcase
9 Cross tie rod
10 Nut
11 Ring
12 O-ring seal
Work Cards, classified into sub-assemblies
type jack up until it touches the main bearing cap (7) and fix in position
with two hexagon bolts (15).
7. Unscrew nuts (14) and place on cross tie.
8. Insert two more tommy bars in holes (1) in the guide tubes. Pull the main
bearing cap down onto these tommy bars with the scissor-type jack (see
With a hot engine it may be necessary to unload the cross tie rods of
the adjacent main bearing.
9. Release the tommy bars in the holes (3) in the cross beam and remove
supports (021.260).
10. Extract the tommy bars from the holes (3) and insert in holes (4).
11. Lower the cross beam and tommy bars and release the tommy bars in
the holes (1) of the main bearing cap (see figure 2 C).
12. Extract the tommy bars from the holes (1) and insert in holes (2).
13. Pull the crankshaft bearing cap down onto these tommy bars with the
scissor lift (see figure 2 D).
14. Carefully clean running surface of the crankshaft bearing shell (8) and do
not damage whilst doing so.
15. Check the condition of the running surface, (see Work Card 000.11).
If the cross tie rods of the adjacent crankshaft bearing have been
unloaded, first tension the crankshaft bearing bolts and cross tie rods
of the checked crankshaft bearing and then the cross tie rods of the
adjacent crankshaft bearings.
For the running-in of the new main bearing shells, see run-in instruc-
tions in section 3 of the Operating Instructions.
V32/40;V32/40G
2010-04-23 - de
Summary
Carry out the work in due time according to the maintenance schedule,
ensure the operational safety of bearings.
The upper crankshaft bearing shell must be removed and checked, if dam-
age or severe scoring from dirt is detected upon checking the lower crank-
shaft bearing shell.
The work includes:
checking the bearing shell.
Safety requirements
▪ Engine secured against starting
Tools/aids required
Quantity Designation Number Status
1 Turning block 021.268 Standard
1 Centring template 021.266 Standard
1 Turning block 021.265 Standard
1 Eye bolt M6 000.023 Standard
Work sequence - Checking the crankshaft bearing shell (removal and fitting)
Starting position Main bearing cap is lowered, lower bearing shell is removed.
Work steps 1. Insert turning block (021.265) in the oil hole in the crankshaft (6), the
crankshaft may have to be turned slightly.
2. Carefully turn out upper main bearing shell (20), do not damage it whilst
doing so (see figure 1).
Crankshaft bearing/main thrust bearing
1. Set centring template (021.266) on cylinder crankcase (5). Insert the cen-
tring bolts of the centring template in the bore for the main bearing cap
fixation (centring template is held using magnets).
2. Oil running surface of the crankshaft bearing shell (20) liberally (rear side
of the bearing shell remains dry).
3. Place crankshaft bearing shell on the centring template and push in as
far as possible by hand.
Work Cards, classified into sub-assemblies
Before pushing in make a note of the position of the bearing shell fixa-
tion.
4. Turn crankshaft (6), until the turning block (021.268) can be inserted
through a hole in the crankshaft bearing shell into the oil hole in the
crankshaft.
In order to avoid warping the thin crankshaft bearing shell when insert-
ing. Place the turning block in position as close as possible to the part-
ing line in the crankshaft bearing.
2007-10-09 - de
back by one hole pitch and insert turning block again. Repeat process
up to the last hole.
6. Turn the crankshaft back until the oil hole is free.
7. Insert turning stone (021.265) directly in the crankshaft oil hole and turn
the crankshaft bearing shell in completely.
8. Remove centring template and pull out turning block with eye bolt
(000.023).
9. Install main bearing cap with lower crankshaft bearing shell (see Work
Card 021.01).
For the running-in of the new main bearing shells, see Operating
Instructions, section 3.4.
2007-10-09 - de
Summary
Carry out the work in due time according to the maintenance schedule,
measure components, assess surface/wear condition.
The axial clearance and the locating bearing rings must be checked at regu-
lar intervals.
The work/work steps include:
measuring components and
assessing the wear surface appearance / wear condition.
Tools/aids required
Quantity Designation Number Status
1 Ratchet tool 008.023 Standard
1 Torque wrench 008.011 Standard
1 Extension piece 12.5x125 001.911 Option
1 Socket spanner insert 19x12.5 001.755 Option
1 Crow bar 001.391 Option
1 Thickness gauges 0.05-1 000.451 Option
1 Magnetic post - Inventory
1 Dial gauge - Inventory
1 Lubricant (containing molybdenum - Inventory
disulphide)
Technical data
Designation Information
Locating bearing ring 3,0 kg
32/40
2. Mount the dial gauge on the magnetic post, fasten the magnetic post
and place the dial gauge on the coupling flange or in another accessible
Crankshaft bearing/main thrust bearing
Ensure that the crankshaft locating bearing rings do not fall out.
9. Tighten the hexagon bolts with prescribed torque. (see Work Card
000.30)
32/40
Summary
Carry out the work in due time according to the maintenance schedule,
ensure the operational safety of the bearings.
The crankshaft bearing shells on the outer crankshaft bearing must be
checked at regular intervals.
The work/work steps include:
inspecting the bearing shells,
removing components,
refitting components.
Tools/aids required
Quantity Designation Number Status
1 Guide tube (V engine) 021.258 Standard
1 Guide tube 021.032 Standard
1 Torque wrench 008.017 Standard
1 Adapter 20x12.5 001.923 Option
1 Extension piece 12.5x125 001.911 Option
1 Cross handle 001.891 Option
2 Socket spanner insert 36x20 001.771 Standard
1 Thickness gauges 0.05-1 000.454 Standard
1 Lifting tackle - Inventory
1 Wood (to support underneath) - Inventory
1 Combination spanner (set) - Inventory
1 Hexagon nut M10 - Inventory
Technical data
32/40;V32/40PGI
Designation Information
Flange bearing complete 165 kg
Flange bearing - upper part 77 kg
2008-01-08 - de
Designation Information
Crankshaft bearing/main thrust bearing
When removing the flange upper part, ensure that the crankshaft bear-
ing shell does not fall out and is damaged in the process.
7. Attach the flange bearing lower part (34) with ropes to the lifting tackle,
tighten the ropes, remove the wooden support and lower the flange
bearing lower part.
8. Carefully clean the crankcase bearing shells (35 and 44) running surface,
do not damage them in the process.
9. Check the condition of the running surfaces (see Work Card 000.11).
Replacing the bearing shells Remove the damaged or worn-out crankshaft bearing shell from the flange
bearing upper part or lower part and insert a new crankshaft bearing shell
(rear part of the crankshaft bearing shell is dry), in so doing, pay attention to
the bearing shell fixation.
Work sequences (Part 2) - 1. Clean and lubricate the crankshaft bearing journals (30).
Assembling the crankshaft 2. Lubricate the running surface of the bottom crankshaft bearing shell (44)
external bearing well.
3. Lift the bottom part of the flange bearing (34) and position the wooden
support (40) under the flange bearing to support it. Remove the ropes.
32/40;V32/40PGI
4. Suspend the upper part of the flange bearing (33) with the rope (37) on
the lifting tackle.
5. Lubricate the running surface of the upper crankshaft bearing shell (35)
2008-01-08 - de
well.
6. Lift the upper part of the flange bearing, lift it over the crankshaft and
place it on the bottom part of the flange bearing, in so doing, pay atten-
Crankshaft bearing/main thrust bearing
When attaching the flange upper part, ensure that the crankshaft bear-
ing shell does not fall out and is damaged in the process.
7. Insert the hexagon bolts (36 and 38) into the holes.
8. Brush the threads and the running surface of the hexagon nuts (39) with
MoS2 lubricant, screw them hand-tight onto the hexagon bolts and
tighten them to the specified torque (see Work Card 000.30), for the
sequence, see figure 2.
9. Push the flange bearing (32) until it abuts the covering (42) in the direc-
tion of the crankcase. In the process, pay attention to the bores for the
taper pins (43).
10. Apply MoS2lubricant to threads and contact surface of the hexagon bolts
(31) and tighten hand-tight.
11. Press four taper pins (43) into the holes.
12. Tighten the hexagon bolts to the specified torque (see Work Card
000.30). For the sequence, see figure 3.
13. Check the crankshaft bearing clearance using thickness gauges
(000.454) (see operating instructions, Section 2.5), in doing so, insert the
feeler gauge approx. 10 mm deep from the coupling side and from the
free engine end.
14. Measure the crank web deflection (see Work Card 000.10) and note in
the operating log sheets.
15. Mount the temperature sensor (if available).
16. Mount the crankcase cover and the covering on the coupling side.
Work Cards, classified into sub-assemblies
For the running-in of the new crankshaft bearing shells, see Section 3.
32/40;V32/40PGI
2008-01-08 - de
Work steps 1. Remove the flange bearing (32) (see work sequence 1, Points 1 to 6).
2. Attach the flange bearing lower section (34) with ropes (37) to the lifting
tackle, tighten the ropes, remove the wooden support and replace it with
a flat wood surface and lower the flange bearing lower section onto it.
3. Remove the lower crankshaft bearing shell (44) from the bottom part of
the flange bearing.
4. Pull out the bottom part of the flange bearing from the crankshaft (30)
and place it on a second surface.
Work steps 1. Place the lower section of the flange bearing (34) onto a flat wooden sup-
port and slide it under the crankshaft (30).
2. Insert the lower crankshaft bearing shell (44) into the bottom part of the
flange bearing (rear part of the crankshaft bearing shell is dry), in so
doing, pay attention to the bearing shell fixation.
3. Fit the flange bearing (32) (see work sequence 1, Points 10 to 25).
Work Cards, classified into sub-assemblies
32/40;V32/40PGI
2008-01-08 - de
Summary
Carry out the work in good time according to maintenance schedule, ensure
the work is properly performed, ensure / return to operational safety.
The torsional vibration damper on the crankshaft is to be replaced at speci-
fied intervals according to the maintenance schedule.
The work/work steps include:
removing the components,
refitting the components.
Safety requirements
▪ Driving shaft secured against turning
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 027.033 Option
1 Screw-on plate 027.033-1 Option
1 Suspension plate 027.033-7 Option
2 Pipe 027.033-13 Option
1 Bracket 027.033-15 Option
2 Swivel ring bolt 027.033-27 Option
1 Power amplifier 008.030 Standard
1 Torque wrench 008.017 Standard
1 Shackle A2.0 002.455 Standard
disulphide)
2008-01-08 - de
Technical data
Designation Information
Cover 28 kg
Torsional vibration damper 1295 kg
Preliminary remarks
Each torsional vibration damper is a special component specifically designed
for an individual piece of equipment. Improper installation can lead to dam-
age of the equipment or to the torsional vibration damper.
Work Cards, classified into sub-assemblies
2008-01-08 - de
Starting position The crankcase cover and the covering on the free engine end have been
removed.
Work steps 1. Screw lifting eye bolt (000.141) into cover (8). Fasten cable with shackle
(002.452) on lifting eye bolt and suspend rope from lifting tackle.
2. Unscrew hexagon socket bolts (7) and remove cover. Place the cover on
a support (see figure 1).
3. Turn the crankshaft (1) so that the torsional vibration damper (3) sits with
the mark "Crank 1" pointing upwards.
4. Unscrew and remove the nuts (6) from the stud bolts (4).
5. Mount the screw-on plate (027.033-1) using hexagon bolts (14) to the
crankshaft (see figure 2 and 3).
6. Push the tubes (027.033-13) onto the spigot on the screw-on plate and
secure with hexagon bolts (12).
7. Push the suspension plate (027.033-7) with pins onto the pipe ends and
secure with hexagon bolts (11).
8. Place bracket (027.033-15) under suspension plate and secure with hex-
agon bolts (15) or nuts (16) onto suspension plate (see figure 3).
9. Place a suitable supporting beam (10) under the bracket.
10. Screw the hexagon bolts (12) into the spigots of the screw-on plate as
far as possible, until the tubes abut the torsional vibration damper.
11. Unscrew and remove the hexagon socket bolts (9).
12. Lightly oil the pipes and pull the torsion vibration damper forwards (see
figure 2). Pay attention to centrings and do not damage them.
13. Screw the swivel ring bolt (027.033-27) into the torsional vibration
damper. Fasten ropes with shackles (002.453) on lifting eye bolts and
2008-01-08 - de
plied with the power amplifier (008.030) and set the torque wrench
(008.017) accordingly.
2008-01-08 - de
Summary
Carry out all work on time in accordance with the maintenance schedule,
ensure 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
Quantity Designation Number Status
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 Sliding calliper Form C - 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
1 Lifting tackle - Inventory
Preliminary remark
Each torsional vibration damper is a special component specifically designed
for an individual piece of equipment. Incorrect disassembly or assembly may
cause serious damage to the system or the torsionial vibration damper.
The manufacturer's instructions must be followed when carrying out work on
the torsional vibration damper.
Lifting eye bolts, shackles and lifting tackle must be appropriately selected
for the respective torsional vibration damper.
Work Cards, classified into sub-assemblies
General
2009-01-23 - de
Starting position Torsion vibration damper dismantled and placed on flange (5) with a wooden
support. Crankshaft flange side of the inner star (9) points towards the top.
Work steps 1. Mark position of the flange (5) and the side plate (7) on the spring packet
(1) of the torsional vibration damper. Mark with a centre-punch.
2. Unscrew hexagon bolts (750) with cup springs (810). See Fig. 2/I.
3. Screw lifting eye bolts into side plate (7). See Fig. 2/II.
4. Attach rope with shackle to lifting eye bolts and suspend from lifting
tackle. See Fig. 2/II.
5. Lift side plate (7) from spring packet (1), turn and place on wooden sup-
port. See Fig. 2/II.
6. Remove slings.
7. Remove O-ring seals (850 and 851) from side plate (7) and spring packet
(1). See Fig. 2/III.
8. Check sealing face of the side plate (7). Refer to data sheet for permissi-
ble wear limit.
9. Checking the permissible wear limit with measuring wedge or sliding cal-
liper. See work sequence 2 - Measuring the wear limit.
10. Screw lifting eye bolts into inner star (9). See Fig. 3/V.
11. Attach rope with shackle to lifting eye bolts and suspend from lifting
tackle. See Fig. 3/V.
Work Cards, classified into sub-assemblies
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 proc-
ess. See Fig. 3/V.
13. Remove 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 packet (1). See fig. 3/VI.
16. Attach rope with shackle to lifting eye bolts and suspend from lifting
tackle. See fig. 3/VI.
General
2009-01-23 - de
17. Lift spring pack (1) and place on wooden support. See fig. 3/VI.
18. Remove slings.
19. Check sealing surfaces of the flange (5). Refer to data sheet for permissi-
ble wear limit.
20. Remove O-ring seals (850 and 851) from flange (5) and spring packet (1).
See Figure 3/VII.
21. Clean all the components.
Measuring wedge 1. Place measuring wedge between spring-leaf tips at the base of groove.
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.
Starting position All parts cleaned and lightly oiled with clean lubricating oil.
Work steps 1. Insert a new O-ring seal (850) wetted with clean lubricating oil in the seal-
ing ring groove of the flange (5). Make sure that it is evenly tensioned
Torsional vibration damper
Crankshaft
2009-01-23 - de
24. Use a dial gauge with magnetic post or sliding calliper to align side plate
(7) with the spring packet (1) (see Figure 8). Take the maximum permissi-
ble radial run-out into account (see drawing).
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
M 36 350 Nm
Table 1: Contact torque for cup springs*
General
* The values only apply when the specified installation specifications for bolts
2009-01-23 - de
are complied with: "Thread lubricated or treated with Molykote and Loctite
applied to both sides of cup springs."
See drawing by Co. Geislinger
* Shape and size of the torsion vibration damper may differ from the illustration in the figures
General
2009-01-23 - de
Summary
Conduct the tasks in due time according to the maintenance schedule,
ensure the operational safety of the screwed connections.
The conrod shank bolts are to be checked at regular intervals using hydraulic
tension tools.
The work/work steps include:
determining pressure release and evaluating
tightening connection with target pressure.
Safety requirements
▪ Driving shaft secured against turning
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Thrust piece 030.258 Standard
2 Nut 030.205 Standard
When hydraulic tensioners are installed, the running gear may not be
turned.
Work Cards, classified into sub-assemblies
The pressure must lie max. 7% under or 5% over the tension pressure
(see Work Cards 000.30 and 000.33).
2007-10-31 - de
Tighten the conrod shank bolts using the specified tension pressure,
not according to elongation. Elongation specifications serve only for
checking purposes. Repeat tensioning process in the case of great
32/40;V32/40PGI
11. Repeat the process (points 3 to 10) in the same way for the conrod
shank bolts (2 and 4) (see figures 1 and 2).
2007-10-31 - de
Summary
Conduct the tasks in due time according to the maintenance schedule,
ensure the operational safety of the screwed connections.
The conrod shank bolts are to be checked at regular intervals using hydraulic
tension tools.
The work/work steps include:
determining pressure release and evaluating
tightening connection with target pressure.
Safety requirements
▪ Driving shaft secured against turning
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Thrust piece 030.243 Standard
1 High-pressure pump 009.342 Standard
When hydraulic tensioners are installed, the running gear must not be
Work Cards, classified into sub-assemblies
turned. Before mounting the tensioning cylinder, ensure that the pis-
tons are fully pressed in.
The pressure must lie max. 7% under or 5% over the tension pressure
2007-10-24 - de
body (1) and the big-end bearing cap (2) is equal on both sides.
3. Mount the hydraulic tensioners onto the big-end bearing bolts (5) (see
figure 1).
Connecting rod/Big-end bearing
Before installing the tensioning cylinder ensure that the pistons are
completely pressed in.
Tighten the big-end bearing bolts using the specified clamping pres-
sure, not according to elongation. Elongation specifications serve only
for checking purposes. Repeat tensioning process in the case of great
deviations and check the measuring devices or pressure gauges. As a
result of irregular circumstances, the big-end bearing bolts can be per-
manently stretched. The big-end bearing bolt, having an as-new
dimension of 462 +/- 0.1 mm may only be permanently extended by 1.0
mm, i.e. if the length of 463.1 mm (untensioned) is exceeded the con-
rod shank bolt must be replaced.
Work Cards, classified into sub-assemblies
2007-10-24 - de
Summary
Carry out the work in due time according to the maintenance schedule,
ensure the bearings' operational safety.
The big-end bearing shells must be checked at regular intervals. To do so,
the big-end bearing cap must be lowered and the big-end bearing bolts
must be dismantled.
The work/work steps include:
inspecting the bearing shells,
removing components,
refitting components.
Safety requirements
▪ Driving shaft secured against turning
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 030.535 Standard
1 Wire rope 200.067 Standard
1 Rope clamp 030.535-7 Standard
1 Screw-on plate 030.320 Standard
1 Support fixture 030.536 Standard
1 Rope guide 030.321 Standard
Technical data
Designation Information
Bearing shell 2,5 kg
Big-end bearing cap 44,5 kg
Preliminary remarks
In order to check the unstressed lower bearing shell, the big-end bearing cap
needs only to be lowered into the oil sump. The shell can be removed for
inspection purposes (work sequence 1 in part as well as 2 and 3). To check
the stressed upper bearing shell, the condition of which is decisive for
assessing the bearing, the big-end bearing cap must also be lowered. In
addition, the big-end bearing bolts must be removed (description in work
sequence 1). Only in this condition can the crankshaft below the upper bear-
ing shell be taken out (see Work Card 030.04). Bearing shells can be
replaced as half-shells.
Work Cards, classified into sub-assemblies
V32/40
2009-05-07 - de
7. Turn the crankshaft by 20 – 25° (in the direction of the big-end bearing to
be removed) (see figure 3).
Connecting rod/Big-end bearing
8. Affix two rope guides (030.261 and 030.262) to balance weights (8) so
that these can still be moved.
9. Screw the rope guide (030.321) to the cylinder crankcase (2) (see figure
3, View Y).
10. Lay the wire rope (200.067) over the rope guides and using shackles
(002.452) affix it to retainers (see figure 3).
11. Append ratchet hoist (002.552) at a suitable location. Hook the wire rope
into the ratchet hoist and secure with wire rope clamp (030.535-7) (see
figure 3). Tension the wire rope.
12. Screw the guide tubes (030.268) into the big-end bearing body and
screw the extension pipe (030.269) in position.
13. Screw the screw-on plate (030.320) to the cylinder crankcase (2) and
screw the support fixture (030.536) to the screwing-on plate depending
upon the relevant cylinder bank
(see figure 3, View X).
14. Unscrew two hexagon bolts (1) from the big-end bearing body.
15. Lower the crankshaft bearing cap onto the support by actuating the
ratchet hoist (see figure 3).
16. Remove the rope guides between the balance weights and the wire
rope.
17. Clean the running surface of the big-end bearing shell (13).
Work Cards, classified into sub-assemblies
V32/40
2009-05-07 - de
Figure 2: Image of the assembled bolt extractor and the big-end bearing bolt
The condition of the upper bearing shell is primarily decisive for the
assessment of the big-end bearing. See Work Card 030.04. The lower
bearing shell is to be checked in conjunction with these tasks, espe-
cially in the event that damage has been detected on the upper bearing
Work steps 1. Take out the big-end bearing shell (13) from the big-end bearing cap (6).
2. Check the condition of the running surface of the lower big-end bearing
shell (see Work Card 000.11).
The bearing shells are numbered consecutively during initial assembly. When
installing new bearing shells, these are to be marked in the same way with
the corresponding number.
V32/40
New bearing shells are delivered ready for installation. Neither the joint face
2009-05-07 - de
for bearing shells in use nor new ones should be filed off or mechanically pro-
cessed in order to achieve a clearance reduction since this would lead to a
2009-05-07 - de
Work steps The installation procedure is the same as the removal procedure but in
reverse. In doing so, observe the following points:
1. When joining the big-end bearing cap (6) to the big-end bearing body
(10) take note of the locating pins.
