Working Instructions MAN 32/40

MAN Diesel & Turbo
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Technical Documentation
Engine
Working Instructions
Engine ................................................ V32/40
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Works No. of engine ........................... 1065270

1065271
010.005
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Plant No. ............................................ 4302268
Translation of the original instructions

6632 B2-05 EN
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MAN Diesel & Turbo
010.005
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MAN Diesel & Turbo SE

86224 Augsburg
Phone +49 (0) 821 322-0
Fax +49 (0) 821 322-49 4180
primeserv-aug@mandieselturbo.com
www.mandieselturbo.com/primeserv
2 (2)
Copyright MAN Diesel & Turbo

All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.
6632 B2-05 EN
Table of contents
Introduction
1.1
1.2
1.3
Preface
How the working instructions/Work Cards are organized, and
how to use them
Status/Availability Required Tools/Auxiliary Equipment
Work Cards, Classified by Subjects
001
000.03
000.08
000.15
000.16
000.17
000.18
002
000.04
000.05
000.07
000.14
000.19
003
000.11
000.11
000.11
000.21
000.22
000.29
Operating media systems/Pipes

Operating media systems flushing and cleaning
Cooling water system Cleaning
Pipes replacement
Pipes cleaning, pickling and preservation
Solderless pipe unions mounting
Solderless pipe unions Additional parts
Operating media/Auxiliary agents
Lubricating oil assessing and treating
Lubricating oil/Fuel Carrying out the spot test
Cooling water inspecting
Engine or components preservation treatment
Loctite Products use
Machine Elements
Galvanised Bearings assessing
Deep Groove Bearing assessing
Bimetal Bearings (without a third layer) assessing
Elastomer Seals storage, cleaning and fitting
Threaded inserts use
Tightening screwed connections Tightening torques (partial
image)
Tightening screwed connections Tightening torques (table)
Tightening screwed connections Tightening torques (turning
moments)
Tightening screwed connections General remarks
Surface Test By Penetration methods
Surface Test By Magnetic leakage flux method
Working and Safety Regulations the use of load carrying equipment/slings
Hydraulic tensioners/High-pressure pump
Working and Safety Regulations using high-pressure tools/
hydraulic tensioners
High-pressure pump use
High-pressure hoses use
Hydraulic tensioner use
Hydraulic tensioner bleeding, testing, renewing sealing rings
Hydraulic tensioner use
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Table of contents
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000.30
000.31
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000.32
000.34
000.34
000.43
004
000.33
009.03
009.05
009.01
009.02
009.07
6632 B2-05 EN
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Work Cards, classified into sub-assemblies
000
3.1
009
000.09
Sub-assembly overview
Foundations/Bearings
Position of crankshaft flange in relation to driven flange determining/checking
Check foundation bolts Aligning engine on the foundations
Cylinder crankcase/tie rod
Crankshaft bearing bolts and cross tie rods inspection, loosening
and tightening
Cylinder head bolts removing and drawing in
Crankshaft/Coupling bolts
Crankshaft Measuring crankshaft deflection
Balance weight bolts inspecting
Crankshaft oil bore closing
Gearwheel on the crankshaft removal and installation
Coupling bolts inspecting
Balance weight removal and installation
Crankshaft bearing/main thrust bearing
Main bearing cap with lower bearing shell lowering and checking
Upper crankshaft bearing shell removing and installing/checking
Main thrust bearing Measure axial clearance/check locating bearing rings
Crankshaft flange bearing/Bearing shells removing, fitting and
checking
Crankshaft extension removing, fitting and checking with external
bearing
Torsional vibration damper Crankshaft
Torsional vibration damper of the crankshaft removing and refitting
Torsional vibration damper inspecting
Connecting rod/Big-end bearing
Conrod shank bolts inspection, loosening and tightening
Big-end bearing bolts inspection, loosening and tightening
Lowering big-end bearing cap/Removing big-end bearing bolt/
checking lower big-end bearing shell
Upper big-end bearing shell removing and installing/checking
Big-end bearing removal and installation
Piston/Piston rings
Piston removal and installation
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012.03
020
000.10
020.01
020.02
020.03
020.04
020.05
021
021.01
021.02
021.03
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012.01
012
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000.25
000.40
Hydraulic tensioner bleeding, testing, renewing sealing rings

Measuring gauge (measuring device) checking the screw elongation
Operating values/Operating results
Ignition and compression pressures determining
Charge air cooler/crankcase Measuring the differential pressure
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Table of contents
009.08
009.06
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021.04
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023.01
2 (5)
027
027.03
027.04
030
030.01
030.02
030.03
030.04
030.05
034
034.01
6632 B2-05 EN
Piston/Piston rings inspecting

Piston pin and piston pin bush removing and installing/checking
Piston dismantling and assembling
Piston rings assessing
Top land ring/cylinder liner
Top land ring removal and installation
Cylinder liner measure
Cylinder liner (with backing ring) removal and installation
Cylinder liner (without backing ring) removal and installation
Cylinder liner honing
Cylinder head/Valve seat rings/Safety valve
Cylinder head bolts inspection, loosening and tightening
Cylinder head removing and refitting
Cylinder head cleaning
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
102.03 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 disassembling 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
113.08 Valve cone grinding
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034.02
034.03
034.04
034.05
050
050.01
050.02
050.03
050.04
050.05
055
055.01
055.02
055.03
055.04
Table of contents
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6632 B2-05 EN
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Valve seating surface inspecting