Summary
Carry out the work in due time according to the maintenance schedule,
ensure the bearings' operational safety.
The big-end bearing shells must be checked at regular intervals. To do so,
the big-end bearing cap must be lowered and the big-end bearing bolts
must be dismantled.
The work/work steps include:
inspecting the bearing shells,
removing components,
refitting components.
Safety requirements
▪ Driving shaft secured against turning
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
Technical data
Designation Information
Bearing shell 2,5 kg
2007-10-25 - de
3. Turn the drive gear so that the crank pins on the crankshaft (5) are hori-
zontal.
While turning the pistons, ensure that the big-end bearing body follows
the crankshaft.
When turning the crank pin away, observe the big-end bearing shell to
ensure that it does not fall out or is damaged.
Starting position The big-end bearing shell has been cleaned, the rear is oil dry, the running
surface is well lubricated.
2007-10-25 - de
reverse. In doing so, when installing the upper big-end bearing shell (16) into
the big-end bearing body (10) attention is to be given to how the bearing
shell is anchored.
When turning the crankshaft into the BDC position, ensure that the
Big-end bearing
Summary
Ensure correct execution of work, allow emergency mode.
Big-end bearings do not need to be removed when performing normal main-
tenance work. This is necessary only in special cases, e.g. emergency oper-
ation of the engine with dismantled running gear and closed oil hole.
The work/work steps include:
Removing components,
installing components.
Safety requirements
▪ Driving shaft secured against turning
▪ Engine secured against starting
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 030.313 Standard
1 Screw-on plate 030.320 Standard
1 Slide piece 030.313-10 Standard
1 Rope - Inventory
2008-01-08 - de
Technical data
Designation Information
Big-end bearing cap 44,5 kg
Big-end bearing body 48,5 kg
Work steps 1. Turn the crankshaft (5) until the big-end bearing is horizontal (see figure
1).
2. Unscrew the nut (3) from the lower connecting rod bolt (4).
3. Fit the sliding block (030.313-10) to the big-end bearing cap (6) (see fig-
ure 1).
4. Remove turning stirrup (030.260) whilst holding the big-end bearing with
the slide piece.
Work Cards, classified into sub-assemblies
5. Turn the crankshaft through 90°, keep the big-end bearing with sliding
block horizontal (see figure 2).
Hold the big-end bearing with slide piece until both parts are in posi-
tion.
6. Insert the support (030.313-30) into the drive casing and place onto the
hexagon bolts (2) (see figure 2).
7. Turn the crankshaft back until the big-end bearing and sliding block is in
position. If necessary release the hexagon bolts (1) and re-align the slid-
ing block (see figure 3).
8. Unscrew a conrod shank bolt (7) at the bottom of the big-end bearing
body (10).
V32/40
2008-01-08 - de
9. Place the plate (030.313-45) in position and screw the guide rod
(030.313-40) through the plate in the connecting rod body (see figure 4).
10. Place screw-on plate (030.320) on the studs (11) and fix to the cylinder
crankcase (9) with hexagon nuts (12) (see figure 4).
When extracting, make sure the big-end bearing shell (15) does not fall
out and therefore become damaged.
When putting down the big-end bearing body, make sure that the big-
end bearing bolts and the conrod shank bolts are not damaged.
19. Remove the bracket and screw-on plate and fit on the opposite side (see
figure 6).
20. Pull the big-end bearing cap outwards (see figure 6).
When extracting, make sure the big-end bearing shell (14) does not fall
out and therefore become damaged.
Work Cards, classified into sub-assemblies
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2008-01-08 - de
2008-01-08 - de
Work steps 1. Note the position of the mark that identifies the exhaust counter side
before installing the big-end bearing cap (6) or body (10).
2. Fix the strap (030.244) onto the big-end bearing cap. Screw the lifting
eye bolt (000.141) into the strap.
3. Fasten the rope (17) with shackle (002.452) to the lifting eye bolt. Attach
rope to lifting tackle.
4. Fit the sliding block (030.313-10) to the big-end bearing cap (see figure
6).
V32/40
2008-01-08 - de
5. Lift the big-end bearing cap and place onto bracket (see figure 6).
Remove strap.
6. Insert the big-end bearing shell (14) into the big-end bearing cap, taking
the bearing shell fixation into account.
Connecting rod/Big-end bearing
7. Push the big-end bearing cap forward onto the bracket and support until
it reaches the crank pin, turning the crankshaft (5) slightly if necessary.
When introducing the big-end bearing cap, make sure the big-end
bearing shell does not fall out and therefore become damaged.
8. Remove bracket and screw-on plate and mount on the opposite side.
9. Fasten the strap to the big-end bearing body.
10. Screw the guide rod (030.313-40) through the plate (030.313-45) in the
big-end bearing body (see figure 5).
11. Lift up the big-end bearing body and place it on the bracket, taking care
not to damage the big-end bearing bolt (4) and conrod shank bolt (7).
Remove strap.
12. Insert the big-end bearing shell (15) into the big-end bearing body, taking
the bearing shell fixation into account.
13. Displace the big-end bearing body on the bracket and support up to the
crank pin and make sure that the big-end bearing bolt (4) is not dam-
aged when introducing the big-end bearing cap (see figure 4).
When introducing the big-end bearing cap, make sure the big-end
bearing shell does not fall out and therefore become damaged.
14. When joining the big-end bearing body to the big-end bearing cap, note
the two locating pins (13).
Work Cards, classified into sub-assemblies
15. Screw the nut (3) onto the upper big-end bearing bolt until it makes con-
tact with the big-end bearing cap.
16. Remove the bracket, guide rod and plate.
17. Manually screw in the conrod shank bolt (7) into the big-end bearing
body until the contact face of the conrod shank bolts abut the big-end
bearing body (see figure 7).
18. Turn the crankshaft through approx. 99°, keep the big-end bearing with
sliding block horizontal (crankshaft with balance weight is vertical, see
figure 2).
Hold the big-end bearing with slide piece until the connecting rod has
been fixed to the balance weight with the turning stirrup.
V32/40
20. Turn the crankshaft back by 90º (crankshaft with balance weight is hori-
zontal, see figure 1)
21. Fix the big-end bearing with turning stirrup (030.260) onto the balance
weight (8) (see figure 1).
Piston/Piston rings
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
071 Dead centre indicator/Speed sensor
073 Crankcase cover/safety valve Work Cards, classified into sub-assemblies
100 Control device operating mechanism
101/102 Camshafts/Camshaft bearings
2010-08-06 - de
Piston
Piston/Piston rings
removal and installation
Summary
Carry out the work in due time according to the maintenance schedule,
ensure 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
repair work.
The work/work steps include:
Removing components,
installing components.
Safety requirements
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Tapered sleeve for inserting the pis- 034.100 Standard
ton rings
1 Tap wrench 034.097 Standard
Technical data
Designation Information
Piston with connecting rod shank 234 kg
purpose with a suitable agent, conrod shank bolts are released, running gear
2007-11-06 - de
at TDC.
Work steps 1. Clean the threaded holes in the piston crown with a manual tap
(034.096).
Piston/Piston rings
2. Lay the support (034.142-1) on the piston (7), screw in two hexagon
bolts and tighten the support to the piston using hexagon nuts. Attach
the rope (5) to the support with the shackle (002.453) (see figure 1).
3. Turn the pistons exactly to BDC and hook the rope to the lifting tackle.
4. Fasten turning stirrup (030.260) to the big-end bearing with hexagon
bolts (18) and to the balance weight (11) with a hexagon bolt (19) (see
figure 1).
5. Unscrew the nuts from the conrod shank bolts (13).
6. Screw two guide tubes (030.263) onto the inner conrod shank bolts until
they abut (see figure 1).
7. Pull out the piston upwards until the sliding block (030.264) can be
screwed on to the connecting rod (10) (see figure 1).
8. When pulling out further, remember that the base of the connecting rod
shank is lifted on slide pieces on the cylinder liner (see figure 1). Pull the
piston upwards over the cylinder liner until the pilot rod (034.006) can be
screwed into the carrier.
9. Pull the pistons carefully from the cylinder liner, in doing so use the pilot
rod as a guide.
When pulling out the base of the connecting rod shank, ensure that it
does not catch on the cylinder liner and that the cylinder liner running
surface is not damaged.
10. Place the pistons with the connecting rod shank (10) onto a wooden sur-
face.
11. Close the lube oil hole in the connecting rod shank and the big-end bear-
ing body to protect it from any dirt penetration.
12. Cover the opening that has been made in the cylinder liner.
3. Set the tapered sleeve (034.100) on the cylinder liner (9), lubricate the
interior surface well.
Piston/Piston rings
4. Affix the carrier (034.142-1) to the piston (7) (see work sequence 1, point
2), attach the rope (5) with the shackle (002.453) to the carrier and screw
the pilot rod (034.006) into the carrier. Attach rope to lifting tackle. Screw
sliding block (030.264) on to the base of the connecting rod shank.
5. Raise piston. Apply clean lubricating oil to piston rings and running sur-
face of piston.
6. Arrange piston ring joints as shown in Fig. 2.
During the insertion process, ensure that the conrod shank foot does
not damage the cylinder liner running surface.
Work Cards, classified into sub-assemblies
3. Unscrew the pilot rod and continue to lower the piston carefully to allow
the piston rings to slide through the lead-in sleeve in the cylinder lining.
Align the piston and connecting rod shank in good time so the holes in
the connecting rod shank are facing towards the corresponding guide
tubes.
4. Lower the piston until the connecting rod shank is guided by the guide
tubes (030.263) and the sliding block (030.264) can be removed (see fig-
ure 1).
5. Carefully continue to lower the piston until it touches the connecting rod
shank on the big-end bearing body. In doing so, observe the locating
pins on the joint face. To facilitate the insertion process, slightly release
the hexagon bolt on the balance weight (11) (see figure 1).
6. Use a feeler gauge (000.451) to check that the joint along the entire cir-
cumference is < 0.05 mm.
7. Unscrew the guide tubes and in doing so, ensure that the conrod shank
bolts do not rotate as well. Screw the nuts finger-tight on to the conrod
V32/40
shank bolts.
2007-11-06 - de
8. Remove the turning stirrup and tension the conrod shank bolts (see
Work Card 030.01)
9. Turn the piston to TDC, detach the rope and remove the tool.
Piston/Piston rings
10. Install the top land ring (see Work Card 050.01).
11. Remove the tread plate (if installed) from the oil sump, close the crank-
case.
Piston/Piston rings
Piston/Piston rings
inspecting
Summary
Carry out the work in good time according to the maintenance schedule,
ensure the work is carried out correctly, check the components as to their
state / extent of their wear.
The pistons and piston rings are to be checked with regard to the appear-
ance of their contact faces as well as the lubricating and wear condition.
The work/work steps include:
measuring components and
assessing the wear surface appearance / wear condition.
Tools/aids required
Quantity Designation Number Status
1 Piston ring expander 034.110 Standard
1 Thickness gauge (set) 000.451 Standard
1 Felt-tip pen/marker pen - Inventory
1 Dial gauge - Inventory
The piston running surface should have a uniform wear surface appear-
ance and be free of machining marks and other damage. Heavy
machining marks or wear points are signs of the following: the engine
has been overloaded; the cooling system is faulty; insufficient lubrica-
tion or the ingress of impurities between the piston and cylinder liner.
Do not damage the graphitated coating on the piston lower part (22)
Piston/Piston rings
when cleaning.
Work Cards, classified into sub-assemblies
For assessment of piston rings see Work Card 034.05 and 034.07.
Piston/Piston rings
10 Piston crown 22 Piston skirt
17 Compression ring
18 Compression ring A Piston ring groove depth
20 Oil control ring B Measuring point (¼A)
Figure 2: Measuring the axial clearance of the piston rings
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17 Compression ring
18 Compression ring
23 Locking lever
When removing and installing piston rings use piston ring pliers (see
figure 3). In order to tighten the piston rings, press down the locking
lever (23). The locking lever automatically returns to its original position
once it is released.
10 Piston crown
30 Dial gauge
Work Cards, classified into sub-assemblies
1. Using the piston ring pliers pull the piston rings onto the piston, in doing
so, position them according to the corresponding marking. Measure the
2007-10-19 - de
32/40
axial clearance of the piston rings in the grooves and record this in the
operation notes (see work sequence 1, point 3).
If a piston that has already been in use is installed into a different cylin-
Piston/Piston rings
der liner, the compression rings and the oil control rings must be
replaced and the cylinder liner will need to be rehoned. The engine
must be run in again (see Operating Instructions, section 3).
For piston ring and piston ring groove measurements and clearances, see
Operating Instructions, section 2.5.4.
A chrome ceramic coated compression ring (17) is fitted into the top piston
ring groove (ring groove 1) in the piston crown. The ring flank marked "TOP"
is the upper flank. The tapered edge on the interior diameter must be at the
top.
Chrome plated compression rings (18) are installed in the second and third
piston ring groove from the top (ring groove 2 and 3). The ring flank marked
"TOP" is the upper flank. The tapered edge on the interior diameter must be
at the top.
The oil control ring (20) with tubular spring must always be installed so that
the ring flank with the marking "TOP" faces upward.
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Piston/Piston rings
removing and installing/checking
Summary
Carry out the work in due time according to the maintenance schedule,
ensure the work is carried out correctly, check the components as to their
state / extent of their wear.
Piston pin and piston pin bush are to be checked at regular intervals and, are
hence to be dismounted.
The work/work steps include:
removing components,
installing components.
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 034.109 Option
1 Retaining bow 034.109-1 Option
1 Shackle A0.6 002.452 Standard
1 Shackle A1.0 002.453 Standard
1 Pliers for locking ring 002.165 Standard
1 Lifting eye bolt M16 000.143 Standard
1 Lifting tackle with rope - Inventory
Technical data
Work Cards, classified into sub-assemblies
Designation Information
Connecting rod shank 93,5 kg
Piston pin 31,5 kg
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32/40
Work sequence 1 - Removing the piston pin (and the piston pin bush)
1 Rope
2 Connecting rod shank
3 Piston pin
4 Piston
5 Wooden support
6 Locking ring
7 Piston pin bush
3. Slightly lift the connecting rod shank (2) so that the load is released from
the piston pin (3).
4. Remove the tilting protection from the connecting rod shank (2).
5. Remove the locking rings (6) and pull the piston pin (3) out as far as
shown in the figure. In doing so, protect the piston (4) from tilting.
6. Lift out the connecting rod shank (2) from the piston (4) and carefully
place it on the support. Unhook the rope (1) from the lifting tackle and
shackle.
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32/40
7. Install the retaining bow (034.109-1) into the piston pin (3) (see figure).
8. Attach the rope (1) with the shackle (002.452) to the retaining bow.
Attach rope to lifting tackle.
Piston/Piston rings
9. Carefully pull out the piston pin (3) fully.
10. Clean the piston pin (3) and the piston pin bush (7) and check for wear
(for a maximum permitted clearance, see Operating Instructions, section
2.5).
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Piston
Piston/Piston rings
dismantling 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.
The work/work steps include:
disassembling components,
assembling components.
Tools/aids required
Quantity Designation Number Status
1 Ratchet tool 008.023 Standard
1 Cross handle 001.891 Standard
1 Torque wrench 008.011 Standard
1 Pliers for the locking rings C 19-60 002.162 Standard
1 Pliers for locking ring 002.165 Standard
1 Socket spanner insert 32x20 001.797 Standard
1 Extension piece 20x400 001.914 Standard
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Technical data
Designation Information
Piston with piston rings, complete 118 kg
(9)
Figure 1: Piston (connecting rod and piston pin removed)
Piston/Piston rings
2. Hook the piston skirt (22) with the rope through the piston pin bore to the
lifting tackle, lift it up and place it on the wooden support (do not set it
onto the guide shoe (8)).
When lifting up the piston skirt, pay attention to the seating and con-
tact surfaces between the piston crown and the piston skirt and do not
damage them.
Work sequence 2 - Smoothing out the contact surface between the piston crown and the
piston skirt
Preliminary remark While an engine is in operation, heat seals may occur at the contact faces
between the piston crown and the piston skirt in localised spot welds which
can cause lifting of the material at the contact faces when the piston is being
removed.
Since, when the piston is being reassembled, the exact starting position can
no longer be achieved, the liftings in the material must be removed or
smoothed out.
Starting position The piston is dismantled and has been cleaned.
Work steps 1. Check the contact surface of the piston crown (10) and the piston skirt
(22) for raised points in the material.
In doing so, ensure in particular that the raised points in the material
are completely removed from the contact surfaces of the piston crown
and the piston skirt, since any remaining raised points can lead to high
selective point compressive stress.
Work steps
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1. Check resting surface of piston crown and skirt, they must be completely
clean and dry.
2. Hook the piston skirt (22) using the rope through the piston pin bore and
attach it to the lifting tackle, lift it up and carefully set it onto the piston
Piston/Piston rings
crown.
Before fitting the piston skirt, ensure the correct location of the bore in
the piston skirt to the clamping sleeve (16) in the piston crown.
When lowering the piston skirt do not get it twisted, pay attention to
the seating and contact surfaces between the piston crown and the
piston skirt and do not damage them.
3. Check the overall length of the hexagon bolts (9) dimension (A). Target
dimension: A ≦ 136.2 mm. (see fig. 1)
If the overall length of the hexagon bolts (9) exceeds the prescribed
target dimension (A) ≦ 136.2 mm the hexagon bolts (9) must be
replaced.
4. Brush the thread and contact face of the hexagon bolts (9) with special
anti-seize agent (Molykote G-n Plus) and screw them until they abut.
5. Tighten the hexagon bolts (9) with torque 200 Nm in two stages alter-
nately and release again.
6. Carry out the final tightening process in 2 steps:
7. Pre-tighten the hexagon bolts (9) with tightening torque 80 Nm.
8. Turn the hexagon bolts (9) on through tightening angle 90°.
Check: It must not be possible to further rotate the hexagon bolts (9) at tor-
Work Cards, classified into sub-assemblies
que 90 Nm.
1. Check the guide shoe (8) mobility.
2. Install the connecting rod shank and the piston pin (see Work Card
034.03). 2007-09-25 - de
32/40
Piston rings
Piston/Piston rings
assessing
Summary
Carry out the work in good time in accordance with the maintenance sched-
ule; check the components dimensionally, 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
maintenance 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 are in use with chrome coated or chrome ceramic coated
running surfaces and chrome plated oil control rings. See Table 1.
Ring Running surface Appearance
Compression rings
Groove 1 Chrome-ceramic coated net of cracks later
Groove 2 chrome coated uniformly grey
Oil control ring
A. As the wear increases, the running pattern area becomes wider and
2007-10-24 - de
wider.
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 working 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. Rings in this condition must be replaced. Figure 4.
Work Cards, classified into sub-assemblies
2007-10-24 - de
Piston/Piston rings
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 spallings 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.
Piston/Piston rings
assessing
Summary
Carry out the work in good time in accordance with the maintenance sched-
ule; check the components’ quality/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
maintenance schedule. They are also to be replaced if, during intermediate
checks, damage to the running surface is detected or there is too much
clearance.
In groove 1, piston rings with the chrome ceramic coated running surface are
in use. The ring version can be identified by the item number stamped on the
upper side of the piston rings.
As opposed to plasma coated or chrome plated rings, the appearance of the
coating of chrome ceramic coated rings changes significantly with increased
wear. The running surface of these rings when still new has a smooth metal-
lic appearance and is uniformly silver grey in colour. After several hundred
hours in operation, a network of cracks or individual longitudinal and trans-
verse cracks becomes visible. This is normal and is the result of hard metal-
oxide ceramic particles burying themselves into the network structure of the
2007-04-23 - de
Piston/Piston rings
Figure 3: Narrow longitudinal cracks in the running direction
This running surface appearance also shows a normal state of wear. The
entire surface is smooth.
Assessment: If the crack width is < approx. 0.1 mm, the piston ring can be
used without any restrictions and can continue to be used.
2007-04-23 - de
Summary
Carry out the work in good time according to the maintenance schedule,
ensure the work is carried out correctly, check the components as to their
state / extent of their wear.
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.
The work/work steps include:
removing components,
installing components.
Safety requirements
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 050.165 Standard
1 Carrier 050.165-1 Standard
055.02
Technical data
Designation Information
Top land ring 33,5 kg
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)!
Work steps 1. Remove any coke deposits on the top land ring (6) and around the cylin-
der liner (5) area. Cover the gap between the piston (7) and the cylinder
liner to prevent foreign objects from falling into it.
Work Cards, classified into sub-assemblies
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32/40
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8. Carefully pull the top land ring out upwards, using the pilot rod as a
guide.
9. Place the top land ring on the wooden support, remove the tools.
When fitting the top land ring, ensure the correct placement of the
marking (M) on the top land ring - backing ring.
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32/40
32/40
to the engine.
3. After completion of the fitting work check that the O-ring seals are OK
with the cooling water under pressure. No water coming out from the
Top land ring/cylinder liner
2007-09-24 - de
32/40
Cylinder liner
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
repair work.
The work/work steps include:
Measuring components and
Assessing contact pattern /wear condition.
Tools/aids required
Quantity Designation Number Status
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 over-
loads 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.
4. Determine the temperature of the cylinder liner (8) during the measure-
ment and make a note of the value.
5. Record the dimensions in the operating log sheet and compare them to
the maximum permitted values (see Volume 010.005 Engine - Operating
Instructions).
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 out-of-roundness is the difference between the measured
values (in the transverse and longitudinal direction of the engine) in one
plane.
Work Cards, classified into sub-assemblies
32/40;48/60B;V48/60CR
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32/40;48/60B;V48/60CR
2008-10-22 - de
2008-10-22 - de
Summary
Carry out the work in good time according to the maintenance schedule,
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.
The work/work steps include:
removing components,
installing components.
Tools/aids required
Quantity Designation Number Status
1 Suspension device 050.157 Standard
1 Carrier 050.157-1 Standard
3 Retaining bow 050.157-3 Standard
1 Removal and fitting fixture 050.099 Standard
1 Carrier 050.099-1 Standard
2 Thrust screw 050.099-15 Standard
1 Pilot rod 034.006 Standard
1 Shackle A1.6 002.454 Standard
2 Shackle A0.6 002.452 Standard
2 Lifting eye bolt M20 000.155 Standard
1 Combination spanner (set) - Inventory
1 Lifting tackle with rope - Inventory
Technical data
Designation Information
Cylinder liner 172,5 kg
Cylinder liner (with backing ring) 407,5 kg
Backing ring 233,5 kg
2007-07-18 - de
32/40
Preliminary remarks
State of wear and ovality are to be determined, the appearance of the run-
ning surface is to be assessed, the interior and exterior surfaces of the oil
bores are to be cleaned and the sealing rings are to be replaced. These
tasks provide valuable experience for running the engine and they make a
contribution to ensuring operational safety.
Under normal conditions cylinder liners are pulled out without removing the
backing ring. They only need to be removed together if the backing ring
needs to be replaced or there needs to be better accessibility.
Work Cards, classified into sub-assemblies
3. Fasten the carrier using hexagon bolts (3) to the backing ring, in doing
so, ensure that the branch socket for the pilot rod (034.006) is located on
When removing the cylinder liner, do not damage the cylinder head
bolts.
6 Cylinder liner
16 Hexagon bolt M8x20
32/40
Make sure that the mark (M) backing ring-cylinder liner is correctly
located (see figure 3).
When placing the carrier onto the backing ring, ensure that the branch
socket for the pilot rod is positioned on the exhaust counter side (AGS).
Work Cards, classified into sub-assemblies
Ensure that the backing ring is positioned in line with the sleeves (8).
Avoid damaging the cylinder head bolts (1) during installation.
12. After completing the assembly tasks (cylinder head attached, cylinder
head bolts tightened, etc.), check, at the existing cooling water pressure
32/40
Summary
Carry out the work in due time according to the maintenance schedule,
measure components, assess surface/wear condition.
The cylinder liners must be removed and cleaned at regular intervals.
The work/work steps include:
removing components,
installing components.
Tools/aids required
Quantity Designation Number Status
2 Spacer pipe 050.133 Standard
1 Removal and fitting fixture 050.129 Standard
1 Cross tie 050.129-1 Standard
1 Carrier (upper) 050.129-5 Standard
1 Carrier (lower) 050.129-12 Standard
1 Spindle (short) 050.129-21 Standard
1 Spindle (long) 050.129-27 Standard
1 Spherical disc 050.129-33 Standard
1 Ball socket 050.129-34 Standard
1 Suspension device 050.157 Standard
1 Carrier 050.157-1 Standard
3 Retaining bow 050.157-3 Standard
1 Shackle A0.6 002.452 Standard
Technical data
2007-09-24 - de
32/40
Designation Information
Cylinder liner 172,5 kg
Preliminary remarks
State of wear and ovality of the cylinder liners are to be determined, the
appearance of the running surface is to be analysed, the interior and exterior
surfaces of the oil holes to be cleaned and the sealing rings are to be
replaced. These tasks provide valuable experience for running the engine
and they make a contribution to ensuring operational safety.
Under normal conditions cylinder liners are pulled out without removing the
backing ring. They only need to be removed together if the backing ring
needs to be replaced or there needs to be better accessibility.
Work Cards, classified into sub-assemblies
3. Insert the long spindle (050.129-27) into the carrier and fix in position
with the hexagon nut (8).
4. Place the upper carrier (050.129-5) on the spindle, place on the cylinder
liner and fix in position with hexagon nut (8).
5. Screw the spindle (050.129-21) onto the long spindle, place the cross tie
(050.129-1) over the spindle and place on the backing ring (4).
When attaching the cross tie, pay attention to the sleeve (11).
6. Insert the ball socket (050.219-34) over the spindle and attach it to the
cross tie.
7. Lubricate the spherical disc (050.129-33) and attach it above the spindle
onto the ball socket. Screw on the collar nut (3).
8. Plug the spacer pipes (050.133) diagonally over the cylinder head bolts
(1) and fix them with the nuts (12).
9. Cover the crankcase using suitable means, especially on the side, to pre-
vent dirt from penetrating into the cooling chambers in the big-end and
crankshaft bearings.
10. By tightening the collar nut, release the cylinder liner and pull it up.
On V engines remove the cross tie (050.129-1) and fix the shackle on
the suspension point on the rib
When removing the cylinder liner make sure that the cylinder head bolts
are not damaged.
32/40
6 Cylinder liner
16 Hexagon bolt M8x20
2007-09-24 - de
32/40
2. Screw the ring nut (000.186) onto the spindle, suspend the rope (2) from
the shackle (002.454) and lifting tackle and fix onto the ring nut. Lift the
cylinder liner.
When fitting the cylinder liner take care with the correct location of the
mark (M) backing ring-cylinder liner and for lack of damage to the cylin-
der head bolts. (figure 4).
32/40
2007-09-24 - de
32/40
Cylinder liner
Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, check components for state/wear condition, re-cre-
ate running surface.
Cylinder liners should be checked at regular intervals and the original running
surface geometry must be re-created.
The work/work steps include:
Honing the reversing area of the piston rings,
Honing the entire running surface.
Tools/aids required
Quantity Designation Number Status
1 Honing device 050.152 Option
1 Rope pull with remote control 050.152-1 Option
1 Cross bar 050.152-2 Option
2 Intermediate piece 050.152-5 Option
4 Stop for stroke limiter 050.152-6 Option
1 Guide arm with control valve 050.152-7 Option
1 Extension 050.152-8 Option
1 Drive unit 050.152-9 Option
1 Air connection with universal joint 050.152-10 Option
1 Honing head 050.152-11 Option
1 Container 050.152-12 Option
1 Funnel 050.152-13 Option
1 Rope - Inventory
1 Cleaning agent (diesel oil / kerosene) - Inventory
Preliminary remarks
The cylinder liners must be rehoned when the piston rings are replaced, or if
the maintenance interval has expired. Honing restores the original roughness
of the cylinder liner running surface. This is necessary to ensure the lubricat-
ing film is thick enough and has sufficient adhesion. While the original micro-
geometry can be extensively restored through honing, it is not possible to
influence the wear profile, i.e. the macrogeometry of the cylinder liner.
The piston rings are normally honed in the TDC area during the first honing
operation, and the entire running surface of the piston rings is honed during
the second.
The cylinder liner honing operation is not particularly time consuming. How-
ever, due care and attention, as well as a certain amount of experience, is
required to operate the device, carry out the work and assess the results. We
therefore recommend you have this work carried out by MAN Diesel & Turbo
personnel, even if this is only once for instruction purposes.
off. The contact pressure of the honing elements is regulated with the sliding
valve located alongside.
Using the lubricating device, consisting of tank (20) and spray nozzles (18)
the grinding area can be lubricated and cleansed of abrasion particles. The
2009-03-09 - de
edge of the cylinder liner, and from there it is guided outward. When switch-
ing from grinding strips to cleaning brushes (14), it is possible to mechanically
Work sequence 1 - Honing the piston ring reversal point in the top dead centre (nip area)
Starting position Cylinder head removed, piston with connecting rod shank removed, big-end
bearing with turning stirrup fastened to balance weight and turned aside far
enough to allow the funnel to be installed. Cylinder liner cleaned (no traces of
coke and lubricating oil) and measured (cylinder liner has not yet reached the
maximum wear dimensions; for limit values see Volume 010.005 Engine -
Operating Instructions). Outlet of cylinder lubrication bores sealed with mod-
elling clay (plasticine) or high-viscosity grease. Crank mechanism covered
with suitable material. Funnel fastened at bottom on cylinder liner and hose
routed to an external collecting tank. Honing device set up and adjusted
according to separate description.
The piston ring reversal points are to be honed as a first work step
using short honing stones before the entire running surface of the pis-
ton ring is honed during a subsequent work step (see work sequence
2).
Work steps 1. Clamp honing stones (20 mm lg.) in each grinding bar (13) at the same
height in the central section of the grinding bar.
The short honing stones can be produced by breaking long honing ele-
ments: Notch using a steel hacksaw blade, clamp in vice and break off.
8. Open the tank's shut-off valve. Check that lubricant is discharged from
the spray nozzles and is coating the honing area. Check that lubricant is
Top land ring/cylinder liner
reaching the collecting tank (32) via the funnel (16) without leaking.
Honing a cylinder liner needs about 4-6 litres of lubricant. Always make
sure a sufficient quantity of lubricant is used when performing the hon-
ing process. It is advantageous to wash away abraded material imme-
diately.
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.
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.
Work Cards, classified into sub-assemblies
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 on honing head (15).
V32/40;V32/40PGI
2. Guide honing head carefully into the cylinder liner (19) and readjust ball
bearing guides (24) if required.
3. Adjust the stroke movement of the honing head with stops (4) so that the
honing stones move in the upper half of the piston's travel range (running
area of piston rings), i.e. the upper and lower edges of the stone travel
2009-03-09 - de
4. Align spray nozzles (18) so that lubricant coats the honing area on exit-
ing. Fill the container (20) with lubricant (diesel oil, gas oil or petroleum).
5. Open the tank's shut-off valve. Check that lubricant is discharged from
the spray nozzles and is coating the honing area. Check that lubricant is
reaching the collecting tank (32) via the funnel (16) without leaking.
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.
11. Remove the honing device. Move to next cylinder or clean the device
and store it safely, or stow it away in a packing box.
12. Remove modelling clay or grease stopper completely from the cylinder
lubrication bores. Actuate the cylinder lube oil pump to wash away resi-
Top land ring/cylinder liner
Type Lifting height (mm) Rotational speed Number of double Time for each Number of double
(rpm) strokes per minute Double stroke * strokes required
(s)
32/40 450 35 18 3.3 60 - 65
Table 1: Processing parameters for the honing of cylinder liners
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2009-03-09 - de
2009-03-09 - de
Summary
Carry out the work in due time according to the maintenance schedule,
ensure operational safety of the bolted connections.
Cylinder head bolts are to be checked at regular intervals using hydraulic ten-
sioners.
The work/work steps include:
Checking bolted connections,
loosening them,
tightening them.
Safety requirements
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Tension screw 055.157 Standard
2 Thrust piece 055.156 Standard
2 Thrust piece 030.243 Standard
1 High-pressure pump 009.342 Standard
1 Hydraulic hand pump 009.320 Standard
4 High-pressure hose 009.306 Standard
2 Hydraulic tensioner 009.097 Standard
2 Hydraulic tensioner 009.096 Standard
tred.
5. Push the thrust pieces (030.243) over the cylinder head bolts on the
exhaust counter side.
6. Screw on the tensioning cylinder (009.097) onto the cylinder head bolts;
in the process, make sure that the tensioning cylinder thrust piece is cen-
tred.
Before installing the tensioning cylinder ensure that the pistons are
completely pressed in.
11. Make a note of the release pressure and compare it to the specified
locking pressure.
12. Adjust high-pressure pump to the specified clamping pressure or acti-
vate hydraulic hand pump up to the specified clamping pressure and
Work Cards, classified into sub-assemblies
6. Screw on the tensioning cylinder (009.097) onto the cylinder head bolts;
in the process, make sure that the tensioning cylinder thrust piece is cen-
Cylinder head/Valve seat rings/Safety valve
tred.
Before installing the tensioning cylinder ensure that the pistons are
completely pressed in.
2009-01-29 - de
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
repair work.
The work/work steps include:
Removing components,
installing components.
Safety requirements
▪ Operating media systems closed/depressurised
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Suspension device 055.205 Standard
1 Carrier 055.205-1 Standard
1 Pilot rod 034.006 Standard
1 Shackle A1.6 002.454 Standard
1 Lifting tackle with rope - Inventory
1 Combination spanner (set) - Inventory
1 Grease (acid-free) - Inventory
Technical data
Designation Information
Cylinder head, complete 750 kg
Cylinder head 525 kg
2009-03-10 - de
32/40
Starting position Cooling water in the engine has been lowered to below the cylinder heads,
cooling water for the injection valves has been drained.
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)!
2009-03-10 - de
32/40
32/40
Take care to select the correct suspension point (see figure 1).
Cylinder head/Valve seat rings/Safety valve
Do not damage the cylinder head bolts (5) and the studs (8).
13. Close all openings on the engine using suitable means, close off the
exhaust connection with the closing cover.
14. Clean the cylinder head (see Work Card 055.03).
6. Insert new O-ring seals (7 and 20) that have been lubricated with acid-
free grease in the ring grooves, making sure they are evenly tensioned all
Do not damage the stud bolts (8) and cylinder head bolts (5); observe
the position of the sleeves (10, 19 and 22).
8. Screw the nuts (6) onto the cylinder head bolts (5).
9. Push pipe couplings over the charge air pipe section (17) and fasten.
10. Mount exhaust pipe on cylinder head and attach casing.
11. Attach delivery pipe of fuel injection pipe (see Work Cards 221.01 and
434.01).
12. Attach all pipes and pipe mountings to the cylinder head and attach the
starting valve.
13. Tighten the cylinder head bolts to the prescribed tightening pressure (see
Work Card 055.01).
14. Check the valve clearance and readjust if necessary (see Work Card
111.02).
15. Fill up the cylinder head and injection valve cooling system with cooling
water, vent the cooling water pipes.
16. Open all closed cocks.
32/40
Cylinder head
Summary
Carry out the work in due time according to the maintenance schedule,
ensure/restore operational safety.
Cylinder heads have to be cleaned from soot and coke deposits at regular
intervals.
This includes:
Cleaning the components
Tools/aids required
Quantity Designation Number Status
1 Degreasing and cold cleaning agent - Inventory
1 Cleaning trough - Inventory
1 Wire brush - Inventory
1 Safety goggles - Inventory
1 Protective gloves - Inventory
2009-04-28 - de
Sealing face on the cylinder head and the sealing groove in the top land ring
Summary
Check components for condition/wear condition, prevent operating prob-
lems/damage.
The sealing face on the cylinder head or in the top land ring must be
checked every time the cylinder head is removed, and, if necessary, re-
worked.
The work includes:
Grinding the sealing face or the sealing groove.
Tools/aids required
Quantity Designation Number Status
1 Grinding-in fixture 050.119 Option
1 Grinding wheel 050.119-1 Option
2 Bow 050.119-2 Option
1 Shackle A0.6 002.452 Standard
1 Lifting eye bolt M12 000.142 Standard
1 Combination spanner (set) - Inventory
1 Depth gauge - Inventory
1 Grinding paste, silicon-free - Inventory
The grinding tool can be used for the cylinder head and top land ring.
The correct side in each case is shown in Fig. 1.
For a refinished sealing face or sealing groove, gap (A) between the cyl-
inder head and top land ring must be at least 0.5 mm (see figure 2 in the
"work sequence" section).
2007-10-31 - de
32/40
Work sequence 1 - Grinding the sealing face on the cylinder head or sealing groove in
the top land ring
Work Cards, classified into sub-assemblies
Starting position The cylinder head has been removed and has been clamped into the turn-
over stand. The top land ring has been removed and the sealing ring has
been taken out.
Work steps 1. Affix the bow (050.119-2) to the grinding wheel (050.119-1), in doing so,
pay attention to whether the sealing face (B) or the sealing groove (C) is
to be ground.
2. Apply grinding paste to the grinding wheel.
3. Set the grinding tool onto the sealing face or insert it in the sealing
groove, see figure 1.
2007-10-31 - de
32/40
If necessary, hook the grinding tool with the shackle (002.452) to the
4. Rotate the grinding tool back and forth, lift it up every now and then so
that the grinding paste can be redistributed.
Only grind off as much material until the sealing face or the sealing
groove is bare and undamaged, therefore check the sealing face or the
sealing groove during the grinding process often.
5. Once the grinding process has been completed, remove the grinding
tool (050.119) and carefully clean the sealing face or the sealing groove.
6. By measuring the difference, determine the size of gap (A) between the
cylinder head (2) and the top land ring (3) at numerous points. Minimum
gap: 0.5 mm
2 Cylinder head
3 Top land ring
4 Sealing ring
5 Cylinder liner
6 Backing ring
A Gap
Figure 2: Gap between the top land ring –cylinder liner when the sealing ring is fitted
2007-10-31 - de
32/40
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
Quantity Designation Number Status
1 Turnover stand 055.153 Option
1 Combination spanner (set) - Inventory
Technical data
Designation Information
Cylinder head 32/40 503 kg
Cylinder head 32/40 PGI 515 kg
Cylinder head 32/44 CR 538 kg
General
The turnover stand is suitable for:
▪ thoroughly cleaning and checking the cylinder head (see Work Card
055.03),
Work steps 1. Affix the adapter plates (2 and 9) to the cylinder head (8).
2. By turning the hand wheel on the shuttle gearbox (3), place the adapter
head (4) in such a way that the support bracket (5) is at the top (see fig-
ure).
3. Open the support bracket and the locking latch (10).
4. Set the cylinder head down (see figure) and clamp it down with the sup-
2008-09-19 - de
5. Remove the suspension device. With a locking lever (7) flipped upward,
the cylinder head may now be brought into any desired position by turn-
Cylinder head/Valve seat rings/Safety valve
6. The adapter plates can be left attached to the frame (1) for storage.
valves)
5 Support bracket 10 Locking latch
Figure 1: The cylinder head is mounted in the turnover stand
32/40;32/44CR;V32/40PGI
2008-09-19 - de
Speed sensor
Summary
Execute work on time according to the maintenance schedule, free compo-
nents from dirt/residues, ensure / restore operational safety.
Check speed sensors at regular intervals and replace if necessary.
The work / work steps include:
Removing components,
checking parts/ components,
installing components.
Safety requirements
▪ Engine secured against starting
▪ Engine shut down
▪ Power supply/generation interrupted
Tools/aids required
Quantity Designation Number Status
1 Thickness gauges 0.05-1 000.451 Option
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
Work sequence 1 - Checking the speed sensor Work Cards, classified into sub-assemblies
Starting position Engine shut off.
Work steps 1. Check the cable (8) to the speed sensors (3).
2. Turn the crankshaft (1) with flywheel (2) so that the front end of a gear
tooth is positioned at the centre of the speed sensor.
3. Measure the distance (F) between the front end of the gear tooth and the
speed pick-up with feeler gauge (000.451).
Distance (F) = 1.0 ... 3.0 mm.
4. Check the remaining speed sensors in the same manner.
Engines without a Slow Turn facility are less likely to be fitted with a
speed sensor.
2007-10-31 - de
32/40
Work steps 1. Pull out plug (11) from relevant revolution recorder (3).
2. Turn the crankshaft (1) with flywheel (2) so that the front end of a gear
tooth is positioned at the centre of the speed sensor.
3. Unscrew the hexagon nuts (5) of the relevant revolution recorder and pull
the revolution recorder from the holder (4).
4. Unscrew the hexagon nut on the new revolution recorder.
5. Fit the revolution recorder to the holder (4) with hexagon nuts (5) (see fig-
ure 1).
6. Insert the feeler gauge (000.451) between the front end of the gear tooth
and the speed sensor at distance (F).
7. Screw the hexagon nuts (5) in alternately until the feeler gauge is a tight
fit.
2007-10-31 - de
32/40
After final tightening of the hexagon nuts (5) check the gap (F) once
again.
32/40
Summary
Carry out the work in due time according to the maintenance schedule,
ensure/restore operational safety.
Safety valves on crankcase covers must be checked for ease of motion at
regular intervals.
The work includes:
Checking parts/components.
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
Technical data
Designation Information
Crankcase cover with safety valve 16,5 kg
Preliminary remarks
The purpose of checking the ease of movement of all safety valves mounted
on the crankcase is to ensure that increases in pressure/pressure waves,
e.g. following an explosion, can be safely reduced.
32/40
5. Fit crankcase cover and fix in position with hexagon nuts and washers.
5 Compression spring
Figure 1: Safety valve fitted to the crankcase cover
2009-03-10 - de
32/40
Summary
Carry out the work in due time according to the maintenance schedule,
ensure operational safety of the bolted connections.
Studs for intermediate wheel axles are to be checked at regular intervals
using hydraulic tensioners.
The work/work steps include:
determining and evaluating the loosening pressure and
tightening the connection as per specified pressure.
Safety requirements
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Thrust piece 030.243 Standard
2 Tensioning screw 021.251 Standard
2 Intermediate ring 021.250 Standard
32/40
1 Axle 6 Washer
Work Cards, classified into sub-assemblies
6. Push the thrust pieces (030.243) over the nuts (2) and screw the tension-
ing cylinder (009.096) until it abuts.
7. Push the intermediate rings (021.250) over the tension screws and screw
the tensioning cylinder (009.097) until it abuts the intermediate rings on
The pressure must lie max. 7% under or 5% over the tension pressure
(see Work Cards 000.30 and 000.33).
12. Make a note of the release pressure and compare it to the clamping
pressure.
13. Set the high-pressure pump to the specified clamping pressure or
actuate the hydraulic hand pump until the specified clamping pressure
has been reached and tighten both nuts hand-tight.
14. Release pressure and remove tandem tensioners.
15. Place the side disc (9) on axle (1) for double spur wheel (8).
16. Fasten the washers (6) using the hexagon bolts (4) including the new
lockwashers (5) to the axles.
17. Attach the covering (11) onto the coupling side and the crankshaft exter-
nal bearing.
18. Reset the pistons of the tensioning cylinders (see Work Card 009.01).
32/40
2007-10-31 - de
32/40
Summary
Carry out tasks in due time according to the maintenance schedule, check
the components for their quality / wear condition
The camshaft drive must be checked at regular intervals for any variances,
the contact pattern is to be analysed so that any source for disturbances can
be recognised in due time and if needed can be removed.
The work includes:
Checking parts/components.