Camshaft adjusting device
Control piston of the injection camshaft removing and refitting
Control piston of the injection camshaft dismantling and assembling
125
Operating device
125.02 Three-way valve M306 checking, overhauling
125.04 Three-way valve M317 checking, overhauling
125.05 3/2-way solenoid valve M329 checking, overhauling
125.30 Emergency shutdown device Functional testing at the engine
125.08 5/2-way solenoid valve M367 checking, overhauling
125.09 Pressure-reducing valve M409 checking, overhauling
125.10 Compressed air filter M462 checking, overhauling
125.12 Limit switch M745 checking, overhauling
125.14 2/2-way solenoid valve M314/M315/M316 checking, overhauling
140
Speed regulation
140.01 Electronic speed governor Check in the case of an error
160-162 Starting air pilot valve/Starting valve/Main starting valve
160.01 Starting air pilot valve dismantling and assembling
161.01 Starting valve inspection, removal and installation
161.02 Starting valve dismantling and assembling
161.03 Starting valve Grind seating surface in the cylinder head
162.01 Main starting valve dismantling and assembling
200
Fuel-injection pump/drive
200.01 Fuel injection pump inspecting
200.02 Fuel injection pump shut off
200.03 Fuel injection pump removal and installation
200.04 Fuel-injection pump disassembly and assembly
200.07 Fuel injection pump Measure plunger lift
203
Governor control linkage
203.01 Governor control linkage servicing and checking
203.02 Governor control linkage actuate manually
221
Fuel injection valve
221.01 Fuel injection valve removal and installation
221.02 Fuel injector inspecting
221.03 Fuel injector dismantling
221.04 Fuel injector assembling
221.05 Fuel injection valve Grind seating surface in the cylinder head
221.06 Fuel injection valve Grind sealing faces on threaded piece
280-289 Charge air and exhaust pipe
280.01 Charge air and exhaust pipe for emergency operation converting
280.02 Charge air bypass device disassemble and assemble, renew sealing elements
289.01 Exhaust pipe inspecting
300/350 Lubricating oil and cooling water pump
300.01 Lubricating oil pump dismantling and assembling
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113.09
120
120.01
120.02
4 (5)
6632 B2-05 EN
Lubricating oil pump assessing the individual parts

Cooling water pump dismantling and assembling
Charge air cooler
Charge air cooler removal and installation
Charge air cooler check, clean air system
Fuel injection pipe /Buffer piston/Fuel pipe
Fuel injection pipe removing and refitting
Fuel injection pipe dismantling and assembling
Fuel injection pipe Grind sealing faces on pressure tube
Buffer piston inspecting
Appendix
4.1
Insulation
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300.02
350.01
322
322.01
322.01
434
434.01
434.02
434.03
434.04
Table of contents
MAN Diesel & Turbo
6632 B2-05 EN
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1 Introduction
2 Work Cards, Classified by Subjects

3 Work Cards, classified into sub-assem-
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Introduction
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4 Appendix
6632 1 B2-05 EN
1 (1)
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1.1
Preface
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Preface
Introduction
MAN Diesel & Turbo
Work cards and maintenance The work instructions/Work Cards are closely connected to the engine maintenance schedule, contained in Volume 010.005 of the Technical Documenschedule
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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 clarified with the help of images. The Work Cards describe, by way of introduction, the purpose of the work and, amongst other things, they contain information 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.
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
6682 1.1-01 EN
General
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Filing System
1 (1)
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1.2
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How the working instructions/Work Cards are organized, and how to use
them
How the working instructions/Work Cards are organized, and how to use them
Make-up
Introduction
MAN Diesel & Turbo
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 followed by the individual work steps.
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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
The Work Cards are listed in the directories of sections 2 and 3. The directory in section 2 contains the Work Cards summarised according to the subjects / keywords, the directory in section 3 contains instructions sorted
according to the sub-assembly system of the engine.
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How are the required Work

Cards found?
Dangers, error sources, technical requirements and supplementary information are highlighted by notes. While doing so, the following symbols are used,
depending upon the importance:
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Safety Instructions
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The sub-assembly overview ensures access to the filing system of the directories 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.
Imminent danger
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For directly imminent dangers! Possible consequences: Death or

severe injury, total property destruction!
Potentially dangerous situations
6682 1.2-02 EN
General
Possibly dangerous situations

For possibly dangerous situations! Possible consequences: Minor
injuries, possible property damage!
Introduction
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For potentially dangerous situations! Possible consequences: Severe

injury!
1 (2)
1.2
MAN Diesel & Turbo
Introduction
Source of error
Additional information
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For tips on error sources.
For application tips and supplementary information.
Clearances and tolerances, temperatures and pressures are listed in Volume

010.005 Engine - Operating Instructions in section 2.5.
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Clearances and tolerances,

temperatures and pressures
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
General
Introduction
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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.
2 (2)
6682 1.2-02 EN
1.3
Status/Availability Required Tools/Auxiliary Equipment

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.
Tools/Aids
Quantity
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Tools/aids required
Designation
Number
Status
322.056
2 Bracket
322.056-1
1 Strip
322.056-4
4 Shackle A0.6
002.452
Standard
1 Open-end wrench and ring spanner (set)
--
Standard
1 Hexagon screwdriver (set)
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Standard
1 Lifting tackle with rope
--
Inventory
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1 Removal and mounting device
Table 1: Example: list of tools/aids required
Option
Option
Option
In addition to the required quantity, designation and tool number, the table
also contains information on the status/availability of the tools listed. The following 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 specification.
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Status/Availability
Introduction
MAN Diesel & Turbo
Basic tool
Introduction
6682 1.3-02 EN
General
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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 supply can be extended to include the basic tool if requested. The constituent
parts of the basic tool are listed in the table below.
1 (6)
1.3
MAN Diesel & Turbo