Tools/aids required
Quantity Designation Number Status
1 Thickness gauges 0.05-1 000.451 Option
1 Combination spanner (set) - Inventory
Preliminary remarks
We recommend having overhaul work to the camshaft drive performed at a
customer service support point or by a MAN Diesel & Turbo fitter.
2009-06-24 - de
Camshafts/Camshaft bearings
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
071 Dead centre indicator/Speed sensor
073 Crankcase cover/safety valve Work Cards, classified into sub-assemblies
100 Control device operating mechanism
101/102 Camshafts/Camshaft bearings
2010-08-06 - de
Injection camshaft
Camshafts/Camshaft bearings
Removing and installing camshaft section
Summary
Ensure correct execution of work, fit/adjust components properly.
The removal and fitting of camshaft sections is not among the activities
specified in the service schedule. This is required for repairs and requires a
considerable measure of technical expertise.
The work/work steps include:
Removing components,
installing components,
Logging the measured values.
Safety requirements
▪ Driving shaft secured against turning
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
32/40
Technical data
Designation Information
Camshaft section 45 kg
Preliminary remarks
The replacement of camshaft sections is only required in case of damage
and is to be considered purely as repair work. Before actually removing the
damaged camshaft section certain measured values need to be made or
determined in order to recreate the original condition when subsequently fit-
ting the new camshaft section. On IMO certified engines the value quoted for
the plunger lift, quoted in the acceptance test record or IMO certification,
must be set again. If the specified setting range is not complied with the cer-
tificate will become void.
Work steps 1. Unscrew the hexagon socket bolts (4) and remove the lubricating oil line
(1) to the thrust bearing.
2. Unscrew hexagon bolts (2) and remove thrust bearing of the injection
camshaft (3).
3. Mark the location of the camshaft section with a marker pen (e.g. at the
point of maximum cam lift)
4. Place the rope sling from the outside, or through the hole in the pump
drive, over the camshaft section and slightly tighten the rope with the lift-
ing tackle.
5. Release the screwed connections (7, 8) of the camshaft section (11) and
unscrew the hexagon nuts (8).
6. Remove the screwed connection (9) of the camshaft section (11).
7. Separate the camshaft by displacement in the axial direction (see figure 1
at the bottom). Make sure that the camshaft section to be removed (11)
is pulled out of the centrings of the bearing rings (10) completely.
2007-10-31 - de
8. Remove the camshaft section through the opening on the cylinder crank-
32/40
case (5).
Camshafts/Camshaft bearings
1 Lube oil pipe 5 Cylinder crankcase 9 Hexagon bolt
2 Hexagon bolt 6 Fuel injection pump 10 Bearing ring
3 Thrust bearing 7 Hexagon bolt 11 Camshaft section
4 Hexagon socket bolt 8 Hexagon nut 12 Rope
Figure 1: Removing the camshaft section (illustration shows in-line engine)
32/40
8. Tighten the camshaft bolted connections with MoS2 lubricant and pre-
scribed tightening torque (see Work Card 000.30).
9. Determine and adjust the plunger lift of the subsequent camshaft sec-
tions (seen in the direction of the camshaft drive) in the same way.
Camshafts/Camshaft bearings
2007-10-31 - de
32/40
Injection/valve camshaft
Camshafts/Camshaft bearings
Check thrust bearing
Summary
Check components for state/wear condition, ensure/ restore operational
safety.
Examine the thrust bearings of the valve and injection camshaft regular inter-
vals for damage, determine the axial clearance. This helps detect changes /
problem sources in a timely manner and rectify them if necessary.
The work includes:
Checking parts/components.
Tools/aids required
Quantity Designation Number Status
1 Shackle A0.6 002.452 Standard
1 Lifting eye bolt M12 000.142 Standard
1 Combination spanner (set) - Inventory
1 Lifting tackle with rope - Inventory
1 Sliding calliper - Inventory
1 Depth gauge - Inventory
1 Sealing compound - Inventory
1 Grease (acid-free) - Inventory
32/40
2. Clean all the components and check for damage. Replace if necessary.
3. Determine the projection (A) on the butting disc and the dimension (B) on
the bearing body and note them down. Calculate the axial clearance
from the measurements and compare with the permissible clearance.
Refer to the Operating Instructions section 2.5.
4. Check the bearing bush (3) for damage or grooves caused by dirt (see
Work Card 000.11), replace if necessary.
2009-01-15 - de
32/40
Camshafts/Camshaft bearings
7 Bearing body A Projection
8 Butting disc B Dimension
Figure 2: Measuring the projections to determine the axial clearance
1. Screw lifting eye bolt (000.142) into bearing body (7), fasten rope to lifting
eye bolt with shackle (002.452) and suspend rope from lifting tackle.
2. Place new O-ring seal (12) coated with acid-free grease in ring groove,
ensuring that it is not twisted.
3. Lightly oil the running surface of the bearing bush (3).
4. Fit the bearing body carefully, making sure that the oil bore (13) is at the
bottom.
5. Screw the hexagon bolts (5) in position hand-tight.
6. Oil the contact face of the butting disc (8) and fit in position.
32/40
Summary
Carry out the work in good time in accordance with the maintenance sched-
ule; check the components’ quality/wear condition.
The rotation vibration damper on the valve camshaft must be inspected for
the appearance of wear in the sleeve spring packets at regular intervals.
The work includes:
Checking parts/components.
Tools/aids required
Quantity Designation Number Status
1 Pipe clamp 027.019 Standard
1 Removing fixture 027.018 Standard
1 Ratchet tool 008.023 Standard
1 Torque wrench 008.011 Standard
1 Extension piece 12.5x250 001.912 Option
1 Socket spanner insert 19x12.5 001.755 Option
1 Eye bolt 000.028 Standard
1 Lifting tackle - Inventory
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Rope - Inventory
1 Sealing compound (Silicone Rhodor- - Inventory
sil)
1 Lubricant (containing molybdenum - Inventory
Technical data
Designation Information
V32/40;V32/40PGI
Number the spring sleeve packets, bolts and bores, because when
being reinstalled, the spring sleeve packets and bolts of one bore must
be installed in the same ones.
Never remove all bolts and spring sleeve assemblies at the same time,
i.e. in every second bore, the bolt and the sleeve spring assembly
remain installed.
6. Pull out the sleeve spring pack (9) using the removing tool (027.018).
7. Clean the bolt (8) and sleeve spring packet (9) and check them, if neces-
sary replace them.
In the event of broken springs, replace entire sleeve spring pack only.
lubricant.
10. Compress the sleeve spring packets (9) using the clamp (027.019) and
insert it into the bore. Remove the clamp and press the sleeve spring
packet in completely using appropriate means (e.g. a copper bar).
11. Brush the bolts (8) with MoS2 lubricant and insert them.
12. Attach the side disc (14) and locate on the torsional vibration damper.
13. Brush the threads and the contact surface of the hexagon bolts (13)
using MoS2 lubricant, screw them in and tighten them using the specified
torque (see Work Card 000.30).
14. Place the cap (11) on the damper carrier (12), align centrally and fix in
position with hexagon socket bolts (10).
V32/40;V32/40PGI
15. Clean contact face on the cap (4) and cylinder crankcase.
16. Release the hexagon bolts (5) to permit alignment of the cap (6) during
fitting.
17. Brush the abutting surface between the cover (4) and the cylinder crank-
2007-10-29 - de
18. Fit the cap (4), including block distributor (1), cap (6) with oil supply and
oil pump (7).
2007-10-29 - de
Valve clearance
Summary
Carry out the work in accordance with the maintenance plan in good time,
enable/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
▪ Drive shaft secured to prevent it from rotating
▪ Engine secured against starting up
▪ Engine stopped
Tools/aids required
Quantity Designation Number Status
1 Locating device 113.227 Standard
2 Fixing screw 113.227-1 Standard
1 Setting device 113.226 Standard
Preliminary remarks
Execute an inspection and adjustment, if necessary, for the valve clearance,
2010-07-16 - de
during commissioning, when new parts are installed or the rocker arms are
re-fitted after servicing activities.
Running gear of relevant cylinder has been turned to the ignition TDC posi-
tion (inlet and exhaust valves are closed). Cylinder head cover removed.
parts).
Running gear of relevant cylinder has been turned to the ignition TDC posi-
tion (inlet and exhaust valves are closed). Cylinder head cover removed.
Work steps 1. Lift the rocker arms (2 and 3) by hand, until they rest on the push rods
with no clearance.
2. Screw in fixing screws (113.227-1) thus keeping the rocker arm (2 and 3)
in a clearance-free position. See Fig. 2.
3. Mount torque wrench (008.011) in socket wrench (113.226-2). See Fig.
2.
4. Release and unscrew nuts (17) on valve adjuster screws (25), clean
threads and contact faces.
5. Screw back the valve adjuster bolts (25) using socket wrench
(113.226-1).
6. Apply MoS2 lubricant to the threads and support surface of the nuts (17)
and screw onto the valve adjustment screw (25) for an inlet valve (19).
7. Slide feeler gauge (000.455) between valve stem and calotte (26) of the
inlet valve (19).
8. Screw in valve adjuster screw (25), until feeler gauge fits without clear-
ance.
9. Tighten nut (17) with specified torque (see Work Card 000.30), whilst
Work Cards, classified into sub-assemblies
2010-07-16 - de
Summary
Impart necessary knowledge, ensure correct execution of work.
Rocker arm support with control lever are to be dismantled within the scope
of maintenance and repair work.
The work/work steps include:
Dismantling components,
fitting components.
Safety requirements
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Locating device 113.227 Standard
2 Fixing screw 113.227-1 Option
1 Lifting eye bolt M16 000.143 Standard
1 Shackle A1.0 002.453 Standard
Technical data
Designation Information
2007-07-18 - de
32/40
32/40
Starting position Contact surfaces on rocker arm bracket, distance sleeves, cylinder head,
valve cones, rocker arms and push rods have been cleaned.
Work steps 1. Insert rocker arm (2,3) in rocker arm bracket and fasten with fixing
screws (113.227-1).
Rocker arm casing/Rocker arm
Push rods
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
071 Dead centre indicator/Speed sensor
073 Crankcase cover/safety valve Work Cards, classified into sub-assemblies
100 Control device operating mechanism
101/102 Camshafts/Camshaft bearings
2010-08-06 - de
Push rods
checking and evaluation
Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, check components for state/wear condition.
Inspect cam followers and valve cams at regular intervals. A visual inspection
and running surface evaluation must be carried out.
The work includes:
Checking parts/components.
Safety requirements
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Case for TKC-1481 and TM-1010 101.142 Option
1 Video-adapter A1-11C 101.141 Option
1 Colour monitor TM-1010 101.140 Option
1 CCD colour camera TKC-1481 101.139 Option
Preliminary remarks
The guide pipes (101.128 and 101.130) are ready fitted and should not
be dismantled.
2007-10-31 - de
Push rods
12 Bush for light guide 18 Plug for light guide
13 Ocular 19 Angle piece
14 Locking lever for bending-direc- 20 Flexible part
tion selection (top/bottom)
15 Locking lever for bending-direc- 21 Objective (direct view)
tion selection (top/bottom)
16 Locking lever for bending-direc- 22 Optical adapter
tion selection (right/left)
17 Locking lever for bending-direc- 23 Objective (side view)
tion selection (right/left)
Figure 1: Fibrescope with objective lenses and high-power light source
5 Tool box
2007-10-31 - de
Work sequence 1 - Fitting the guide pipes (on the example of Bank B)
Starting position Crankcase cover is removed. Crankshaft turned so that the relevant piston is
at TDC.
Work steps 1. Introduce the guide pipes (101.128) into the drive casing and insert up to
the stop in the openings in the cylinder crankcase (1). See Figs. 3 and 4.
2. Place the support (101.129) over the guide pipes and studs (24) on the
cylinder crankcase and fix in position with nuts (25). See Fig. 3.
3. Fix the guide tubes onto the support (101.129) with knurled screws.
Work sequence 2 - Checking the valve cams and cam follower rollers
Work steps 1. Blow through the guide pipes (101.128) with compressed air to remove
lube oil from the camshaft (2).
2. Place the objective (21 or 23) on the optical adapter (22) on the fibre-
scope (101.134).
3. Remove the intermediate adaptor from the support on the high-power
light source (101.133) and place on the light source plug (18).
4. Plug the light guide plug (18) on the fibrescope (101.134) in the bush (12)
on the high-power light source (101.133) and start up.
5. Set the locking lever for bending-direction selection (14 and 17) in posi-
tion "F".
6. Plug the flexible part (20) in the guide pipe and push upwards up to the
valve camshaft (2). Observe the process in the ocular (13).
Work Cards, classified into sub-assemblies
Any drops of oil adhering to the valve cam can be removed by com-
pressed air if required. See Fig. 6.
2007-10-31 - de
10. Turn the engine over and check the entire valve cam running surface.
11. By alternate moving the lever for binding-direction selection and sliding
the flexible part (20) move this upwards to the cam follower roller (4). See
Push rods
Fig. 5.
12. Turn the engine over and check the entire roller running surface.
13. Set the locking lever for bending-direction selection (14 and 17) in posi-
tion "F" to pull back the flexible part (20).
Push rods
8 Inlet cam (Bank B)
10 Oil drops on the running surface
Push rods
Push rods
removal and installation
Summary
Check components for quality/ wear status, ensure /restore operating safety.
push rods are to be disassembled and assessed within the scope of mainte-
nance and repair work.
The work / work steps include:
Removing components,
Checking parts/ components,
Installing components.
Technical data
Designation Information
Push rod 6,5 kg
attention to the transverse slot in the push rod and milled groover on the
thrust piece.
3. Rotate push rod (1) by about 90° (for position of the marking M on the
push rod see figure 2) and connect push rod to the thrust piece. See Fig.
1.
4. Install second push rod (1) in the same manner.
5. Check movability of the push rods (1).
2007-10-31 - de
1 Push rod
3 Cam follower (inlet /exhaust valve)
4 Cylinder head
5 Valve camshaft
1 Push rod
2 Thrust piece
3 Cam follower (inlet /exhaust valve)
32/40;L32/44CR;V32/40PGI
Push rods
1 Push rod
4 Cylinder head
AS Exhaust side
M Marking on the push rod
Figure 3: Position of the marks on the push rods, if the push rods are connected to
the thrust pieces (plan view)
Valve rotator
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
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Felt-tip pen/marker pen - Inventory
Principle of operation
Inlet valve When the valve is opened, the cup spring (4) in the valve rotator is flattened
by the rising force of the valve spring. See figure 1 and figure 2. In the proc-
ess, it exerts load on the balls inserted in the pockets of the basic body (1),
forces them to roll off on their inclined running surfaces and rolls off on the
balls itself. The cap, cup spring and valve spring are, on the other hand, held
in position rotationally by friction. The relative rotation between cup spring/
cap and basic body is transferred to the valve via the basic body. When the
Wear protective gloves during assembly work! Do not walk on hot sur-
faces!
Due to dirt, especially of the ball pockets due to residues in the oil (due
to abrasion, combustion products) there can be malfunctions. The dep-
ositions stick to the individual parts and hinder the balls in their move-
ment. The valve rotator must be removed, dismantled, washed carefully
and lubricated before reassembling (see Work Card 113.02).
1 Base body
2 Ball
4 Cup spring
Work Cards, classified into sub-assemblies
5 Cover
6 Circlip
7 Pressure spring
2009-06-26 - de
Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, check components for state/wear condition.
Inlet and exhaust valves as well as valve rotator are to be disassembled at
regular intervals and overhauled if necessary.
The work / work steps include:
Disassembling components,
Separating parts/ components,
Installing components.
Safety requirements
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Valve spring tensioner 113.211 Standard
1 Thrust piece 113.211-1 Standard
Technical data
Designation Information
Inlet valve cone 3,5 kg
Exhaust valve cone 3,5 kg
Work steps 1. Fix bridge (113.211-7) to the cylinder head (9) with two hexagon bolts
(21). See Fig. 2.
2. Insert thrust piece (113.211-1) over the spindle on the bridge and posi-
tion it centrally over the valve rotator (15) or thrust bearing (17). See Fig.
2/I.
3. Screw the hexagon nut (20) onto the spindle.
4. Press down the thrust piece by rotating the hexagon nut (20), compress-
ing the compression springs (12 and 14) until the two-part tapered piece
(16) can be removed. Keep the valve cone (10 or 18) on the valve cone
plate by hand while pressing down the compression springs. Remove
tapered pieces. See Fig. 2/II.
Make sure that the valve cone does not rotate as well. If necessary,
Work Cards, classified into sub-assemblies
push back the valve cone on the valve cone plate again to the valve
seat.
If the valve cone is not held, it falls out on removing the tapered piece
from the valve guide.
32/40;L32/44CR;V32/40PGI
5. Unscrew hexagon nut (20) and relieve compression springs (12 and 14).
See Fig. 2/III.
6. Screw back the hexagon nut (20) completely, remove thrust piece from
the valve rotator (15) or thrust bearing (17), and swing to the next valve
rotator or thrust bearing.
7. Remove valve rotator (15) or thrust bearing (17) and compression springs
(12 and 14).
2007-11-06 - de
8. Push out valve cone (10 or 18) from valve guide (11) and place it on
clean surface.
9. Remove the remaining valves in the same manner (see point 2 to 8).
12. Clean all individual parts and check for damage (for max. clearance see
Operating Instructions, section 2.5), renew if necessary.
13. Clean hollow fillet of the valve cones (10 and 18) and transitions above
the vane area (exhaust valve) to produce a metallic bright finish (e.g. wet
blasting). Carry out magnetic crack testing. (see Work Card 000.34) If
cracks are displayed, discuss with an authorised Service Centre regard-
ing continued use.
14. If necessary, regrind valve cone (10 and 18) or valve seat (see Work Card
113.04 and 113.05).
15. Check state of the valve guide (11) and remove if necessary (see Work
Card 113.05).
16. Push the valve cone (10 or 18) into the valve guide (11) and determine
radial clearance by means of a feeler gauge (000.451), note and com-
pare with specified clearance. Refer to the Operating Instructions in sec-
tion 2.5.
17. Check valve seats (see Work Card 113.03).
Work sequence 2 - Dismantling and assembling the valve rotator Work Cards, classified into sub-assemblies
Starting position Valve rotator removed and placed on the support (snap ring is on top).
Work steps 1. Remove snap ring (6). See Fig. 3.
2. Remove cover (5) and cup spring (4).
3. Remove all balls (2) and compression springs (7) from the basic body (1).
4. Wash all individual parts in a suitable cleaning agent and then dry them.
32/40;L32/44CR;V32/40PGI
5. Check, and if necessary, replace, individual parts for wear and ball inden-
tations.
When changing parts of the valve rotator, the basic body (1) must be
identified with the art. no. of the used wear sets. Clean new parts
before assembling them.
2007-11-06 - de
6. Insert balls (2) and compression springs (7) in the ball pocket tracks in
the basic body (1).
Inlet and exhaust valves
Ensure that balls are at the highest point of the inclined ball pocket
tracks and thus all are in the same direction. See Fig. 3.
7. Insert cup spring (4), place cover (5) on top and install snap ring (6).
8. Place valve rotator (15) in clean lubricating oil and remove shortly before
installation.
Bearings Parts kept in stock must be well packed, protected against dust, water,
humidity and aggressive media. Dust sticks to the individual parts and pre-
vents or hampers rotation during commissioning.
1. Clean bore in the valve guide (11) and the valve seat ring (8 or 19).
2. Insert new O-ring seal (13) in ring groove, whilst ensuring that it is not
twisted.
3. Install compression springs (12 and 14) in the cylinder head (9) and set
valve rotator (15) or thrust bearing (17) on compression springs.
4. Insert thrust piece (113.211-1) over the spindle on the bridge (113.211-7)
and position it centrally over the valve rotator (15) or thrust bearing (17).
See Fig. 2/III.
32/40;L32/44CR;V32/40PGI
During the assembly of the tapered piece hold the valve cone by hand
7. Press down the thrust piece by rotating the hexagon nut (20), compress-
ing the compression springs (12 and 14) until the two-part tapered piece
(16) can be fitted. Insert tapered pieces. See Fig. 2/II.
8. Screw back hexagon nut (20) and release the load on the valve spring
tensioner (113.211).
9. Completely screw back the hexagon nut (20), remove thrust piece from
the valve rotator (15) or thrust bearing (17) and swing aside.
10. Fit the remaining valves in the same manner (see point 1 to 9).
11. Remove valve spring tensioner.
2007-11-06 - de
1 Basic body
2 Ball
4 Cup spring
5 Cover
6 Snap ring
7 Compression spring
2007-11-06 - de
Summary
Execute work on time according to the maintenance schedule, check com-
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.
The work/work steps include:
executing touching tests ,
assessing contact pattern /wear status.
Tools/aids required
Quantity Designation Number Status
1 Touching bracket for engine 114.033 Standard
L,V48/60B+CR: 51/60DF
1 Touching bow for engine 40/54 114.032 Standard
1 Touching bow for engine 58/64 114.054 Standard
1 Touching up device for engine 113.224 Standard
32/40, 32/44CR
1 Combination spanner (set) 009.231 Option
1 Hexagon screwdriver (set) - Inventory
1 Grinding paste, silicon-free - Inventory
1 Touching-test ink - Inventory
Preliminary remark
Exhaust and inlet valves with a faulty wear surface appearance will not have
2009-10-12 - de
Do not damage valve cones by using the wrong cleaning device (e.g.
chipping hammer)!
Result 1 Valve seating surfaces of the valve seat rings are clean, lightly lacquered or
only have slight scar formation. Uniform contact pattern all around - see fig-
ure 4.
Clean as little as possible with grinding paste and then wash valve cone
and valve seat ring carefully. Residues of grinding paste promote fur-
ther wear.
Existing small cracks after cleaning are still permitted, they do not affect the
durability too much.