Designation
Number
Complete basic tool set
009.229
Socket spanner (set) (10x12.5 - 34x12.5)
009.230
socket spanner insert DIN 3124 - 16x12.5
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Introduction
Tool
001.754
001.798
001.755
001.799
001.756
001.757
001.758
001.759
001.760
001.769
socket spanner insert DIN 3124 S - 36x20
001.779
socket spanner insert DIN 3124 S - 41x20
001.780
Cross handle DIN 3122A - 12.5
001.891
Socket spanner insert DIN 3124 - 10x12.5

001.751
001.788
001.752
001.753
001.789
001.790
001.908
Extension DIN 3123B - 12.5x125
001.911
Extension DIN 3123B - 12.5x250
001.912
Universal joint DIN 3123C - 12.5
001.876
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Extension DIN 3123B 12.5x75
General
Introduction
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001.787
2 (6)
6682 1.3-02 EN
1.3
Tool
Designation
Number
Combination spanner (set) (5.5 to 34)

Combination spanner DIN 3113 AK - 5.5
001.521
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Ratchet DIN 3122C - 12.5
002.050
Combination spanner DIN 3113 AK - 7
002.020
002.021
002.052
002.023
002.053
002.054
002.024
002.055
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002.051
002.025
002.056
002.026
002.057
002.027
002.058
002.059
Combination spanner DIN 3113 BL - 22
002.070
002.071
002.072
002.073
002.074
002.075
Single-ended open-jaw spanner DIN 894 - 36
000.566
000.567
000.568
000.569
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Introduction
6682 1.3-02 EN
General
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009.231
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Introduction
MAN Diesel & Turbo
3 (6)
1.3
MAN Diesel & Turbo

Designation
Number
Hexagon screwdriver A 8.06506 - 0.8x5.5
000.391
Hexagon screwdriver A 8.06506 - 1.2x9
000.393
Hexagon screwdriver A 8.06506 - 2x12
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Tool
Philips screwdriver DIN 5262 B-Gr. - 1
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Philips screwdriver DIN 5262 B-Gr. - 2
000.293
Hexagon screwdriver DIN 911 - 5
000.294
000.295
000.297
000.298
000.299
000.300
000.301
000.302
Tommy bar DIN 900A - 5
000.507
000.262
000.263
000.264
000.266
Adapter DIN 3123A - 20x12.5
001.923
Adapter DIN 3123A - 12.5x20
001.927
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000.307
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000.402
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000.401
Hexagon screwdriver DIN 911 - 3L
General
Introduction
4 (6)
000.395
6682 1.3-02 EN
1.3
Designation
Number
Locking ring pliers DIN 5254A - 10-25
002.121
Locking ring pliers DIN 5254A - 19-60
002.122
Locking ring pliers DIN 5256C - 19-60
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Locking ring pliers DIN 5256C - 40-100
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Tool
002.162
002.163
000.451
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Feeler gauge DIN 2275C - 0.05-1
Introduction
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001.391
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Crow bar S 550A - 15
002.198
Introduction
6682 1.3-02 EN
General
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Gripping pliers with slip joint DIN 5231 D-L - 240
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1.3
MAN Diesel & Turbo
Introduction
Tool
Designation
Number
009.470
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Tool box, 5-section, 530x200x200
000.693
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Hammer DIN 1041 - 300L
General
Introduction
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Table 2: Basic tools
6 (6)
6682 1.3-02 EN
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1 Introduction

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4 Appendix
6632 2 B2-05 EN
1 (1)
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001
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Machine Elements
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002
003
004
005
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6632 001-05 EN
1 (1)
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Operating media systems

flushing and cleaning
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Summary
Safety requirements
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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.
Fuel systems isolated / depressurised
Engine secured against starting up
Engine stopped
1. Lube oil system
000.03
MAN Diesel & Turbo
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The pipe section between the indicator filter and the engine inlet flange
requires careful cleaning. To allow the interior of this pipe to be fully inspected, it must be separated at each pipe bend using a pair of flanges. As a
basic rule, all the internal welding seams must be smoothed over by grinding.
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These pipe components are to be acidified, neutralised and treated with

slushing oil according to Work Card 000.16. This is dissolved by the lubricating oil (e.g. Esso Rustban No. 335, Shell Ensis Oil, Valvoline Tectyl, Tecto 6
SAE 30) which is subsequently added. If installation is to take place later, the
openings are to be sealed with covers. Our commissioning staff are instructed to check the cleanliness of this pipe before filling the system.
Dirt particles will always remain in the pipes in spite of careful installation and
cleaning. This requires thorough flushing of the entire lube oil system before
commissioning. The electrical standby pump or priming pump must be used
for this purpose in engines with attached lube oil pumps. Before / during and
after the flushing process, the oil must be cleaned continuously by means of
a separator.
1.2 Flushing oil

For the flushing operation, we recommend a special flushing oil with a (low)
viscosity of 45-70 cSt / 40C (e.g. SAE 20). This oil is light so it requires no
preheating.
6682 000.03-01 EN
General
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1.1 Flushing the engine's lubricating oil system
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Severe bearing damage can arise by dirt particles entering the engine!
1 (6)
000.03
MAN Diesel & Turbo
1.2.1 First flushing process
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If no flushing oil is available, the operating oil SAE 40 subsequently to be

used for operation can be used for flushing. In these cases, the oil must be
preheated to 40-50C (preheating units, separator preheater). The engine
cooling water must be preheated to at least 60C to prevent condensed
water forming (or corrosion in the crankcase). During and after the flushing
operation, the oil must be cleaned continuously by means of a filter and separator.
Only the pipe system outside the engine is flushed.
The lube oil inlet to the engine must be bypassed. A temporary pipe that
serves as a return line must be run from the indicator filter to the crankcase.
The filter candles of the automatic filter must be removed, the filter housing
and bypass lines are to be flushed as well.
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Automatic filter without

continuous flushing
Automatic filter with
continuous flushing
The filter candles in the automatic filter must be removed, the filter housing
and the filter bypass pipes must also be flushed.
If there is no downstream indicator filter, the filter candlesneed not be
removed. In this case, there cannot be any pre-cleaning via an indicator filter,
which means the automatic filter is to be used for cleaning in the initial flushing sequence. Since the dirt particles are returned to the tank by the automatic filter, segregation of the dirt particles from the circulating oil is performed here solely through the separator that runs in tandem.
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The lubricating oil cooler is to be included in the flushing process. Manual

operation of the temperature control valve alternately flushes the cooler and
its bypass pipe. The lubricating oil separator must be put into operation. All
the oil pipes, especially in the area of welding seams, should be knocked off
throughout the flushing process.
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Oil circuit with indicator filter If the maximum differential pressure in the indicator filter is reached, switch to
the other filter chamber and clean the sieve inserts properly. If the contamination of the filter is reduced to a minimum, it is possible to end the initial
flushing process.
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The minimum flushing duration of 24 hours must, however, be maintained.
In this case, the filter candles remain in the automatic filter, because only they
provide the filtering. Continue flushing until the filter contamination has
reduced to a minimum, i.e. until the flushing intervals have reduced to maximum 1 flushing per hour for automatic filters without continuous flushing and,
in the case of automatic filters with continuous flushing, the displayed differential pressure has reached a minimum.
General
2 (6)

If a running in filter is attached to the engine, it must be monitored
continuously for differential pressure and, if necessary, cleaned.
The inserts with filter candles are to be installed in the automatic filter (if they
have been removed), the slide valve for the bypass pipe is to be closed.
6682 000.03-01 EN
2010-03-02 - de
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Oil circuit without indicator

filter
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After the flushing sequence is complete, clean the sieve inserts of the indicator filter and check for any damage.
1.2.2 Second flushing process

After assembly of the filter candles in the automatic filter, continue the flushing process for about 2 hours.
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By fitting the pipe line (cleaned) from the indicator filter to the lube oil inlet on
the engine, the engine with its bearing points and injection valves is now
included in the flushing process. The oil tank for run-down lubrication (if
present) should also be included in the flushing circuit.
000.03
MAN Diesel & Turbo
In order to remove any existing dirt from the lube oil tank for run-down lubrication, the oil inlet and oil outlet pipes are to be crossed over. Short temporary hoses should be installed for this purpose. The oil inlet to the turbocharger is to be closed. The throttle plate fitted in the filling pipe must be
removed. The pressure control valve is to be released.
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OS
E
The engine must be turned over through 2 rotations at half-hourly intervals

during the flushing process. The cylinder lube oil pump may be switched on
only at the time of turning over.
If only low differential pressures build up in the automatic and indicator filter
(1 flushing process per hour), the flushing operation can be terminated.
PU
If a running in filter is attached to the engine, it must be monitored

continuously for differential pressure and, if necessary, cleaned.
The pipes previously removed must be reconnected.
NG
The flushing processes must be carried out in the presence of personnel

from MAN Diesel & Turbo SE.
1.3 Draining and cleaning the system components
R
FO
2010-03-02 - de
1.4 Running in filter
If necessary, a running in filter is attached directly to the engine. The running

in filter inserts are to be used from the beginning of the test run in the engine
manufacturer's premises up to the completion of commissioning on-site.
The filter insert must be cleaned in accordance with the manufacturer's
instructions before being used.
Since the running in filter is not switchable, it has a limited service life when in
use (up to approx. 200 operating hours, depending on the condition of the
lubricating oil). The end of the service life is displayed by a differential pressure sensor on the running in filter. An extended period of operation with an
activated contamination display can lead to problems in the lube oil supply.
Therefore, when the differential pressure alarm is triggered, increased atten-
6682 000.03-01 EN
General
TR
AI
If the flushing process has been carried out using the operating oil and the
findings of the oil analysis are satisfactory, the system does not need to be
drained.
NI
If a special flushing oil has been used, the lube oil system must be drained
completely. Oil that remains in the cooler, filter and separator preheater must
be removed via the drain pipes. The filter inserts must be cleaned correctly
and checked for damage.
3 (6)
000.03
MAN Diesel & Turbo
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 manufacturer's instructions.
ON
LY
Remove the filter insert after the system run-in period (normally after completion 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 reasons that require flushing of the lube oil system, the filter insert must be refitted until the flushing process is complete.
RP
OS
E
2. Fuel pressure system
The specifications for the lube oil supply pipe described under point 1 also
apply for the pipe that runs between the double filter installed directly
upstream of the engine and the engine entry point.
2.1 Flushing the fuel system
This system must also be flushed in two cycles in order to thoroughly remove
all installation debris from the pipes. Gas oil or diesel oil must be used for
this.
PU
First flushing operation
During this procedure, the entire shipyard or plant-side pipe system is

flushed via the existing single or double filter.
NG
The automatic filter and viscosity control system must be bypassed via the
pipes provided.
The shut-off valves of all fuel-injection pumps must be closed.
AI
4 (6)
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.
Second flushing operation