Work Cards, classified into sub-assemblies
Result 2 Valve seating surface of the valve seat ring shows heavy deposit, deeper cor-
rosion cracks and/or distinct impact marks. Wear on valve seat ring - see fig-
ure 5.
General
2009-10-12 - de
Grind or turn as little as possible and then wash valve cone and valve
seat ring carefully. Residues of grinding paste promote further wear.
Existing small cracks after grinding/ turning are still permitted, they do not
affect the durability too much.
Clean as little as possible with grinding paste and then wash valve cone
and valve seat ring carefully. Residues of grinding paste promote fur-
ther wear.
Existing small cracks after cleaning are still permitted, they do not affect the
durability too much.
General
2009-10-12 - de
Result 4 Valve seating surface of the valve cone shows heavy deposit, deeper corro-
sion cracks and/or distinct impact marks. Wear on the valve cone - see fig-
ure 6.
Grind as little as possible and then wash valve cone carefully. Residues
of grinding paste promote further wear.
Existing small cracks after grinding/ turning are still permitted, they do not
affect the durability too much.
Result 5 Valve cone with the start of burning through or cracks in the valve seat
Work Cards, classified into sub-assemblies
2009-10-12 - de
A Stem corrosion
Figure 8: Figure for Result 6
Action
Replace the valve cone.
Result 7 Valve cone with burn-up on the valve plate. Wear on the valve cone - see fig-
ure 9.
Work Cards, classified into sub-assemblies
2009-10-12 - de
Action
Replace the valve cone if the limits indicated on the Work Card 113.09 are
exceeded.
Summary
Impart necessary knowledge, ensure correct execution of work. Execute
work on time according to the maintenance schedule, make possible/ sup-
port economic operation, prevent operational problems/damage.
Removal and installation of valve seat rings are not part of the work specified
in the maintenance schedule.
The work/work steps include:
removing components,
installing components.
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 113.219 Standard
1 Thrust piece 113.220 Standard
1 Guide piece 113.221 Standard
1 Clamping piece 113.222 Standard
1 Extractor 113.218 Standard
1 Extractor 002.512 Standard
Preliminary remarks
2008-09-19 - de
See that the valve seat ring is extracted uniformly i.e. it is not tilted.
9. Check locating hole in the cylinder head for damage, check dimension
(B) (max. allowable 118.022 mm), measure dimension (E) and note (see
figure 3).
If the dimension (B) has been exceeded, oversize valve seat rings are
available from MAN Diesel & Turbo SE. The locating hole will need to
be reworked in this case.
Work Cards, classified into sub-assemblies
2 Cylinder head
B Max. permitted dimension of the
locating hole
E Distance of the two surfaces
32/40;L32/44CR
Figure 3: Locating hole for the valve seat ring in the cylinder head
Work steps 1. Measure dimension from bottom edge to the contact face on the new
valve seat ring and compare with dimension (E). Dimension (E) must be
2008-09-19 - de
2. Insert new O-ring seal (5) in the ring groove on exhaust valve seat ring
(7), ensuring that this is tensioned equally on the entire periphery and not
2. Place thrust piece (113.220) on valve seat ring, insert together over the
guide piece and centre it by hand in the locating hole of the cylinder head
(see figure 5/I).
3. Screw on second hexagon nut (6) on guide piece up to contact.
4. Tighten valve seat ring by turning the hexagon nut until it touches.
See that the valve seat ring is pressed in uniformly and is not tilted.
6. Check gap (D) for uniform width at several places by using feeler gauge
(000.451).
2008-09-19 - de
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/ work steps include:
Checking parts /components,
Dismantling components,
Assembling components.
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 113.219 Standard
1 Thrust piece 113.220 Standard
1 Guide piece 113.221 Standard
1 Clamping piece 113.223 Standard
1 Combination spanner (set) - Inventory
Replace the valve guide if the wear limit is reached. The wear limit is
32/40;L32/44CR;V32/40PGI
reached,
• If the valve cone (20) picks up on the combustion chamber side cylindri-
cal recess (C) of the valve guide (21). See Fig. 1.
• if the wearing edge (A) all around the valve guide (21) can no longer be
seen or felt. This can also only occur on one part of the periphery.
2008-09-19 - de
Work steps 1. Introduce the guide piece (113.221) into the valve guide (8) and hold.
2. Insert clamp piece (113.223) over the guide piece and screw on the hex-
agon nut (6). See Fig. 2.
3. Extract valve guide (8) from cylinder head (2) by turning the hexagon nut
(6).
4. Clean locating hole in cylinder head (2).
5. Clean the valve guide (8) and check for wear/damage, renew if neces-
sary.
32/40;L32/44CR;V32/40PGI
2008-09-19 - de
Ensure that the valve seat guide is pulled in uniformly and is not tilted.
32/40;L32/44CR;V32/40PGI
2008-09-19 - de
Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect 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 Hunger VDS2.3E valve seat lathe.
The work includes:
Creating a correct contact pattern.
Tools/aids required
Quantity Designation Number Status
1 Valve seat lathe of type VDS2.3E 113.230 Option
(277V)
1 Valve seat lathe of type VDS2.3E 113.229 Option
(120V)
1 Valve seat lathe of type VDS2.3E 113.228 Option
(230V)
1 Lathe with boring head 113.228-1 Option
10 Insert 113.228-5 Option
1 Pilot 113.228-6 Option
1 Support frame 113.228-7 Option
2010-06-23 - de
Starting position Cylinder head loaded in the cylinder head turnover stand (see Work Card
055.05) or placed on blocks. Inlet and exhaust valve cone removed. Valve
4. Push the support frame (113.228-7) on to the guide pilot and position
with clamping screw (4). Use the clamping screws (5) (see Fig. 2) to
locate the sprung preloaded dowel pins.
5. Front stem and surface of the pilots (113.228-6) with a few drops of
machine oil.
4. Position the insert with the feed adjusting ring (12) above the centre of
the valve seating surface to be processed.
5. Hold on to the lathe (113.228-1) and slacken the clamping screw (8).
Lower the lathe carefully until the insert is slightly above the valve seating
surface. Push the stop pin (7) gently against the guide pilot (113.228-6)
and locate with the clamping screw (8).
6. Plug the circular plug of the output cable (14) into the socket on the valve
seat lathe and engage locking tag.
Work Cards, classified into sub-assemblies
32/40;V32/40PGI
2010-06-23 - de
2. Turn the feed adjusting ring (9) anticlockwise. One scale division line cor-
responds to an adjustment of 0.025 mm. During the initial boring opera-
tion, the chosen cutting depth should be such that the chip removal from
the entire valve seating surface can be ensured.
2010-06-23 - de
3. Make sure that the swivel arm (15) has engaged in the groove provided
in the feed ring (11).
5. Hold lathe (113.228-1) fixed with both hands and start the boring opera-
tion by pressing the push button (10).
6. Hold the push-button pressed until machining of the valve seating sur-
face is complete.
7. Repeat work steps 1 - 5 in 0.05 - 0.1 mm increments, until the entire
valve seating surface to be worked on is machined bare.
8. Make colour pen marks at several points on the valve seating surface
and carry out the last boring operation as follows:
▪ Movement by one scale division (0.025 mm),
▪ Switch speed switch (13) on power supply unit to "42V" position.
If you cannot obtain the required wear pattern using the valve seat
lathe, have this repair carried out by a MAN Diesel & Turbo Service
Centre.
Work Cards, classified into sub-assemblies
2010-06-23 - de
Valve cone
Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect 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
VKM 3.1.
The work includes:
Creating a correct contact pattern.
Tools/aids required
Quantity Designation Number Status
1 Valve cone grinder VKM 3.1 113.242 Option
1 Clamp for engine 32/40 113.247 Option
1 Grinding wheel 113.258-1 Option
1 Dressing diamond 113.258-3 Option
1 Coolant concentrate 113.258-5 Option
1 Dial gauge - Inventory
1 Magnetic post - Inventory
1 Sliding calliper - Inventory
Preliminary remarks
Exhaust and inlet valves with a faulty wear surface appearance will not have
a long service life. And must be overhauled or replaced.
The overhauling intervals entered in the maintenance schedule are approxi-
mate values, which are dependent on the operating method and the condi-
tion 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.
2008-10-24 - de
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 seal-
ing on the outer area of the valve seating area against the hot gases during
operation.
Work Cards, classified into sub-assemblies
Work steps 1. Before beginning work, check the grinding wheel fastening for firm seat-
ing.
2. Dress grinding wheel with dressing diamond. In doing so, drag the
dressing diamond across the grinding wheel, guiding it at an angle of 15
Due to the cutting speed the grinding wheel diameter must not be
smaller than 150 mm.
11. Dress the grinding wheel again before the last grind.
12. For grinding out (last grinding) set for lower quantity (< 0.02 mm) and
grind out completely.
After grinding out donot lift grinding wheel from valve cone seating
surface, but lift valve cone seating surface away from the grinding
wheel.
2008-10-24 - de
13. Remove burr on the outer diameter of the valve plate with suitable tool
(file, grindstone) or break edge on seat inner diameter using grindstone.
Inlet and exhaust valves
On reaching the maximum value (H) the valve cone may no longer be
used (see table 1).
2008-10-24 - de
1 Valve cone
4 Grinding wheel
(new condition)
A Radius H Max. rework X Tangential point
Figure 5: Rework on the valve cone
Inlet- Exhaust-
Inlet and exhaust valves
2008-10-24 - de
Summary
Combat corrosion attack, keep quality in the permitted range.
When regrinding the valve seating surface, the permissible valve plate thick-
ness is to be determined.
The work/work steps include:
Measuring components and
Assessing contact pattern /wear condition.
Tools/aids required
Quantity Designation Number Status
1 Thickness gauges 0.05-1 000.451 Option
1 Sliding calliper - Inventory
1 Felt-tip pen/marker pen - Inventory
1 Steel ruler - Inventory
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-
General
2008-09-11 - de
est point.
Regrinding the valve seating surface (S) and possibly occurring hot cor-
Inlet and exhaust valves
rosion on the plate bottom could reduce the valve plate thickness to
inadmissible values.
plate diameter
E Tracer arms of the sliding calliper HN Plate thickness in the new condi-
tion at measuring point C
S Seating surface
Figure 1: Determine wear dimension A on the valve plate
Work sequence 2 - Checking for corrosion grooves on the valve plate outer diameter (D)
Work steps 1. Clean valve cone, do not damage surface by using the wrong cleaning
2008-09-11 - de
Operating device
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
071 Dead centre indicator/Speed sensor
073 Crankcase cover/safety valve Work Cards, classified into sub-assemblies
100 Control device operating mechanism
101/102 Camshafts/Camshaft bearings
2010-08-06 - de
Operating device
checking, overhauling
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.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory
Spare parts
Quantity Designation Number
A wear parts kit is available from MAN Diesel & Turbo SE for you to use
Operating device
1. When assembling new sealing rings ensure that they are not twisted.
2. Lightly oil all parts prior to assembly.
Work Cards, classified into sub-assemblies
Principle of operation
Connection 1 2 4
Position I closed connected
Position II connected closed
General
2007-08-01 - de
Operating device
checking, overhauling
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.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Hook wrench - Inventory
1 Grease (acid-free) - Inventory
Spare parts
6. Continue dismantling valve, thoroughly clean all individual parts and blow
off with compressed air.
Operating device
7. Check wear parts (V) for abrasion or hardening (in the case of sealing
rings), replace if necessary.
A wear parts kit is available from MAN Diesel & Turbo SE for you to use
to overhaul the M317 three-way valve.
1. When assembling new sealing rings ensure that they are not twisted.
2. Lightly oil all parts prior to assembly.
Work Cards, classified into sub-assemblies
Operating device
Principle of operation
Connection 1 2 4
5 pressurised connected closed
5 without pressure closed connected
Operating device
checking, overhauling
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.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory
of dirt.
2010-04-29 - de
A wear parts kit is available from MAN Diesel & Turbo SE for you to use
to overhaul the M329 3/2-way solenoid valve.
1. When assembling new sealing rings ensure that they are not twisted.
2. Lightly oil all parts prior to assembly.
2010-04-29 - de
Operating device
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
Principle of operation
The functions shown in Figs. 1 and 2 are available, depending on the pin
arrangement in the valve casing.
2010-04-29 - de
Operating device
Functional testing at the engine
Summary
Check condition/function of components; ensure/restore operating reliability.
Regularly check the control elements in the compressed air or control air
system and overhaul as necessary.
The work/work steps comprise:
Check of the emergency stop device.
Safety requirements
Tools/aids required
Quantity Designation Number Status
1 Screwdriver (Set) - Inventory
1 Protective gloves - Inventory
1 Ear defenders - Inventory
Preliminary remarks
The emergency stop device essentially consists of emergency stop valve
M329/2 (designation of measuring range: 1SZV1012) and emergency stop
buttons as well as the corresponding signal lines. This must be checked at
regular intervals in accordance with the maintenance schedule to make sure
it is working properly. Different versions of the emergency stop valve are
used, depending on the area of application of the engine. The emergency
stop valve features in marine engines and is normally not used in stationary
engines.
General
2010-04-28 - de
tion
Each time the emergency stop valve is removed/installed, a function
check must be carried out. This check must first be carried out with
the engine at a standstill, and subsequently when running in idle.
2010-04-28 - de
1. Press the emergency stop button (2) at the emergency stop valve (1).
Make sure that the emergency stop button (2) is kept pressed down by
Operating device
the arresting device (3) (see Fig. 2).
2. Check the effects of the emergency stop operation:
When the emergency stop valve (1) is triggered, this is accompanied by a
loud bang.
Engines with conventional fuel injection
The control rods of the fuel-injection pumps are at the "Zero Filling" posi-
tion, the engine stops. It is no longer possible to push in the control rods
manually.
Engines with Common-Rail injection
The pressure in the Common-Rail accumulator is released immediately,
the engine stops. The engine control display indicates insufficient pres-
sure in the Common-Rail accumulator.
Stationary engines
Operating device
5 Lock screw
Figure 3: Emergency stop valve M329/2 (measuring range 1SZV1012) installed in sta-
tionary engines
1. Unscrew lock screw (5) and pull off connecting plug (4). (see Fig. 3).
When the connecting plug (4) is pulled out, the electric circuit for the
emergency stop valve (1) is interrupted which causes it to trigger.
2. Check the effects of the emergency stop operation:
When the emergency stop valve (1) is triggered, this is accompanied by a
General
2010-04-28 - de
loud bang.
Engines with conventional fuel injection
The control rods of the fuel-injection pumps are at the "Zero Filling" posi-
tion, the engine stops. It is no longer possible to push in the control rods
manually.
Operating device
Engines with Common-Rail injection
The pressure in the Common-Rail accumulator is released immediately,
the engine stops. The engine control display indicates insufficient pres-
sure in the Common-Rail accumulator.
Overspeed
Before the engine is started, a corresponding emergency stop button
(6) must be pressed without fail. In engines equipped with an electronic
speed governor, there is a danger of the engine accelerating and going
into overspeed. When the emergency stop button (6) is pressed, the
engine control detects the emergency stop.
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
1. Plug in the connecting plug (4) for the emergency stop valve (1) and
screw in the lock screw (5) (see Fig. 3).
2010-04-28 - de
Operating device
checking, overhauling
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.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory
Spare parts
1. When assembling new sealing rings ensure that they are not twisted.
2. Lightly oil all parts prior to assembly.
Work Cards, classified into sub-assemblies
Principle of operation
Connection 5 4 1 2 3
Magnet deenergised connected connected closed
Magnet energised closed connected connected
General
2007-08-01 - de
Operating device
checking, overhauling
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.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory
Spare parts
6. Check wear parts (V) for abrasion or hardening (in the case of sealing
rings), replace if necessary.
Operating device
A wear parts kit is available from MAN Diesel & Turbo SE for you to use
to overhaul the M409 pressure reducing valve.
1. When assembling new sealing rings ensure that they are not twisted.
2. Lightly oil all parts prior to assembly.
Work Cards, classified into sub-assemblies
General
2007-03-28 - de
Operating device
11 Cylinder screw 14 Knurled screw
12 Casing top section
13 Casing bottom section V Wear parts
Figure 1: Sectional view of the pressure-reducing valve M409
Operating device
checking, overhauling
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.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory
Spare parts
Quantity Designation Number
You can obtain the filter insert for the M462 compressed-air filter from
Operating device
11 Hexagon nut
12 Filter insert
13 Hexagon bolt
Work Cards, classified into sub-assemblies
2007-03-28 - de
Operating device
checking, overhauling
Summary
Check components for quality/wear condition, ensure / restore operational
safety.
Electric/ electronic control and/or switch elements are to be checked and, if
necessary, overhauled at regular intervals.
The work/work steps include:
Disassembling components,
Checking parts/ components,
Assembling components.
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Screwdriver (Set) - Inventory
Spare parts
Quantity Designation Number
1 Roller lever
2 Cylinder screw
3 Cylinder screw
4 Cover
2007-03-28 - de
Operating device
checking, overhauling
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.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory
workplace, even the smallest dirt particles can cause faults in the valve
or in the compressed air / control air system.
1. When assembling new sealing rings ensure that they are not twisted.
2. Lightly oil all parts prior to assembly.
Principle of operation
Connection A B
Work Cards, classified into sub-assemblies
2007-07-31 - de
Speed regulation
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
071 Dead centre indicator/Speed sensor
073 Crankcase cover/safety valve Work Cards, classified into sub-assemblies
100 Control device operating mechanism
101/102 Camshafts/Camshaft bearings
2010-08-06 - de
Speed regulation
Check in the case of an error
Summary
Ensure correct execution of work, allow emergency mode.
Electronic speed governors are largely maintenance-free. However, if operat-
ing problems do occur, the cause of the error must be remedied as quickly
as possible.
The work includes:
Repair of the speed governor.
Tools/aids required
Quantity Designation Number Status
1 Hexagon screwdriver (set) - Inventory
the cause of the previous fault has been eliminated. If this is the case,
repeat points 5 to 9. Do this until no further error flags appear on the dis-
play.
10. Press the "2nd", "CLEAR ERR", "2nd" and "ERASE ERR" buttons in this
order to delete errors that are not automatically deleted and to erase the
error memory.
11. Disconnect the hand-held parameterising unit, mount the cover on the
digital controller. Close the speed governor cubicle.
Work Cards, classified into sub-assemblies
2007-11-06 - de
error flags that are set to "1" and consult MAN Diesel & Turbo SE.
Speed regulation
ERR EED OVER 1 = error indicated by error flag
▪ Mount hand crank on governor control linkage (see Work Card 203.02)
and operate engine by hand.
ERR_ADC7 3047
ERR_ALINE 3068 SERR_ALINE 3168
ERR_AMPLIFIER 3005 SERR_AMPLIFIER 3105
ERR_BOOST 3023 SERR_BOOST 3123
ERR_CALC_TIME 3069 SERR_CALC_TIME 3169
ERR_CLEAR_FLASH 3065
ERR_CPU2 3014 SERR_CPU2 3114
ERR_CURVE 3060 SERR_CURVE 3160
ERR_DATA 3062 SERR_DATA 3162
ERR_FEEDBACK 3001 SERR_FEEDBACK 3101
ERR_FEEDBACK 3002 SERR_FEEDBACK2 3102
ERR_FEEDBACK 3003 SERR_FEEDBACK3 3103
V32/40
Speed regulation
(ERR) (SERR)
ERR_GAS_PRESS_RED 3031 SERR_GAS_PRESS_RED 3131
ERR_INTER 3072 SERR_INTER 3172
ERR_LMG_INPUT 3029 SERR_LMG_INPUT 3129
ERR_LOGICAL 3064 SERR_LOGICAL 3164
ERR_MAP 3061 SERR_MAP 3161
ERR_MEMORY 3063 SERR_MEMORY 3163
ERR_OIL_ECY 3010 SERR_OIL_ECY 3110
ERR_OIL_PRESSURE 3024 SERR_OIL_PRESSURE 3124
ERR_OIL_WARN 3009 SERR_OIL_WARN 3109
ERR_PICK_UP1 3007* SERR_PICK_UP1 3107
ERR_PICK_UP2 3008* SERR_PICK_UP2 3108
ERR_PROG_FLASH 3066* SERR_PROG_FLASH 3166
ERR_SETPOINT1 3020 SERR_SETPOINT1 3120
ERR_SETPOINT2 3021 SERR_SETPOINT2 3121
ERR_SETPOINT3 3022 SERR_SETPOINT3 3122
ERR_SPEED_OVER 3006 SERR_SPEED_OVER 3106
ERR_STACK 3070 SERR_STACK 3170
ERR_SYNCHRON_INPUT 3028 SERR_SYNCHRON_INPUT 3128
ERR_TEMP_CHARGE_AIR 3027 SERR_TEMP_CHARGE_AIR 3127
ERR_TEMP_COOL_WATER 3025 SERR_TEMP_COOL_WATER 3125
ERR_TEMP_OIL 3026 SERR_TEMP_OIL 3126
ERR_USER 3067 SERR_USER 3167
ERR_VOLTAGE 3011 SERR_VOLTAGE 3111
Summary
Execute work on time according to the maintenance schedule, ensure/
restore operational safety.
Starting air pilot valves are to be checked at regular intervals and overhauled,
if necessary.
The work / work steps include:
Removing/disassembling components,
Replacing sealing rings/elements,
Assembling/fitting components.
Tools/aids required
Quantity Designation Number Status
1 Thickness gauges 0.05-1 000.451 Standard
1 Combination spanner (set) - Inventory
1 Depth gauge - Inventory
Technical data
Designation Information
Starting air pilot valve 8,5 kg
Work steps 1. Unscrew the air supply pipe (2) and control air pipe (4) from the casing
(9). Figure 1.
2. Remove the complete starter pilot valve and dismantle, clean all the
parts, blow out the pontrol air holes, check the sliding surfaces and the
set of seals (6) for wear, and replace if necessary.