The entire system, including the automatic filter and viscosity control system,
is pressurised during this operation.
Continue with the flushing operation until only slight differential pressures
build up in the filters.
Once this flushing operation is complete, clean all filter inserts and inspect
them for damage. Open the shut-off valves of the fuel-injection pumps and
close the bypass pipe of the viscosity control system.
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.
6682 000.03-01 EN
2010-03-02 - de
TR
R
General
FO
NI
Connect the fuel delivery and return pipes upstream of the engine. The return
flow via the flushing line to the heavy fuel oil service tank is effected by
changing over the three-way cock upstream of the mixing tank. The tank
should not contain heavy fuel oil at this point. In this case, once the system
has been filled with diesel oil or gas oil and a sufficient quantity returns to the
heavy fuel oil service tank, the fuel selection three-way cock can be switched
to the inlet of this tank. Diesel or gas oil is now pumped round the entire system.
The flushing processes must be carried out in the presence of personnel

from MAN Diesel & Turbo SE.
ON
LY
2.2 Draining and Cleaning the System Components
000.03
MAN Diesel & Turbo
Drain the sludge from the final preheater, the filter chambers and the mixing
tank through their drain pipes. After 24 hours settling time, the service tank
must also have the sludge drained off.
3. Cooling water system
RP
OS
E
Ensure that the surfaces exposed to cooling water are free of corrosion and
any other residue before commissioning the engine and injection valve cooling system.
If rust is detected, the system needs to be cleaned in accordance with Work

Cards 000.08 and 000.16.
The cooling water system must be flushed with fresh water prior to commissioning the engine. Add a detergent to the water in order to remove any residues of the preservative used. Suitable agents are listed alphabetically in
Table 1. Detergents from other manufacturers may also be used provided
they have the same properties. After cleaning, rinse with untreated fresh
water.
PU
In order to filter out coarser impurities, temporary installation of mud traps is

a must. The mesh must be 1 mm for the low and high temperature system.
The smallest gap in the injection valve is 0.5 mm. Provisional installation of a
mud trap with a width of mesh of 0.25 mm is necessary for flushing the
cooling water system of the injection valves in order to prevent dirt deposits
here and thus avoid reduced heat dissipation.
NG
The integration of two gate valves in each case means that there will be no
water leakage when cleaning or removing the mud traps.
After flushing, the fresh water is to be treated in accordance with the quality
requirements for cooling water (Operating instruction Sheet 3.3.7).
Unitor
HDE - 777
4 - 5%
4 h at 50 - 60 C
MaxiClean 2
2 - 5%
4 h at 60 C
0,05 - 0,5%
4 h at ambient temperature
0,5%
4 h at 50 - 60 C
4%
12 h at 50 - 60 C
Aquabreak
TR
Seaclean Plus
Vecom
Ultrasonic
Multi Cleaner
Table 1: Detergents for removing oily residues
FO
2010-03-02 - de
4. Compressed air system

4.1 Installation-side system
The whole system must be carefully cleaned before operating the engine. All
pressure and control pipes must be free of flammable media and slag, scale
and rust.
6682 000.03-01 EN
General
Nalfleet
Cleaning Time / Temperature
Drew
Concentration
NI
Product
AI
Manufacturer
5 (6)
000.03
MAN Diesel & Turbo
ON
LY
High noise levels when blowing by! Always use ear protection!
Danger of explosion when flammable media are present, e.g. slushing

oil!
RP
OS
E
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 starting 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.
PU
4.2 Engine-side system
In the case of doubt as to whether the pipes are free from flammable media
(e.g. slushing oil), please proceed as follows before the first "live" actuation of
the emergency/main starting valve:
NI
NG
High noise levels when blowing by! Always use ear protection!
AI
6 (6)
1. Remove the starting pipe in front of the first cylinder and check for flammable 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 evaporate.
5. Fit the starting valves and return to the initial state.
6682 000.03-01 EN
2010-03-02 - de
TR
R
General
FO
Danger of explosion when flammable media are present, e.g. slushing