2007-11-05 - de
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Starting position Check all parts for cleanliness and assemble and fit in the reverse order. The
following must be particularly observed:
Work steps 1. Check the control piston (5) mobility.
2. Check the gap (A) after screwing both the hexagon bolts (3) in (see Oper-
ating Instructions Section 2.5), if necessary remove the starter pilot valve
again and correct by changing the dimension (B) by removing foils from
the spacing washer (1).
3. Upon completion, check the air pipes (2 and 4) for leakage and function-
ality.
2007-11-05 - de
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Starting valve
Summary
Execute work on time according to the maintenance schedule, ensure/
restore operational safety.
Starting valves are to be checked at regular intervals and overhauled, if nec-
essary.
The work/work steps include:
checking for leakages,
removing components,
installing components.
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 161.018 Standard
1 Thrust piece 161.018-1 Standard
1 Spindle 161.018-5 Standard
1 Cleaning tool 055.149 Standard
1 Ratchet tool 008.023 Standard
1 Torque wrench 008.011 Standard
1 Shackle A0.6 002.452 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Socket spanner insert 24x12.5 001.757 Standard
1 Ring nut M12 000.182 Standard
1 Combination spanner (set) - Inventory
1 Lifting tackle with rope - Inventory
Technical data
Designation Information
Starting valve 6,5 kg
Thrust flange 5,5 kg
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32/40
If the starting line becomes hot during operation, the engine should be
shut down immediately whenever possible and the faulty starting valve
replaced. Make all air pipes pressureless before work on the starting
valve. Close the shut-off valve on the compressed air tank.
1 Cylinder head
2 Thrust flange
3 O-ring seal
4 O-ring seal
5 Starting valve
6 Stud
7 Hexagon nut
8 Control air line
Work Cards, classified into sub-assemblies
1 Cylinder head
5 Starting valve
9 Adjacent cylinder head
10 Collar nut M20
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2. Fit starting valve (5) with the spindle (161.018-5) and ring nut (000.182).
3. Coat screw thread and contact face of the hexagon nut (7) with MoS2
lubricant, screw on and tighten alternately to specified torque (see Work
Starting air pilot valve/Starting valve/Main starting valve
Card 000.30).
4. After installing the starting valve, check for leakage (see work sequence
1).
Work Cards, classified into sub-assemblies
2007-07-18 - de
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Starting valve
Summary
Execute work on time according to the maintenance schedule, ensure/
restore operational safety.
Starting valves are to be checked at regular intervals and overhauled, if nec-
essary.
The work/work steps include:
disassembly of components,
replacement of sealing rings/sealing elements,
assembly of components.
Tools/aids required
Quantity Designation Number Status
1 Ratchet tool 008.023 Standard
1 Torque wrench 008.011 Standard
1 Socket spanner insert 19x12.5L 001.767 Standard
1 Lubricant (containing molybdenum - Inventory
disulphide)
1 Grinding paste, silicon-free - Inventory
1 Touching-test ink - Inventory
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4. Reshape the expanded PTFE ring by placing the piston into the oiled
casing (20).
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Starting valve
Summary
Execute work on time according to the maintenance schedule, ensure/
restore operational safety.
Starting valves are to be checked at regular intervals and overhauled, if nec-
essary.
The work includes:
Creating a correct contact pattern.
Tools/aids required
Quantity Designation Number Status
1 Grinding-in fixture 055.197 Standard
1 Spindle 055.197-1 Standard
1 Guide bush 055.197-3 Standard
1 Guide bush 055.197-5 Standard
1 Grinding wheel 055.197-9 Standard
1 Small grinding plates (set) 055.197-13 Standard
1 Pliers for locking rings 055.197-19 Standard
1 Quick-acting cleanser Loctite 7061 055.197-21 Standard
1 Tap wrench 055.197-23 Standard
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1 Cylinder head
A maximum allowable dimension
Figure 1: Summarised display of the max. permitted dimension for grinding the start-
ing valve seating surface
Starting position Starting valve disassembled.
Work steps 1. Insert grinding wheel (055.197-9) onto the spindle (055.197-1) and fix
with hexagon nut (22) (see figure 3).
2. Pull out consumed grinding plates (055.197-13) from the grinding wheel
and remove any adhering adhesive residues by using quick-acting
cleanser (055.197-21).
3. Stick new grinding plates onto the grinding wheel (see figure 2).
4. Place grinding device in the cylinder head (1), paying attention to the
guide bush (055.197-5).
5. Insert guide bush (055.197-3) with outer Ø 70 mm and guide grinding
tool into the starting valve bore.
6. Rotate grinding tool to and fro, raise in-between and blow off grinding
dust with compressed air.
Work Cards, classified into sub-assemblies
Remove only so much material that valve seating surface is shiny and
undamaged over the entire width, Non-return valve seating surface
often during the grinding process. Maximum permitted dimension A:
388.5 mm. If a measured spacing is larger than the permitted dimen-
sion, the cylinder head must be changed.
6629 161.03-02 EN
Figure 2: Gluing the grinding plates in position
Work Cards, classified into sub-assemblies Starting air pilot valve/Starting valve/Main starting valve
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3 (4)
161.03
161.03 MAN Diesel & Turbo
Starting air pilot valve/Starting valve/Main starting valve
Work Cards, classified into sub-assemblies
Summary
Execute work on time according to the maintenance schedule, ensure/
restore operational safety.
The main starting valve is to be checked, cleaned and overhauled, if neces-
sary, at regular intervals.
The work / work steps include:
Disassembling components,
Separating parts/ components,
Installing components.
Tools/aids required
Quantity Designation Number Status
1 Tools, Basic Scope 009.229 Option
1 Grinding paste, silicon-free - Inventory
1 Threaded rod - Standard
Technical data
Designation Information
Main starting valve 26,2 kg
When opening the starting air and pontrol air systems, see that no dirt Work Cards, classified into sub-assemblies
can enter the valves and pipes. Block open pipe ends with plastic caps
or adhesive tape. Dismantle main starting valve and control valves only
in a clean workplace, use grease solvent and compressed air for clean-
ing.
Keep the workplace absolutely clean when assembling and act with extreme
care. Even the smallest dirt particles can cause malfunctions.
32/40;L32/40CR;L40/54
Work steps 1. Release pipe connections, remove hexagon bolts (1) and dismantle valve
(pay attention to sealing rings (2)).
2. Block open pipe ends against penetration of dirt.
3. Release and remove hexagonal bolts (3), mark the position of the casing
(4) to the valve seat (14).
4. Separate casing from valve seat. Remove, clean and blow with com-
2007-07-18 - de
pressed air all individual parts (5-7) and check the condition, replace if
necessary.
5. Release and remove closing cap (8), take out vent valve, separate into all
individual parts (9-13).
Starting air pilot valve/Starting valve/Main starting valve
6. Clean and blow with compressed air all individual parts and check the
condition, change if necessary.
7. If necessary, finish grind valve piston (5) or venting taper (9) in valve seat
(14 or 10) using fine grinding paste.
When grinding, remove only a little material and grind only until a matt
grey annular surface has appeared without scarring. The tightness can
be tested by using fuel or touching-test ink. A threaded rod M10 is used
for grinding the valve piston (5) which is screwed into the valve piston.
Work Cards, classified into sub-assemblies
Fuel-injection pump/drive
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
071 Dead centre indicator/Speed sensor
073 Crankcase cover/safety valve Work Cards, classified into sub-assemblies
100 Control device operating mechanism
101/102 Camshafts/Camshaft bearings
2010-08-06 - de
Fuel-injection pump/drive
inspecting
Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, check components for quality/wear condition.
Check Fuel injection pumps at regular intervals.
The work includes:
Checking parts/ components.
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
Preliminary remarks
The attrition of the pump elements depends mainly on abrasive or corrosive
components of the fuel. Preheating as specified, separation and filtering as
well as timely servicing and change of wear parts (baffle screws) also contrib-
ute towards extending the life in the face of adverse initial conditions.
3. Insert hexagon bolt (22) again and fasten with hexagon nut (23).
4. Block off the fuel pipes (fuel system not pressurised).
5. Unscrew both baffle screws (7) of each injection pump (16) and check for
wear, replace baffle screws if necessary.
6. Screw baffle screws (17) including new sealing rings (18) into fuel injec-
tion pump (16) hand-tight.
7. Open the fuel pipes.
8. Check the leakage fuel drain at extended intervals. If there are major
2007-06-15 - de
32/40
leakage losses, remove the relevant pump element (27). If the sealing
rings (19) and O-ring seals (20 and 21) are OK, then the pump element
must be replaced.
Fuel-injection pump/drive
shut off
Summary
Ensure correct execution of work, allow emergency operation.
Injection pumps must always be switched off if the individual running gears
need to be taken out of service.
The work includes:
Checking parts/components
Tools/aids required
Quantity Designation Number Status
1 Spring washer 200.078 Standard
1 Hexagon screwdriver (set) - Inventory
Preliminary remarks
In the event of malfunctioning of the injection system, on cylinder head, on
the valve control or on dismounted running gear, the associated injection
pump should be switched off, so that an emergency operation can be
ensured (see operating instructions Section 3.6).
When switching off the control rod of the corresponding injection pump is
blocked in the ZERO position.
The fuel supply to the injection pump must not be blocked off (pump
plunger lubrication).
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2007-06-15 - de
32/40
Fuel-injection pump/drive
removal and installation
Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, check components for state/wear condition.
Fuel injection pumps are to be dismantled within the scope of maintenance
and repair work.
The work/work steps include:
Removing components,
installing components.
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 200.079 Standard
1 Lever 200.079-1 Standard
1 Bracket 200.079-6 Standard
1 Pin 200.079-7 Standard
1 Spring clip 200.079-8 Standard
1 Ring extension SW24 200.073 Standard
1 Ratchet tool 008.023 Standard
1 Torque wrench 008.011 Standard
1 Shackle A0.6 002.452 Standard
1 Cross handle 001.891 Standard
1 Socket spanner insert 19x12.5 001.755 Standard
1 Offset screwdriver 000.445 Standard
Technical data
Designation Information
2007-11-05 - de
32/40
The correct length of universal head between the buckling lever and
control rod has been set by the manufacturer and locked in position.
We would point out that the jointed head must not be dismantled and
the set length between the injection pump and the speed governor
must only be adjusted to correct the zero setting.
2. Unscrew the hexagon nuts (45) from the ring extension (200.073).
3. Screw the retainer (200.079-6) on the injection pump.
Fuel-injection pump/drive
can create problems. In this case continue at work step 14. The work
steps 9 to 13 need not be carried out in this case.
4. Insert the lever (200.079-1) in the retainer and connect with pin
(200.079-7). Secure the pin with the dowel pin (200.079-8).
5. Fasten the cable (44) with the shackles (002.452) onto the lever and sus-
pend from the lifting tackle.
6. Lift the rope until the lever is roughly in the position shown in figure 2/I.
7. Lift the injection pump by pushing the lever until it is located outside the
hole (see figure 2/II).
8. Hold the injection pump in this position and remove to the side.
When removing, ensure that studs are undamaged and that the injec-
tion pump does not collide with anything or does not stick, thereby
damaging components.
9. Remove the charge air pipe section (43) located above and fix the rope
directly on the holder (200.079-6) with shackle (002.452) with pin
(200.079-7) and dowel pin (200.079-8).
10. Remove injection pump (16) carefully upwards with lifting tackle.
11. Cover the resulting opening on the cylinder crankcase (30).
12. Place aside injection pump on clean support.
13. Completely detach the tool.
14. Clean injection pump externally.
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4. Insert the lever (200.079-1) in the retainer and connect with pin
(200.079-7). Secure the pin with the dowel pin (200.079-8).
2007-11-05 - de
32/40
5. Fasten the cable (44) with the shackles (002.452) onto the lever and sus-
pend from the lifting tackle. Lift the injection pump.
6. Insert new O-ring seal (47), lubricated with acid-free grease, in the ring
groove, ensuring that this is tightened equally around the entire circum-
Fuel-injection pump/drive
ference and is not twisted.
7. Lift the injection pump by pushing the lever down.
8. Slide the injection pump under the charge air pipe (43) and over the hole.
9. Release the pressure on the lever, thus causing the injection pump to
lower into the hole.
Ensure that the injection pump during fitting does not hit anywhere or
remain hanging, damaging parts.
10. Fix the rope directly on the retainer (200.079-6) with shackle (002.452)
with pin (200.079-7) and dowel pin (200.079-8).
11. Lift the injection pump.
12. Insert new O-ring seal (47), lubricated with acid-free grease, in the ring
groove, ensuring that this is tightened equally around the entire circum-
ference and is not twisted.
13. Place the injection pump (16) over the hole and carefully lower into the
hole with lifting tackle.
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The correct length of universal head between the buckling lever and
control rod has been set by the manufacturer and locked in position.
We would point out that the set length must only be adjusted to cor-
rect the zero setting between the injection pump and the speed gover-
nor.
2007-11-05 - de
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Fuel-injection pump
Fuel-injection pump/drive
disassembly and assembly
Summary
Execute the work in time according to the maintenance schedule, ensure the
correct execution of work, ensure / restore operational safety.
Fuel injection pumps are to be dismantled within the scope of maintenance
and repair work.
The work/work steps include:
Dismantling components,
Replace packing rings /sealing elements,
Assembling components.
Tools/aids required
Quantity Designation Number Status
1 Removing fixture 200.109 Standard
1 Thrust plate 200.109-1 Standard
1 Support ring 200.109-2 Standard
1 Removal and fitting fixture 200.074 Standard
1 Bridge 200.074-1 Standard
1 Thrust piece with spindle 200.074-6 Standard
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5. Screw back the spindle and release the compression springs (see figure
2/IV).
6. Completely detach the tool.
7. Remove tappet including pump plunger (29) and place it on a clean sup-
port.
Do not touch pump plunger with bare hands. Protect control edges on
pump plunger from damage.
8. Measure the clearance (A) between the thrust plate (59) and piston foot
plate (63), note it down and compare with the prescribed clearance.
9. Unscrew the hexagonal socket screws (62) and remove the tappet.
10. Take out the thrust plate and pull the piston base plate off the pump pis-
2009-06-08 - de
32/40
ton.
11. Remove the compression spring from the housing, remove the spring
plate (55) and control sleeve (26).
Fuel-injection pump/drive
12. Remove securing wire (76) and unscrew both the baffle screws (17).
13. Unscrew hexagonal socket screws (49) and remove thrust ring (50).
14. Place the support ring (200.109-2) on the housing (34).
15. Place the thrust plate (200.109-1) on monobloc cylinder (28) and fix in
position with hexagon bolts (84) (see figure 3).
16. Screw three hexagon bolts (83) in thrust plate and screw down onto the
support ring until it abuts.
17. Pull out monobloc cylinder (28) from housing (34) and place it on clean
surface.
Make sure that the monobloc cylinder does not tilt over when being
removed.
18. Unscrew the cylinder (71) and remove the control rod (25).
19. Measure and note down the axial and radial play of the roller (32) and
compare it with the specified tolerances.
20. Check the entire valve support for leakage and ease of movement of
individual parts, disassemble the valve support if necessary.
21. Clean all individual parts with clean diesel fuel and check for wear or
damage.
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Fuel-injection pump/drive
Work Cards, classified into sub-assemblies
32/40
Metallic sealing and contact faces must be absolutely dry at the time of
assembly.
Work Cards, classified into sub-assemblies
When pushing the monobloc cylinder in the casing ensure that it does
Fuel-injection pump/drive
not tilt.
Before fitting the plate spring check once again that the marks on the
regulating sleeve and control rod line up.
Do not touch pump plunger with bare hands. Protect control edges on
17. Place the tappet (31) over the piston foot plate and fix in position with
four hexagonal socket screws (62).
18. Measure the clearance (A) between the thrust plate and piston foot plate,
note it down and compare with the prescribed clearance.
19. Slide pump piston and tappet carefully into the monobloc cylinder or
pump casing, paying attention to the position of the longitudinal slot in
the tappet for locking screw (57).
20. Screw back spindle (74), set bridge (200.074-1) diagonally on the hous-
ing and fasten with hexagon nuts (75) (see figure 2/I).
21. Rotate spindle until pressure piece (200.074-6) rests on tappet (see fig-
ure 2/II).
2009-06-08 - de
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22. Push tappet by turning the spindle far enough down that the locking
screw including new sealing ring (58) can be installed (see figure 2/III).
23. Completely detach the tool.
24. Screw in baffle screws (17) with new seals (18) into the housing and
tighten with specified torque (see Work Card 000.30). Fit securing wires
Fuel-injection pump/drive
(76).
2009-06-08 - de
32/40
Fuel-injection pump/drive
Measure plunger lift
Summary
Enable/support economic operation.
Check fuel injection timing as part of the IMO certification.
The work includes:
Determination of the plunger lift.
Safety requirements
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Measuring device 200.098 Standard
1 Support 200.098-1 Standard
2 Spacer sleeve 200.098-3 Standard
1 Rail 200.098-5 Standard
1 Pin 200.098-6 Standard
When fitting take care with the fitting position of the prism.
2007-07-17 - de
9. Determine and note the values for the remaining cylinders in the same
manner.
Fuel-injection pump/drive
10. Determine the mean value and compare with the mean value of Parent-
Engines in the Technical File, section 3 of the IMO Certification.
Summary
Carry out the work in due time according to the maintenance schedule,
ensure correct execution of the work, ensure /restore operational safety.
Regularly check the regulating linkage and lubricate.
The work includes:
Checking parts/components.
Tools/aids required
Quantity Designation Number Status
1 Grease gun 003.005 Standard
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Lubricating grease, acid-free - Inventory
The control rod was set precisely at the time of commissioning of the
engine and needs only changing individual parts and possibly correc-
tion on attachment of a new injection pump.
At the Zero position of the control linkage, all the control rods of the
fuel injection pumps must be at "ZERO" since otherwise it may not be
possible, under certain circumstances to shut off the engine because
individual fuel injection pumps are still pumping.
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2007-11-05 - de
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32/40
Summary
Ensure correct execution of the work, allow emergency operation.
Regulating linkage can be actuated by hand if the electronic speed governor
fails. A lever is to be fitted and the supply rate adjustment is made by hand.
The work includes:
Shutting down/Assembling components.
Tools/aids required
Quantity Designation Number Status
1 Hand lever 203.008 Standard
1 Combination spanner (set) - Inventory
Preliminary remark
32/40
In the event of seizing (pick-up) of bearings in the speed governor, the con-
nection between the speed governor and the regulation linkage must be bro-
Governor control linkage
ken. This is achieved by marking the position of the lever (9) on the governor
output shaft (11) and removing the lever together with the connecting rod (6).
An alarm is initiated in the engine room because the distance transmitter (7)
is also taken out of service when the speed governor is separated from the
regulating linkage.
Work Cards, classified into sub-assemblies
32/40
Summary
Execute work on time according to the maintenance schedule, enable/ sup-
port economic operation, prevent operational problems/damage.
Fuel injection valves affect the loading of the injection system and the engine
operating data. They are to be checked if there are deviations in the operat-
ing data, overhauled if necessary or replaced.
The work/work steps include:
removing components,
installing components.
Safety requirements
▪ Operating media systems closed/depressurised
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 221.182 Standard
1 Extractor sleeve 221.182-1 Standard
1 Threaded spindle 221.182-2 Standard
32/40
Starting position Cooling water for injection valve cooling system (if equipped) has been fully
drained. Shut-off valves on fuel pipes are closed. The oil pump (reserve) is
switched off, the cylinder head cover is taken off, the indicator valve is open.
Only remove the injection valve when the indicator valve is open. The
combustion chamber can be under high pressure when the valve is
closed.
Work steps 1. Unscrew the pipe line for the cooling water supply from the cylinder head
(6) and empty the cooling bores of the injection valve (8) by blowing them
out with compressed air. Screw the pipes back on again.
2. Unscrew and remove the hexagon nut (10).
3. Remove the fuel injection pipe (see Work Card 434.01).
4. Undo the threaded piece (7), screw it right out and remove it from the
cylinder head.
5. Take off the thrust piece (11).
Work Cards, classified into sub-assemblies
6. Screw the extractor (221.181) into the thrust ring (12) and remove the lat-
ter (see Fig. 2).
7. Screw on the threaded spindle (221.182-2) until it makes contact on the
injection valve (8) (see Fig. 3).
8. Push the extractor sleeve (221.182-1) over the threaded spindle; in doing
so, observe the location of the cut-out for the stud (13). Screw on the
spindle nut (221.182-3).
9. Extract injection valve by turning the spindle nut until it is loose.
Only remove the injection valve using the removal and fitting fixture.
10. Unscrew and remove the spindle nut (221.182-3) and take off the extrac-
2007-10-24 - de
32/40
32/40
Figure 1: Cylinder head with injection valve and parts of the fuel injection pipe
1. Screw lifting eye bolt (000.142) onto threaded spindle, fasten rope with
shackle (002.453) on lifting eye bolt and hook rope onto lifting tackle.
Fuel injection valve
2. Carefully pull out the injection valve from the cylinder head; in the proc-
ess, make sure that the O-ring seal (18) is also removed (see Fig. 4).
3. Cover the opening in the cylinder head.
4. Place the injection valve on the workbench and detach the device.
5. Remove the sealing ring (18).
6. Externally clean the entire injection valve with fuel, and remove any coke
deposits with a wire brush. Only use a wooden spatula to scrape off the
injection valve in order to prevent damaging the nozzle bores. Proceed
with particular care when cleaning the cylindrical shoulder of the nozzle
body.
2007-10-24 - de
32/40
32/40
Clean and check exterior of injection valve from obtained via reserve
stock or replacement delivery.
Work steps 1. Mount the O-ring seal (18) on the injection valve (8); in doing so, make
sure that it fits tightly on the valve body.
2. Insert new O-ring seals (16) which have been oiled with clean lubricating
oil in the ring grooves; in doing so, make sure that they are evenly ten-
sioned all around the circumference and that they are not twisted.