oil!
Cooling water system

Cleaning
ON
LY
Summary
000.08
MAN Diesel & Turbo
Remove contamination/residue from operating fluid systems, ensure/reestablish operating reliability.
RP
OS
E
Cooling water systems containing deposits or contamination prevent effective cooling of parts. Contamination and deposits must be regularly eliminated.
This comprises the following:
Cleaning the system and, if required,
removal of limescale deposits,
flushing the system.
Cleaning
The 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
Drew
HDE - 777
Nalfleet
MaxiClean 2
Unitor
Aquabreak
Vecom
Ultrasonic
Multi Cleaner
4 - 5%
4 h at 50 60 C
2 - 5%
4 h at 60 C
0.05 0.5%
AI
Duration of cleaning procedure/temperature
4%
4 h at ambient temperature
12 h at 50 60 C
Table 1: Cleaning agents for removing oil sludge
Lime and rust deposits can form if the water is especially hard or if the slushing oil concentration is too low. A thin lime scale layer can be left on the surface as experience has shown that this protects against corrosion. If however, 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.
R
FO
2010-02-09 - de
TR
Lime and rust deposits
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.
Products that remove limescale deposits are generally suitable for removing
rust. Suitable cleaning agents are listed alphabetically in the table entitled
"Cleaning agents for removing lime scale and rust deposits". Products by
6682 000.08-01 EN
General
Concentration
Product
NI
Manufacturer
NG
PU
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 providing they have similar properties. The manufacturer's instructions for use must
be strictly observed.
1 (3)
000.08
MAN Diesel & Turbo
ON
LY
Manufacturer
Product
Concentration
Duration of cleaning procedure/temperature
Drew
SAF-Acid
Descale-IT
Ferroclean
5 - 10%
5 - 10%
10%
4 h at 60 - 70 C
4 h at 60 - 70 C
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
RP
OS
E
other manufacturers can be used providing they have similar properties. The
manufacturer's instructions for use must be strictly observed. Prior to cleaning, check whether the cleaning agent is suitable for the materials to be
cleaned. The products listed in the table entitled "Cleaning agents for removing lime scale and rust deposits" are also suitable for stainless steel.
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 application:
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 temperature of the solution should be 40 - 50 C.
Diluted hydrochloric acid may only be used to clean steel pipes. If hydrochloric 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 neutralised and flushed. This residual acid promotes pitting. We therefore recommend you have the cleaning carried out by a specialist.
NG
PU
AI
General
2 (3)
The cooling system must be flushed several times once it has been cleaned
using cleaning agents. Replace the water during this process. If acids are
used to carry out the cleaning, neutralise the cooling system afterwards with
suitable chemicals then flush. The system can then be refilled with water that
has been prepared accordingly.
Only carry out the cleaning operation once the engine has
cooled down
Only start the cleaning operation once the engine has cooled down.
Hot engine components must not come into contact with cold water.
Open the venting pipes before refilling the cooling water system.
Blocked venting pipes prevent air from escaping which can lead to
thermal overloading of the engine.
6682 000.08-01 EN
2010-02-09 - de
TR
Following cleaning
FO
NI
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
process depends on the thickness and composition of the deposits. Values
are provided for orientation in the table entitled "Detergents for removing lime
scale and rust deposits.
Cleaning products can cause damage
ON
LY
The products to be used can endanger health and may be harmful to

the environment.
Follow the manufacturer's handling instructions without fail.
000.08
MAN Diesel & Turbo
6682 000.08-01 EN
General
R
FO
2010-02-09 - de
TR
AI
NI
NG
PU
RP
OS
E
The applicable regulations governing the disposal of cleaning agents or acids

must be observed.
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Pipes
replacement
ON
LY
Summary
000.15
MAN Diesel & Turbo
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.
RP
OS
E
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
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 accordance 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).
NG
PU
Pipe Dimensions/Materials
Lube oil pipes with larger diameter, especially the pipe after the lube oil filter(s), are to be manufactured by bending. Connection flanges and sockets
must be joined to the pipes by gas welding.
R
FO
2007-03-26 - de
TR
Production of lube oil pipes
When gas welding is used, the slag on the filler rod jacket is not required.
This is of special importance, since the roots of the welding seam penetrate
to the inside of the pipe, i.e. the joint gap must be completely filled. On the
inside of the pipe no unfilled butt joints may remain since foreign bodies
could become stuck there. They would not (hardly ever) be eliminated by
cleaning the pipes, and could be drawn into the engine bearings during operation. Operational malfunction caused by damage to the bearings could
result. If prefabricated pipe bends have to be welded in, then intermediate
flange connections are to be used, whereby their number and location are to
be selected in such a way that the welding seams inside the pipe line can be
seen clearly, filled up and checked.
6682 000.15-01 EN
General
AI
If hot-bending becomes necessary when using other pipe qualities or larger

dimensions, or if soldering and/or welding is used on the pipes, then the
pipes must be acidified, leached and washed afterwards (see Work Card
000.16).
NI
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.
1 (2)
000.15
MAN Diesel & Turbo
The above welded joints can also be made using the TIG welding method.
Both with gas welding and with TIG welded joints, the tack and finished
welding seams must be carried out using the same welding method.
Laying/Support
AI
TR
2007-03-26 - de
R
General
FO
NI
NG
PU
RP
OS
E
ON
LY
When laying the pipes, ensure that the pipe routing and fastening is as vibration-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.
2 (2)
6682 000.15-01 EN
Pipes
cleaning, pickling and preservation
ON
LY
Summary
000.16
MAN Diesel & Turbo
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 preserved if required.
RP
OS
E
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 arises 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.
PU
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 process.
All pipe connections are to be blocked off until assembly.
R
FO
2007-10-25 - de
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
extracted using fans and dispersed via scrubbers. The vapour from the alkaline bath must also be directed outside using a fan. The regional protection
regulations must also be observed.
6682 000.16-01 EN
General
TR
AI
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
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.
NI
Mechanical Cleaning
NG
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 compressed air system must be thoroughly rinsed before commissioning the
engine installation.
1 (4)
000.16
MAN Diesel & Turbo
The water bath needs a water connection and a compressed air connection.
The alkaline bath must be capable of being heated up to 80C.
ON
LY
Observance of Occupational Safety Regulations
Treatment of Steel Pipes by Pickling
RP
OS
E
In accordance with occupational safety regulations for handling acids

and alkaline solutions, those who perform acid and alkaline solution
treatments, must wear an acid-resistant suit, rubber boots, rubber
gloves and safety goggles. A water hose must be available in the
immediate vicinity of the acid/alkaline baths for immediate use.
First pickle in the hydrochloric acid bath and then in the tri-sodium phosphate bath for neutralising the acid and for simultaneous short-term preservation.
Hydrochloric acid (HCI) is available commercially at a concentration of 31-33
%, and with less than 1% arsenic.
PU
Mixing ratio for the HCl bath: H20 = 3: 2 (by weight).
Violent Chemical Reaction
NG
Pour the acid into water, not the other way around!
The treatment must not to be performed at a temperature below 20 C. The