3. Fill the interior (spring chamber) of the injection valve through the leakage
fuel drain bore with clean fuel.
4. Screw the threaded spindle (221.182-2) onto the injection valve.
2007-10-24 - de
32/40
5. Screw lifting eye bolt (000.142) onto the threaded spindle (221.182-2),
fasten rope with shackle (002.453) on the lifting eye bolt and hook rope
During cleaning, make sure that no foreign bodies are allowed to drop
into the combustion chamber!
7. Carefully install the injection valve in the bore; in doing so, make sure that
the bore for the threaded piece (7) is in the correct position. Press on the
injection valve until it rests in place.
8. Disconnect the shackle from the lifting eye bolt, unscrew and remove the
lifting eye bolt and threaded spindle.
9. Install thrust ring (12) with extractor.
10. Push the thrust piece (11) over the stud (13) and lay it on the thrust ring.
11. Coat the thread of the threaded piece (7) with MoS2 lubricant, screw it
into the injection valve and tighten it to the specified torque (see Work
Card 000.30).
12. Attach the fuel injection pipe (see Work Card 434.01).
13. Coat the thread and contact face of the hexagon nut (10) with MoS2
lubricant, screw it finger-tight onto the stud bolt (13) and tighten it in sev-
eral stages to the specified torque (see Work Card 000.30).
32/40
Summary
Check components for state/wear condition, ensure/ restore operational
safety. Fuel injection valves affect the loading of the injection system and the
engine operating data. 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
Quantity Designation Number Status
1 Nozzle tester L, V32/40 221.208 Standard
1 Connecting piece 221.208-30 Standard
1 Nozzle tester L, V32/40 221.209 Standard
1 Connecting piece 221.209-30 Standard
1 Slushing oil - Inventory
1 Receptacle for slushing oil - Inventory
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
Observation
The tool numbers of the individual parts of the pressure-testing set are com-
posed of the tool number of the pressure-testing set and the item number of
the individual part. See Figs. 1 and 2.
32/40;32/40CR;32/40DF
Preliminary remarks
Functional performance and setting of the injection valve affect the combus-
2009-10-15 - de
tion process, the operating data and the loading of the injection system. If
there are changes in the operating data (ignition pressure, exhaust gas tem-
perature) the valves concerned should be checked for opening pressure and
leakages. The nozzle tester makes it possible to carry out pressure testing
using a hydraulic hand pump. The device ensures comfortable working
Fuel injection valve
Note
In the testing of injection valves of modern 4-stroke engines the atomisation
is no longer a test criterion, because the behaviour of the injection nozzle in
engine operation cannot be verified.
An inferior spray pattern does not indicate anything with regard to the func-
tioning of the injection nozzle in the engine. It is fully functional if it fulfils the
criteria for opening pressure, tightness and free nozzle apertures.
Work steps 1. Insert injectors in the locating head and tighten uniformly with the
retainer.
2. Screw in connecting piece (30) on the pressure hose connection of the
injector and screw high-pressure hose (28) onto the connecting piece.
3. Place the nozzle jet receptacle (13-15) under the injection nozzle and
push it up into a position where the jets are likely to strike the outer walls
2009-10-15 - de
Never allow the injection nozzle to spray into the open air, only into the
receptacle! Do not touch fuel jets, as they penetrate skin tissue and
cause painful inflammation! Do not use open flames at the workplace!
Smoking is strictly prohibited! An oil mist extractor should be used
wherever possible!
The following steps are involved in checking and setting the injectors:
▪ Check opening pressure,
▪ Check nozzle bores,
▪ Set target pressure,
▪ Check tightness.
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. The test pressure must not exceed 400 bar! In case of new nozzle
elements, the nozzle needle may stick during the first spray test and
must be released by intensive flushing. In the case of injection nozzles
already used, collect the slushing oil contaminated with fuel and do not
use it in the pressure-testing set again.
In case of new nozzles, there can be a drop in the opening pressure of
Work Cards, classified into sub-assemblies
2. Release hexagon nut (44) and turn back adjusting screw (45) until com-
pression spring (49) is released.
3. Close pressure relief valve. Actuate hand pump (26) uniformly and adjust
opening pressure with adjusting screw (45) to 30 bar.
Figure 3: Assessment of the nozzle orifices. Left - open, right - partly blocked
Compression spring
Do not set a higher pressure than indicated, otherwise the compression
spring will be deformed. Adjust to the indicated higher spray pressure
value only after assembling a new compression spring to compensate
for the initial setting of the compression springs.
2009-10-15 - de
Summary
Check components for state/wear condition, prevent operational problems/
damage.
Fuel injection valves affect the loading of the injection system and the engine
operating data. They are to be checked if there are deviations in the operat-
ing data, overhauled if necessary or replaced.
The work/ work steps include:
Disassembling components,
Checking parts/components.
Tools/aids required
Quantity Designation Number Status
1 Tensioner for nozzle nut L, V32/40 221.210 Standard
1 Reducing jaw for injection valve (set) 221.210-6 Standard
1 Socket spanner 55 221.143 Standard
1 Tensioner for nozzle nuts 32/40 CR, 221.211 Standard
32/44 CR
1 Reducing jaw for injection valve (set) 221.211-6 Standard
1 Socket spanner 221.194 Standard
Preliminary remark
Work Cards, classified into sub-assemblies
Dismantle injection valves if, during the tests according to Work Card
221.02, errors are detected and if the nozzle element has to be changed
due to the operation time. The disassembly is done in the tensioner for
nozzle clamping nut.
2007-06-15 - de
3. Insert injection valve with injection nozzle downwards in the flange and
tighten the yokes (4,5) evenly.
Fuel injection valve
4. Release hexagon nut (44) and turn back adjusting screw (45) until com-
pression spring (49) is released.
5. Unscrew hexagon bolts (60) on the flange (1). Turn flange with injection
valve by 180° and screw in the hexagon bolt again.
6. Release nozzle clamping nut (52) carefully.
7. When unscrewing the nozzle clamping nut (52) use the following method:
Unscrew released nozzle clamping nuts and, at the same time, prevent
them from axially lifting from the holder (46) by continuously hitting the
nozzle body (42) lightly with a rubber mallet.
8. Unscrew the nozzle clamping nut and remove nozzle body. Ensure that
the nozzle needle (43) does not fall out.
9. Extract nozzle needle (43) from nozzle body and place it in fuel for clean-
ing.
Work Cards, classified into sub-assemblies
Nozzle needle
Never interchange nozzle needles from one nozzle body to another.
They are manufactured in pairs.
10. Unscrew hexagon bolts (60) on the flange (1). Turn back flange with
injection valve by 180° and screw in the hexagon bolts again.
11. Disassemble injection valve from the tensioner flange and place on the
workbench.
12. Unscrew setting screw.
32/40;32/40DF;32/44CR
Fault sources
Pay particular attention to those fault sources which have led to unsat-
isfactory results in the inspection of the injection valve.
Work steps 1. Differentiation feature nitrated nozzle elements and seat insert nozzle ele-
ments (see figure 3).
Figure 3: Differentiation feature: Left – nitrated nozzle element, right – seat insert noz-
zle element (figure shows injection valve of the engine type L,V 32/40)
1. Clamp a suitable cleaning wire in the chuck (002.701) for cleaning the
nozzle bores and insert through nozzle bores (see figure 4).
41 Cleaning wire
42 Valve body
32/40;32/40DF;32/44CR
2. Check if the nozzle needle can be moved in the nozzle body easily and
without perceivable resistance (see figure 5).
42 Nozzle body
43 Nozzle needle
to do this.
6629 221.03-05 EN
Work Cards, classified into sub-assemblies Fuel injection valve
32/40;32/40DF;32/44CR
7 (7)
221.03
MAN Diesel & Turbo 221.04
Summary
Impart necessary knowledge, ensure correct execution of work.
Fuel injection valves affect the loading of the injection system and the engine
operating data. They are to be checked if there are deviations in the operat-
ing data, overhauled if necessary or replaced.
The work includes:
Assembling components.
Tools/aids required
Quantity Designation Number Status
1 Tensioner for nozzle nut L, V32/40 221.210 Standard
1 Reducing jaw for injection valve (set) 221.210-6 Standard
1 Socket spanner 55 221.143 Standard
1 Tensioner for nozzle nuts 32/40 CR, 221.211 Standard
32/44 CR
1 Reducing jaw for injection valve (set) 221.211-6 Standard
1 Socket spanner 50 221.194 Standard
1 Tensioner for nozzle nut L, V32/40 221.212 Standard
DF
Starting position Injection valve disassembled, all individual parts carefully cleaned, damaged
parts replaced.
Work steps 1. Clean set screw (47) and hole carefully as given in Loctite specifications.
2. Screw eye bolt (001.412) into thrust piece (48), hold holder (46) at an
angle (with sealing face facing up) and guide in thrust piece including
compression spring (49) and spring plate (50). In doing so, pay attention
to the position of the groove for the set screw (47) (see Fig. 1).
Check that the spring plate is positioned correctly.
3. Coat thread of the set screw (47) with securing compound Loctite 243
on a length of 5 mm and screw into holder until set screw no longer
projects.
Check that the thrust piece can still move in an axial direction.
4. Unscrew eye bolt.
5. Screw in setting screw (45), do not tighten compression spring yet.
6. Depending on the engine type, insert a suitable reducing jaw in the
mounts on the flange (1) of the tensioner. See Fig. 2.
7. Insert holder (46) in the flange (1) so that the sealing face for valve body
(42) faces downwards. Tighten the yokes (4,5) evenly. Rotate flange by
180° and fix in position.
8. Dip nozzle needle (43) in clean fuel and guide into the nozzle body, check
for easy movement.
Work Cards, classified into sub-assemblies
9. Check nozzle needle stroke between top edge of nozzle body and offset
on the nozzle needle.
For set value see Volume 010.005 Engine - Operating Instructions, Sec-
tion "Technical Data".
10. Dry sealing face with paper towel. Insert nozzle body with nozzle needle
on holder, paying attention to the position of the two parallel pins (51).
11. Coat pressure shoulder (D) on nozzle body (42) with "Optimol Paste
White T" lubricant. See Fig. 1.
12. Coat screw threads of holder and nozzle clamping nut (52) as well as
32/40;32/40DF;32/44CR
pressure shoulder (D) on the nozzle clamping nut with "Optimol Paste
White T" lubricant. See Fig. 1.
13. Screw nozzle clamping nut onto the holder hand-tight and in a second
step tighten with specified torque (see Work Card 000.30). Rotate
adapter head by 180° and fix in position.
14. Screw hexagon nut (44) loosely on adjusting screw and tighten only after
2008-10-22 - de
Figure 1: Injection valve (figure shows injection valve for the engine type 32/40)
2008-10-22 - de
2008-10-22 - de
Summary
Ensure correct execution of work, assess contact pattern/wear status,
restore contact pattern.
The injection valve seat in the cylinder head is to be checked by means of
touching test and, if necessary, remachined every time the fuel injection valve
is removed.
The work includes:
Creating a correct contact pattern.
Tools/aids required
Quantity Designation Number Status
1 Grinding-in fixture 055.197 Standard
1 Spindle 055.197-1 Standard
1 Guide bush 055.197-3 Standard
1 Guide bush 055.197-5 Standard
1 Grinding wheel 055.197-7 Standard
1 Small grinding plates (set) 055.197-13 Standard
1 Pliers for locking rings 055.197-19 Standard
1 Quick-acting cleanser Loctite 7061 055.197-21 Standard
Work steps
Fuel injection valve
6 Cylinder head
15 Sleeve
62 Washer
63 Hexagon bolt
7. Rotate grinding tool to and fro, raise in-between and blow off grinding
dust with compressed air.
2008-09-19 - de
Remove only so much material that valve seating surface is shiny and
6 Cylinder head
15 Sleeve
17 Sleeve
A max. permitted dimension
Figure 3: Abbreviated representation of the max. permitted dimension for grinding the
fuel injection valve seating surface
2008-09-19 - de
Summary
Ensure correct execution of work, assess contact pattern/wear status,
restore contact pattern.
The sealing faces on the threaded piece to the fuel injection valve must be
checked for damage every time they are removed and must be machined if
required.
The work includes:
Creating a correct contact pattern.
Tools/aids required
Quantity Designation Number Status
1 Pressure pipe grinding device 434.042 Option
1 Adapter plate 434.042-1 Option
1 Threaded ring 434.042-2 Option
1 Bearing ring 434.042-3 Option
1 Bearing flange 434.042-4 Option
1 Spacer ring 434.042-7 Option
1 Spacer ring 434.042-8 Option
1 Stop gauge (threaded piece) 434.042-9 Option
2 Bearing block 434.042-10 Option
1 Swivel arm 434.042-11 Option
1 Bracket 434.042-12 Option
1 Stop 434.042-13 Option
32/40
Work sequence 1 - Attachment of the threaded piece to the pressure pipe grinding
device
Work Cards, classified into sub-assemblies
Work steps 1. Release both clamping levers (434.042-41) and swing out grinder (3) with
bracket (434.042-12) up to the stop.
2. Screw on and tighten adaptor flange (434.042-22) with hexagon socket
bolts (2) on threaded ring (434.042-2).
3. Fasten stop gauge (434.042-9) on adaptor flange with two hexagon
socket bolts (6).
2007-11-05 - de
32/40
When fixing the stop gauge on adapter flange, support with tommy bar
Fuel injection valve
There is a left hand thread on the threaded piece on the injection valve
side.
5. Screw in the pressure pipe in the adapter flange by using counter flange,
until pressure pipe taper is in contact with the stop gauge.
6. Screw on counter flange on adaptor flange and tighten by using face
spanner (434.042-38) and hook wrench (434.042-37).
7. Place clamping piece (434.042-42) at the end of the threaded piece (see
figure 1).
8. Detach stop gauge (434.042-9).
9. Insert tommy bar (000.262) radially in threaded ring (434.042-2) and
screw it in on adapter plate (434.042-1) until it abuts.
10. Press the yellow stop on the grinder, set up grinding disc (434.042-16)
with emery paper (434.042-44) on grinder and fasten using fastening nut.
11. Pull back slide (434.042-18) with support adjusting crank (4).
12. Swing the bracket (434.042-12) up to the stop again and fix on the slide
with two clamping levers (434.042-41).
Work Cards, classified into sub-assemblies
Sealing faces are difficult to rework and this requires particular care.
Work steps 1. Swing the swivel arm (434.042-11) with grinder up to the right hand stop
(5).
2. Drive grinding wheel (434.042-16) with support adjusting crank onto the
sealing face of the threaded piece, until the grinding wheel touches the
sealing surface at a tangent.
3. Move swivel arm up to the left stop (434.042-13), such that the grinding
wheel faces the threaded piece.
The advance is not on the support adjusting crank. The adjusted posi-
tion remains unchanged during the entire grinding sequence. Lightly
rework the sealing faces, only smoothen removing as little material as
possible.
7. Move swivel arm up to the left hand stop, so that the grinding wheel
faces the threaded piece and switch the grinder off.
8. Evaluate the result of the grinding process. Repeat the grinding process
until the sealing face has a uniform polished appearance.
32/40
Pull out used emery paper immediately and replaced by a new one.
9. Remove threaded piece from pressure pipe grinding device and remove
counter flange.
Fuel injection valve
Work Cards, classified into sub-assemblies
2007-11-05 - de
32/40
Summary
Ensure correct execution of work, enable emergency operation.
To enable emergency operation of the engine in the event of failure of a tur-
bocharger, refitting must be done on the charge air and exhaust systems.
The work/work steps include:
Dismantling components,
fitting components.
Safety requirements
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Blind flange 280.024 Standard
1 Blind flange 280.025 Standard
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Sealing compound - Inventory
Work sequence 1 - Refit charge air and exhaust line for emergency operation
(installation of the blind flanges)
Starting position Breakdown of a turbocharger. Cartridge and volute casing of relevant turbo-
charger removed, supply of lubricating oil to turbocharger interrupted.
V32/40
2009-03-09 - de
compensator (5).
2. Insert blind flange (280.025) between axial compensator and flange of
turbocharger (seal in contact with turbocharger) and screw back in with
flange bolts (4).
3. Detach connector (2) between turbocharger and charge air cooler (3). (If
not already removed with volute casing)
4. Close charge air cooler with blind flange (280.024) and flange bolts (7).
5. Seal off bypass pipe (if installed) downstream of bypass valve using suita-
ble equipment, or cut off the power supply to the solenoid valve M392
(8).
2009-03-09 - de
Work sequence 2 - Backfitting of the charge air and exhaust pipe (removal of the blind
flanges)
The refitting is done in reverse sequence as that for fitting the blind flanges. In
doing so, observe the following points:
1. After removal of the blind flanges (280.024 and 280.025), apply Hylomar
SQ 32/M sealant to the flange surfaces between the connecting piece
and the charge air pipe as well as between the axial compensator and
the turbocharger.
2. Tighten all flange bolts with the specified torque (see Work Card 000.31).
3. Check the flanged joints for leakage.
Exhaust pipe
Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect 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.
The work/work steps include:
Inspection of parts/ components,
Dismantling and assembling of components.
Tools/aids required
Quantity Designation Number Status
1 Torque wrench 008.017 Standard
2 Lifting eye bolt M12 000.142 Standard
1 Wire brush - Inventory
1 Lifting tackle with rope - Inventory
1 Lubricant (containing molybdenum - Inventory
disulphide)
Leaky exhaust pipes can be seen by the black colouring at the corre-
sponding places on the insulation.
2. Unscrew the hexagon nuts (8) at the base of the respective section of the
exhaust pipe and remove the clamps (5).
3. Screw lifting eye bolts (000.142) in the eyes (12) on the exhaust pipe sec-
tion (6) and attach to the hoist with a rope.
4. Pull the section of exhaust pipe slowly upwards. In doing so, do not
damage the compensators (4).
V32/40
2007-07-17 - de
2007-07-17 - de
Check the exhaust pipe for foreign bodies after damage to piston or
valve. Broken pieces can be drawn from the exhaust flow into the tur-
bine and cause serious damage.
V32/40
2007-07-17 - de
Summary
Check components for state/wear condition, prevent operational problems/
damage.
lube oil pumps are mostly maintenance-free. If, however, there are problems,
it is necessary to check the individual components for damage and change
them if necessary. If bearings are damaged then the complete pump should
be replaced.
The work / work steps include:
Disassembling components,
Separating and assembling,
Refitting components.
Tools/aids required
Quantity Designation Number Status
1 Forcing-off device 009.340 Option
1 Counter support 009.340-11 Option
1 Forcing-off device 009.331 Option
1 Forcing-off device 009.331-3 Option
1 Pipe 009.331-6 Option
Preliminary remarks
The lube oil pump consists of two separate pumps which are similar in struc-
ture and which are connected by an intermediate washer (17).
Work steps 1. Remove pipes and blind flanges (4) from the lube oil pump, letting oil
drain to the tank. Pay attention to seals and sealing rings.
Work Cards, classified into sub-assemblies
2. Hang pump with rope onto lifting tackle and tighten rope.
3. Unscrew fastening screws on drive cover (3), remove pump carefully and
place on a wooden support.
4. Remove cylinder screw (24) for securing the nut (1) with screwdriver
(000.293).
5. Mount forcing-off device (009.331-3) on driving pinion (2), insert pipe
(009.331-6) and unscrew nut (1).
32/40;48/60;L32/44CR;L58/64
6. Press down driving pinion with forcing-off device and forcing-off disc
(009.331-8).
7. Release the hexagon bolts (23) between the pump casing (5) and the
intermediate disc (17) and turn out.
8. Separate pump 2 from pump 1, taking care with the parallel pins.
Remove intermediate washer (17).
9. Release the hexagon bolts (23) between the pump casing (5) and the
drive cover (3) and turn out.
2008-01-08 - de
10. Mark both pumps drive shafts (19), impeller axles (20) and bearing units
(8) for refitting in the same position.
11. Remove drive shafts and impeller axles and bearing units.
12. Extract the taper pins from the drive cover (3) with suitable material and
remove the drive cover with fitted bearing unit.
14. Unscrew two opposing hexagon bolts (14) on the valve cover (15) and
replace with two threaded spindles M8, approx. 100 mm long.
15. Screw on two hexagon nuts M8 on both spindles until they rest on the
valve cover, unscrew the remaining hexagon bolts.
16. Remove the pretension of the compression spring (12) by uniformly
screwing back the two hexagon nuts M8 whilst holding the two threaded
spindles.
17. Remove valve cover (15) and remove compression spring (12) with valve
piston (11).
18. Clean all parts, check for damage. Check bearing and sliding surfaces
for running pattern and wear. Renew all sealing rings, seals and high-ten-
sion rings.
Starting position All parts cleaned, checked. All sealing rings, seals and high-tension rings
renewed. The assembly or fitting is done in reverse order of the dismantling
or removal. In doing so, observe the following points:
2008-01-08 - de
3. Do not put any paper gaskets between the drive cover, casing and pres-
sure limiting valve.
4. Apply oil to the thread of the hexagon bolt (9, 23), screw in, not forgetting
high tension rings (locking rings) and tighten with the specified torque
(see Work Card 000.30).
5. If pump 2 is fitted to pump 1 ensure correct meshing of the gears on the
drive shafts (19).
6. Check complete pump for easy movement.
7. Set up driving pinion (2) for reassembly on the lightly oiled cone of the
drive shaft (21), attach forcing-off device (009.331-3) and set pipe
(009.331-6).
8. Oil nut (1), screw it on the drive shaft (19) and tighten with specified tor-
que (see Work Card 000.30).
9. Measure and note distance (A) between front surface of the drive shaft
(19) and nut (1) with a depth gauge.
10. Tighten nut with specified torque (see Work Card 000.30). Repeat meas-
urement according to work sequence 2 point 9 and compare both val-
ues.
Distance (A) must have increased by minimum 0.6 mm to max. 1.2 mm.
11. Secure nut (1) by powerfully tightening the cylinder screw (24).
12. Clean the sealing face between pump and engine before attaching and
coat with "Hylomar SW32M" sealing compound.
13. Fill pump with oil.
14. Connect the pipes without tension onto the pump, screw the blind flange
(4) in position.
15. Check pump and pipes for leakages and noises when starting the
engine. Loud noises show that the pump is sucking air, therefore the
pump cannot deliver the full capacity and cavitation can occur.
Work Cards, classified into sub-assemblies
32/40;48/60;L32/44CR;L58/64
2008-01-08 - de
2008-01-08 - de
Summary
Check components for consistency/wear condition, ensure/restore opera-
tional safety.
Lube oil pumps are largely maintenance free. If, however, there are prob-
lems, it is necessary to check the individual components for damage and
change them if necessary. If bearings are damaged then the complete pump
should be replaced.
The work/work steps include:
measuring components and
assessing the wear surface appearance / wear condition.
Tools/aids required
Quantity Designation Number Status
1 Feeler gauge (set) 000.451 Option
1 External micrometer - Inventory
1 Inside micrometer - Inventory
1 Abrasive (emery cloth K400) - Inventory
1 Oil stone - Inventory
1 Sealing compound - Inventory
Preliminary remarks
These assessment criteria are to be used for the assessment of wear parts
on lube oil pumps. The purpose of the criteria stated is to enable a decision
to be made on whether or not parts of the gear pumps can remain in service.
The assessment criteria regarding continued use are based on the assump-
tion that the operating conditions of the lube oil pumps do not change within
the scope of the operating period. This is particularly applicable to the quality
and purity of the lubricant used, its maintenance and the maximum tempera-
tures that occur and loads on the pumps.
2007-04-18 - de
1. Seals
As a basic rule, the existing seals must be replaced with new ones each time
the lubricating oil pump is removed.
Grooves containing O-ring seals must be carefully cleaned and inspected for
foreign matter or edge damage. Minor edge damage can be smoothed by
hand using an emery cloth (400 grain in accordance with DIN 69176, Part 1
or finer) and a scraper.
Leftover liquid sealant must be completely removed before the pump can
mounted with the new sealing compound applied.
2. Gear shafts
2.1 Gearing
1 Tooth flanks
Work Cards, classified into sub-assemblies
▪ Spalling < 1 cm2 in the transitional area between the axial butting surface
and tooth flank
4 Bearing journals
It will not be possible to use the gear shafts or bearing flanges due to dam-
age in the area of the axial butting surfaces if
▪ scoring or scratches on the axial butting surfaces are deep enough to be
felt out by fingernails or the point of a pencil.
The axial play is determined by the gear shaft and bearing flanges
which have been harmonised with one another. Individual parts there-
fore cannot be replaced in this case. We recommend you replace the
existing lubricating oil pump and have it overhauled by MAN Diesel &
Turbo or an authorised Service Centre.
2007-04-18 - de
3. Bearing bushes
Lubricating oil and cooling water pump
6 Bronze layer
7 Sliding layer
2007-04-18 - de
Summary
Check components for state/wear condition, prevent operational problems/
damage.
cooling water pumps are mostly maintenance-free. If, however, there are
problems, it is necessary to check the individual components for damage
and replace them if necessary.
The work / work steps include:
Disassembling components,
Separating and assembling,
Refitting components.
Tools/aids required
Quantity Designation Number Status
1 Forcing-off device 350.011 Option
1 Forcing-off bolt 350.011-1 Option
1 Forcing-off disc 350.011-3 Option
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 Torque wrench 008.011 Standard
1 Pliers for the locking rings C 19-60 002.162 Standard
1 Extension piece 12.5x125 001.911 Standard
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3 Shaft 17 Seal
4 Bearing casing 18 Flange
5 Ball bearing 19 Spiral casing
6 Locking ring 20 sealing screw on distribution
block
8 Ball bearing 21 Hexagon nut
Work Cards, classified into sub-assemblies
10 Seal 22 Washer
11 sealing screw on distribution 33 Gear wheel
block
12 Hexagon nut 34 Washer
13 Washer 35 Hexagon bolt
15 Impeller nut 36 Hexagon bolt
16 Impeller A Clearance
Figure 1: Cooling water pump
Work steps 1. Release and remove oil and water pipes on the cooling water pump, tak-
ing care with the seals.
2. Hang cooling water pump with rope onto lifting tackle and tighten rope.
3. Release hexagon bolts (36) and unscrew.
4. Push off the cooling water pump with two hexagon bolts with peg (M16),
remove carefully and place on wooden support.
5. Release hexagon nuts (12), unscrew and remove inlet flange (18), taking
care with the washer (13) and sealing ring (17).
2007-10-23 - de
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6. Release hexagon nuts (21), unscrew and remove spiral casing (19). Take
care with the seal (10) and washer (22).
7. Release impeller nut (15) whilst holding against the gearwheel (33) with
the forcing-off device (009.331-3) (see figure 3).
8. Pull off the impeller (16) with dismantling device (350.011) (see figure 3).
9. Remove shaft seal ring (25 - 27), taking care with the individual parts.
3 Shaft
4 Bearing casing
16 Impeller
25 Slide sealing ring
26 Thrust ring
27 Seat ring
30 Shaft seal
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6. Clean all parts, check for wear, renew damaged or worn parts.
5. Insert shaft seal ring correctly (sealing lip must point to the ball bearing).
Make sure that the sealing lip is not damaged.
6. Remove the gearwheel (33) as follows (point 7 - 11):
7. Lightly oil the shaft cone and slide the gearwheel up tight.
Use thin oil! Gearwheel is fixed only after pushing out the oil film on the
shaft cone!
8. Oil hexagon bolt (35) apply washer (34) insert both together and tighten
with specified torque (see Work Card 000.30).
9. Measure and note gap (A) between the gearwheel and bearing casing
(4).
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When measuring the axial clearance must be each on the same side,
10. Tighten hexagon bolt with specified end torque (see Work Card 000.30).
11. Repeat measurement as per point 9 and compare both values. Gap (A)
must have reduced by 0.8 to 0.9 mm.
12. Coat the sealing face between the spiral casing (19) and bearing casing
(4) with Hylomar sealing compound and fit spiral casing.
13. Check the shaft running surface and seal seat in the sealing plate for
cleanliness and fit the shaft seal (25 - 27) as described below (point 14 -
15):
14. Press the seat ring (27) in the lightly oiled seat in the bearing casing.
15. Lubricate the shaft and hole of the slide thrust ring (25) with vegetable oil
and slide the thrust ring (26) with slide seal ring on the shaft (see figure 4)
until the pressure ring abuts the seat ring.
Do not damage or scratch the sealing faces. Do not let the shaft seal
ring run dry. Fill up pump with water before commissioning!
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Summary
Carry out the work in accordance with the maintenance plan in good time,
enable/support economic working, prevent operational problems/damage.
The charge air cooler has a significant effect on the performance data and
thus also on the engine performance. It is therefore necessary to check it at
regular intervals and clean it.
The work/work steps include:
Checking operating data,
Removing components,
Cleaning parts chemically/ mechanically,
Fitting components.
Safety requirements
▪ Operating media systems closed/depressurised
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 322.041 Option
1 Bracket 322.041-1 Option
Technical data
Designation Information
Charge air cooler 210 kg
Air side cleaning of the charge air cooler is required if the differential
pressure in the upper load range has reached 800 mm water gauge.
This value is valid for 1 and 2-stage charge air coolers. Connections
before and after charge air cooler are available for a differential pres-
sure measuring unit. Instead of the sealing screws quick-acting cou-
plings can be provided.
Work steps 1. Isolate the cooling water feed and return flows and remove the cooling
Work Cards, classified into sub-assemblies
2008-01-08 - de
8. Unscrew hexagon bolts (2), release the locknut on the clamping device
(5) and turn back several rotations.
9. Pull the charge air cooler forwards by about 500 mm with the ratchet
hoist.
V32/40
2008-01-08 - de
2008-01-08 - de
If there is heavy dirt or encrusting of the finned tubes the lining should
Charge air cooler
2. When using a water-soluble cleaning agent, rinse charge air cooler after
cleaning with abundant water, otherwise blow with compressed air.
The recommended cleaning agents include the following:
Designation Manufacturer
Air Cooler Cleaner Unitor Ship Service AS
Mastemyr
N-1410 Kolbotn/Norway
ACC Plus Unitor Ship Service AS
Mastemyr
N-1410 Kolbotn/Norway
Air Cooler Cleaner Vecom B.V.
Maassluis/Holland
Air Cooler Cleaner ACC-9 Drew Chemical Corp.
Boonton
New Jersey/USA
Air Cooler Cleaner ACC/ME Drew Chemical Corp.
Boonton
New Jersey/USA
Atlas D.G. Cleaner Atlas Mc Alpine LTD
Erith
Kent/England
Work Cards, classified into sub-assemblies
2008-01-08 - de
The installation of the charge air cooler is done in reverse sequence. In doing
so, observe the following points:
1. Pull the charge air cooler into the charge air cooler casing so that about
half is inside and remove the axle (322.041-28). Make sure that both
spindles are completely retracted (see figure 3/I).
2. Check the seals for perfect condition, replace if necessary.
3. Paint the sealing surfaces with sealing compound.
4. Check all pipe connections for tightness after commissioning.
Summary
Carry out the work in accordance with the maintenance plan in good time,
enable/support economic working, prevent operational problems/damage.
The charge air cooler has a significant effect on the performance data and
thus also on the engine performance. It is therefore necessary to check it at
regular intervals and clean it.
The work/work steps include:
Checking operating data,
Partitioning and cleaning of the charge air cooler,
Emptying the partitioned space and Refitting after cleaning.
Safety requirements
▪ Engine secured against starting
Tools/aids required
Quantity Designation Number Status
1 Cleaning device 322.051 Standard
2 Flange with seal 322.051-14 Standard
2 Blind flange 322.050 Standard
2 Flange with seal 322.040 Standard
2 Flange with seal 322.038 Standard
4 Plugging screw DIN 910-M22x1.5 - Standard
4 Seal DIN 7603-A22x27 - Standard
1 Combination spanner (set) - Inventory
Air side cleaning of the charge air cooler is required if the differential pressure
in the upper load range has reached 800 mm water gauge. This value is valid
Charge air cooler
for 1 and 2-stage charge air coolers. Connections before and after charge air
cooler are available for a differential pressure measuring unit. Instead of the
sealing screws quick-acting couplings can be provided.
2007-07-17 - de
Work steps 1. Remove all connections from the connection plate (9) and close the
thread with sealing screws and seal.
2. Remove hexagon bolts (2) with hexagon nuts (3) and insert the blind
flange (322.050) between the axial compensator (4) and the connection
flange of the turbocharger (1) (seal is on the axial compensator) and
screw the flange connection back together.
3. Release the pipe coupling between the charge air cooler and the charge
air pipe and move it sideways (away from the charge air cooler).
4. Remove the connector after the charge air cooler and screw the flange
(322.038) with seal and hexagon bolts (8) onto the charge air cooler (see
figure 2 and 3).
5. Remove the air injection pipe or blind flange on engines without air by-
pass pipe, from connection (9271) and fit the flange (322.040) with seal
(see figure 2).
6. Remove the condensed water pot (if fitted) on connection (9299) and fit
flange (322.051-14) with seal on connection (9299).
Work sequence 3 - Refitting after cleaning and draining the partitioned space
The refitting is done in reverse sequence as that for fitting the blind flanges. In
doing so, observe the following points:
1. After removing the flanges (322.050 and 322.038) including seals, paint
the flange surfaces between the connection piece and the charge air
cooler (7) with Hylomar SQ 32/M sealant.
2. Before tightening the hexagon bolts (8) align the connector flush with the
charge air pipe.
3. Slide the pipe coupling over the gap charge air pipe connector and
tighten. Check for leakage and re-tighten if necessary (tightening torque
Work Cards, classified into sub-assemblies
2007-07-17 - de
Summary
Carry out the work in accordance with the maintenance schedule in good
time, check the components for condition/wear condition
Remove fuel injection pipes for maintenance and repair work on the injection
valves or injection pumps.
The work/work steps include:
removing the components,
refitting the components.
Safety requirements
▪ Operating media systems closed/depressurised
▪ Engine secured against starting
▪ Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Plate for adjustable wrench 32 009.088 Standard
1 Ratchet tool 008.023 Standard
1 Torque wrench 008.011 Standard
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Figure 1: Fuel injection pipe (figure shows covering without socket for engine diagnosis system)
Starting position Casing on the exhaust counter side removed, shut-off valves on the fuel
pipes closed, cylinder head cover removed.
Work steps 1. Slacken and fully unscrew the hexagon nuts on the injection valve (see
Work Card 221.01).
2. Remove the leakage fuel drain pipe (15) from the covering lower section
(10).
3. On engines with engine diagnosis system (MODIS) extract the plug from
the covering section.
4. Release the hexagon nuts (7) and unscrew the set screws (6) half way.
5. Loosen the hexagon bolts (16).
6. Release nuts (5), unscrew and push back.
7. Pull off pressure tube (8) from threaded piece (2). To do this, slightly lift or
depress the adapter (4) and threaded piece depending upon the position
of the tolerance.
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If several fuel injection pipes are removed, label these first so that each
Before fitting the fuel injection pipe, check the nuts (18) for secure fit on
the thrust piece (8). (see Work Card 434.02)
It is important to start the fitting at the injection pump. Work Cards, classified into sub-assemblies
6. Insert the pressure pipe in the threaded piece, in doing so slightly lift or
depress the adapter and threaded piece depending upon the tolerance
position.
7. Screw nut and threaded piece in position.
8. Tighten both nuts (5) with the specified torque (see Work Card 000.30).
9. Tighten the hexagon bolts (16).
10. Coat the thread and contact face of the hexagon nuts on the fuel injec-
tion valve with MoS2 lubricant, screw them finger-tight onto the stud
bolts and, working in an alternating sequence, tighten them in several
2008-05-21 - de
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ating temperature, initially only tighten the two hexagon nuts finger-
tight, and once the temperature of the components has been equalized
they should then be tightened to the specified torque.
11. Tighten both set screws (6) initially so that the covering remains movable.
12. Determine whether the tip of the set screws is located in the groove on
the nuts.
Take particular care with this otherwise the twisted tensioning makes
the covering tight at the ends.
13. Tighten the set screws, screw the hexagon nuts (7) up to the stop.
14. On engines with engine diagnosis system (MODIS) place the plug in the
socket.
15. Fit the fuel drain pipe on the covering.
16. Attach the casing on the exhaust counter side.
17. Attach the cylinder head cover.
Work Cards, classified into sub-assemblies
2008-05-21 - de
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Summary
Check components for consistency/wear condition, ensure/restore opera-
tional safety.
The fuel injection pipes must be dismantled for checking and reworking of
the pressure pipe sealing faces.
The work/work steps include:
disassembling components,
assembling components.
Tools/aids required
Quantity Designation Number Status
1 Spanner 434.041 Standard
1 Combination spanner (set) - Inventory
1 Grease (acid-free) - Inventory
3. Unscrew the hexagon nuts (12) and remove the hexagon bolts (11).
4. Remove the covering parts (10 and 14) from the pressure pipe (8).
5. Clean all the components and check for damage. Replace if necessary.
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dismantled.
Work steps
1. Place new O-ring (20) coated with acid-free grease in ring groove, ensur-
ing that it is not twisted.
2. Remove the covering parts (10 and 14) from the pressure pipe (8) and fit
together. Insert hexagon bolts (11) and loosely screw on the hexagon
nuts (12).
3. Align the covering sections and tighten the hexagon nuts.
4. Place new O-rings (19) coated with acid-free grease in ring groove,
ensuring that it is not twisted.
2007-07-18 - de
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6. Screw nuts (18) on pressure pipe with spanner (434.041) until they abut
(left-hand thread!), (see figure 1, Detail Y).
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Summary
Checking components for consistency/wear condition, ensure/restore opera-
tional safety.
The sealing faces on the pressure pipe of the fuel injection line must be
checked for damage every time they are removed and reworked if neces-
sary.
The work includes:
Creating a correct contact pattern.
Tools/aids required
Quantity Designation Number Status
1 Pressure pipe grinding device 434.042 Option
1 Adapter plate 434.042-1 Option
1 Threaded ring 434.042-2 Option
1 Bearing ring 434.042-3 Option
1 Bearing flange 434.042-4 Option
1 Adapter flange (pressure pipe) 434.042-5 Option
1 Counter flange (pressure pipe) 434.042-6 Option
1 Spacer ring 434.042-7 Option
1 Spacer ring 434.042-8 Option
2 Bearing block 434.042-10 Option
1 Swivel arm 434.042-11 Option
1 Bracket 434.042-12 Option
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Work sequence 1 - Attachment of the fuel injection pipe to the pressure pipe grinding
fixture
Work Cards, classified into sub-assemblies
Work steps 1. Release both clamping levers (434.042-41) and swing out grinder (3) with
bracket (434.042-12) up to the stop.
2. Screw on and tighten adaptor flange (434.042-5) with hexagon socket
bolts (2) on threaded ring (434.042-2).
3. Fasten stop gauge (434.042-14) on adaptor flange with two hexagon
socket bolts (6).
2007-09-21 - de
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When fixing the stop gauge on adapter flange, support with tommy bar
Fuel injection pipe /Buffer piston/Fuel pipe
5. Screw in the fuel injection pipe in the adaptor flange by using counter-
flange, until pressure pipe taper is in contact with the stop gauge.
6. Screw on counter-flange on adaptor flange and tighten by using face pin
wrench (434.042-38) and hook wrench (434.042-37).
7. Detach stop gauge (434.042-14).
8. Insert tommy bar (000.262) radially in threaded ring (434.042-2) and
screw it in on adapter plate (434.042-1) until it abuts.
9. Press the yellow stop on the grinder, set up grinding disc (434.042-16)
with emery paper (434.042-44) on grinder and fasten using fastening nut.
10. Pull back slide (434.042-18) with support adjustment crank (4).
11. Swing the bracket (434.042-12) up to the stop again and fix on the slide
with two clamping levers (434.042-41).
Work Cards, classified into sub-assemblies
Sealing faces are difficult to rework and this requires particular care.
Work steps 1. Swing swivel arm (434.042-11) with grinder up to the right-hand stop (5).
2. Turn the support adjusting crank until the grinding wheel (434.042-16)
makes tangential contact with the sealing face of the fuel admission pipe.
3. Move the swivel arm up to the left-hand stop (434.042-13) until the front
face of the grinding wheel is facing the fuel admission pipe.
Do not allow the grinding wheel to come into contact with the adapter
flange.
6. You can adjust the feed at the threaded ring (434.042-2) using the
tommy bar (000.262). The maximum advance feed for each operating
cycle is one scale division on the threaded ring
7. Move the swivel arm up to the left-hand stop until the front face of the
grinding wheel is facing the fuel admission pipe then switch off the
grinder.
8. Assess the result of the grinding operation. Repeat the grinding operation
until the sealing face is clean and even.
If you cannot obtain the required wear pattern using the delivery pipe
grinding device, have this repair carried out by a MAN Service Centre.
2007-09-21 - de
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Remove used emery paper immediately and replace with new emery
Fuel injection pipe /Buffer piston/Fuel pipe
paper.
9. Detach the fuel admission pipe from the delivery pipe grinding device and
remove the counter flange.
Work Cards, classified into sub-assemblies
2007-09-21 - de
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Buffer piston
Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, check components for quality/wear condition.
Check buffer piston at regular intervals. Renew the set of piston seals.
The work / work steps include:
Removing/disassembling components,
Replacing sealing rings/elements,
Assembling/fitting components.
Tools/aids required
Quantity Designation Number Status
1 Thickness gauges 0.05-1 000.451 Option
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Standard
1 Hexagon bolt M10x200 - Inventory
1 Lubricant (Copa Slip) - Inventory
1 Locking wire - Inventory
1 Pliers for locking wire - Inventory
2 Strip (Nylon) - Inventory
Preliminary remarks
If there are impact noises on the buffer piston during the operation, this is an
indication of a break in the compression springs. Undamped pressure waves
of the fuel injection pumps in the fuel inflow and outflow systems can occur
3. Screw the stop screw back in position and secure with locking wire (see
figure 1).
4. For checking the OMEGAT piston seal set (2) carefully remove the leak oil
pipe on the connection (12).
5. If leak fuel collects the set of piston seals must be replaced as described
in work sequence 3.
Work sequence 2 - Dismantling and checking the components of the buffer piston
Starting position Engine stopped, fuel pipes blocked off.
Work steps 1. Release the hexagon nuts (8) evenly and unscrew them, remove the
cover (4). Take care with seal ring (11).
General
2007-07-18 - de
The springs (6 and 7) are normally released before removing the hexa-
1 Piston
2 OMEGAT set of piston seals
9 Nylon strip
2007-07-18 - de
1 Introduction
2 Work Cards, Classified by Subjects
3 Work Cards, classified into sub-assem-
blies
4 Appendix
Appendix
2010-08-06 - de
Insulation
4.1 Insulation
Appendix
2010-08-06 - de
Version 1
Checkliste
Every possible insulation part has to be visibly checked for damages, functionality or
misfit on a short period base. Especially these insulation parts which have been
mounted on highly vibrating engine elements have to be checked as a matter of
routine.
Version 1
Checkliste
1. Generelle Schäden
General damages
Version 1
Checkliste
2. Schraubverbindungen
Screwed joints
Lockere Schrauben müssen festgezogen werden.
Loose screws need to get tightened.
If loose screw fittings will be found, an
immediate tightening is necessary. Lost
screws need to get replaced.
Version 1
Checkliste
Version 1
Checkliste
4. Hakenverschlüsse
Hook connections
Version 1
Checkliste
5. Beschädigte Isoliermatten
Version 1
Checkliste
Version 1
Checkliste
Version 1
Checkliste
Version 1
Checkliste