duration is determined by visual inspection.
NI
With pipes with threads, acid corrosion on the crest of the thread must be
monitored. It determines the duration of treatment in this case.
Mixing ratio for the bath Na3PO4: H2O = 1: 8 (by weight). Treatment temperature 80 C.
2007-10-25 - de
TR
AI
The acid solution which remains in the grooves and pores in the surface texture is neutralised in a tri-sodium phosphate bath, where the pipes are simultaneously coated with a phosphate layer which protects against corrosion in
the short-term.
General
FO
After completion of the pickling procedure, the acid solution adhering to the
pipes must be washed off in the water bath.
2 (4)
6682 000.16-01 EN
Treatment of Copper Pipes
RP
OS
E
ON
LY
Copper pipes should not be treated in a hydrochloric acid bath if steel

pipes are to be pickled afterwards.
The reaction of the copper (Cu) with the dilute hydrochloric acid (HCl)
the salt copper chloride, dissociated in the aqueous solution (CuCl2). If
a steel pipe is then placed in the pickling bath again, the base iron in
the steel oxidises by the discharge of its positive charge units, so that
iron ions go into solution, while the copper separates out. The steel
pipe is coated with an adherent layer of copper which is in no way
securely affixed. Copper deposits are undesirable on the internal walls
of fuel-carrying pipes. Washed-off copper particles would cause
subsequent operational malfunctions in the injection elements, such as
pumps and nozzles.
000.16
MAN Diesel & Turbo
Treatment of Copper Pipes
First pickle in the sulphuric acid bath and then possibly in the tri-sodium
phosphate bath for neutralising the acid, and for phosphatising.
Sulphuric acid (H2SO4) is commercially available at a concentration of 98 %
(concentrated acid). It must be transported in closed tanks.
PU
Mixing ratio for the bath H2SO4 : H2O = 1: 8 (by weight).
Violent Chemical Reaction
NG
Pour acid into water, not the other way around.
Before using, the prepared bath should rest for 24 hours.
NI
Duration of treatment: At the beginning, with copper pipes 1/4 hour, and, as
the ages progressively, increase the duration accordingly.
Pressure Testing of Pipes
Preservation of Pipes
FO
2007-10-25 - de
Water pipes are pressure tested with water, lube oil, fuel and air pipes with
slushing oil. For the required test pressures see section 2 of the manual.
When stored for a short period indoors and/or in dry surroundings, phosphatisation and an oil film are sufficient for corrosion protection. Also during longterm storage for service, phosphating before the actual preservation with
slushing oil, lacquer or grease offers a good basic preservation. Pipe ends
and connection points are to be sealed with coloured plastic caps. Plastic
6682 000.16-01 EN
General
TR
A neutralisation in the tri-sodium phosphate bath is not necessarily required,

with longer storage, however, it is advisable for the prevention of verdigris
formation.
AI
After taking the pipes out of the sulphuric acid bath the pipes must be rinsed
with water and dried afterwards using a gentle flame.
3 (4)
000.16
MAN Diesel & Turbo
AI
TR
2007-10-25 - de
R
General
FO
NI
NG
PU
RP
OS
E
ON
LY
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 fitting.
4 (4)
6682 000.16-01 EN
Solderless pipe unions

mounting
ON
LY
Summary
000.17
MAN Diesel & Turbo
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.
Quan- Designation
tity
1 Tools, Basic Scope
1 Pipe cutter
1 Counterbore
1 Machine oil
Advantages of solderless pipe unions
Number
Status
009.229
Option
Inventory
Inventory
Inventory
RP
OS
E
Tools/aids required
PU
Solderless pipe unions are preferably used where pipes with a small diameter
can be cold-bent, i.e. where no heat treatment is necessary. The usual process of pickling and neutralising is then not required.
NG
Copper pipes must be provided with reinforcing sleeves on the inside. See
Work Card 000.18.
Work steps
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
without sub-assembly, if they are firmly screwed in to the engine.
Pipes of larger outside diameter and all connections in free pipes are
best pre-assembled in the vice. The open-jaw spanner should have an
approx. fifteen fold length of the width across flats (possibly extended
6682 000.17-01 EN
General
R
FO
2008-10-28 - de
TR
AI
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
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
grinding/filing.
NI
1. Cut pipe at a right angle and deburr. Pipe cutters (see figure 1) are perfect 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!
1 (4)
000.17
MAN Diesel & Turbo
by using a pipe). Otherwise proceed as above. The final tightening is

easier if the cap nut is loosened several times so that oil is once again
admitted between the friction surfaces.
ON
LY
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.
AI
TR
2008-10-28 - de
Figure 1: Required tools - counterbore cutter, pipe cutter and pipe bending device
General
FO
NI
NG
PU
RP
OS
E
Ensure that each pipe end again reaches the same inner cone where
pre-assembly took place.
2 (4)
6682 000.17-01 EN
PU
RP
OS
E
ON
LY
000.17
MAN Diesel & Turbo
The straight pipe end extending into the screw connection must have a minimum length of double the height (H) of the cap nut.
6682 000.17-01 EN
General
7 Mark
Figure 3: Assembly of pipe unions. Assembly on site - on the left, pre-assembly in the
vice - on the right
R
FO
2008-10-28 - de
TR
AI
NI
NG
1 Cap nut
4 Cutting ring and tapered ring
2 Stop
5 Inner cone
3 Pipe
6 Visible collar
Figure 2: Mode of action and control of pipe unions. Starting condition - in the middle
of the illustration, after tightening - at the bottom, checking - at the top.
3 (4)
000.17
MAN Diesel & Turbo
With longer or more highly stressed pipes, pipe supports are required.
RP
OS
E
ON
LY
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).
R Bend radius
D Outside diameter
AI
TR
2008-10-28 - de
R
General
FO
NI
NG
PU
H Height of the cap nut

2H Min. distance to a pipe bend
Figure 4: Minimum distances/Bend radii
4 (4)
6682 000.17-01 EN
Solderless pipe unions

Additional parts
ON
LY
Summary
Insert/replace components, process and install professionally. Accessories

for solderless pipe unions extend their application range. The following can
be used: Reinforcement sleeves, nozzle inserts and screwed hose connections.
The work/work steps include: Proper processing and installation.
RP
OS
E
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
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.
NG
PU
Reinforcing sleeves
000.18
MAN Diesel & Turbo
6682 000.18-01 EN
General
2008-10-28 - de
FO
2 Nozzle insert
Figure 2: Use of nozzle inserts. Left nozzle insert, right factory assembled pipe union
AI
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 beforehand. Ensure that the pipe end is shortened by the length of the nozzle collar.
TR
Nozzle inserts
NI
1 Reinforcing sleeve
Figure 1: Use of Reinforcing Sleeves. Left top sleeve inserted, left bottom - sleeve
knocked in. Right factory assembled pipe union
1 (2)
000.18
MAN Diesel & Turbo

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).
RP
OS
E
ON
LY
Screwed hose connections
4 Hose clamp
AI
TR
2008-10-28 - de
R
General
FO
NI
NG
PU
3 Hose
Figure 3: Using screwed hose connections
2 (2)
6682 000.18-01 EN
002
NG
PU

Machine Elements
FO
TR
AI
NI
001
002
003
004
005
RP
OS
E
ON
LY
MAN Diesel & Turbo
6632 002-05 EN
1 (1)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Lubricating oil
assessing and treating
ON
LY
Summary
000.04
MAN Diesel & Turbo
Collating and assessing operating media parameters, maintaining the consistency within the permitted range, avoiding/reducing damaging effects. Lubricating 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.
Spot test/oil analysis
RP
OS
E
Oil Evaluation
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 sample 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 filter, while the engine is running. This ensures that the result will be representative for the oil in the engine.
PU
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.
NG
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 condition of the waste lube oil, to be determined with sufficient accuracy. Supporting documents can be obtained from Mar-Tec., Warnckesweg 6, 22453
Hamburg.
TBN
(related to fresh oil)
FO
2007-10-25 - de
Contamination
Metal content
ISO 3104
> 185
ISO 2719
% vol.
< 0,2
(0.5% only permissible for a short period)
ISO 3733
% TBN
50
ISO 3771
in general < 1.5 depends on the available

dispersing power and viscosity increase
DIN 51 592
depends on engine type and operating conditions
ASTM 5185-91
TR
Water content
> 110
< 220
mm2/s
% by weight
mg/kg
IP 316
Table 1: Examination of Lube Oil - Parameters/Threshold Values
Colour
No conclusions concerning the level of contamination can be drawn from

used doped lubricating oil, since very fine soot particles (< 1.0 mm) are
present as a result of the dispersant-detergent-capacity, which lead to intensive black colouring of the oil, even at lower concentrations. The total con-
6682 000.04-02 EN
General
Flash point (PM)
Measurement method
Viscosity at 40C
Limit value
AI
Characteristic value
NI
In general, the following values are sufficient for the routine examination of
used oil:
1 (3)
000.04
MAN Diesel & Turbo
Fuel in the lubricating oil
Fuel in the lubricating oil can be verified by determining the flash point and
the viscosity of the cleaned used oil, in comparison with the values from fresh
oil. Oil change due to thinning of the lubricating oil is necessary if the oil viscosity falls by one viscosity class, or if the flash point has dropped below 185
C. If a laboratory test cannot be performed, the viscosity can be determined
approximately as described below:
ON
LY
tamination of the lube oils can be ascertained, amongst others, by using DIN
51592 or IP 316. The appearance of the spot test also allows conclusions to
be drawn.
Water in the lubricating oil
RP
OS
E
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.
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 promotes, amongst other things, corrosion of the polished running gear components and the formation of oil sludge, i.e. increased viscosity.
PU
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 intervals.
Air in the lubricating oil
NG
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
automatic filter fitted, in all operational configurations and on all types of
engine. Depending on the application, an indicator filter, designed as double
filter, can also be fitted downstream of the automatic filter. It is required
especially in marine systems with single engine operation, as stipulated in the
classification.
AI
2 (3)
If the correct components are selected, and if the system is serviced in an

optimum way, maintenance of the filter(s) at the intervals as per the diesel
engine will be adequate.
The separator performs the task of clearing the particles of dirt from the lubricating oil. The dirt caused by engine operation, such as soot, abrasion products etc. is eliminated from the system by the separator.
In contrast to the lube oil filter, the lube oil separator works in bypass. The
design criterion in this case is the recirculation of the lube oil content within
the time period specified by the diesel engine manufacturer with the corresponding approximate value.
6682 000.04-02 EN
2007-10-25 - de
TR
R
General
FO
Oil Treatment
NI
Oil Treatment
Air emulsion (oil has white appearance) or severe surface foaming appears if
there are leaks on the intake side of the pump, through which air reaches the
oil. This compromises, amongst other things, the formation of a hydrodynamic lubrication condition in the bearing and promotes ageing of the oil.
ON
LY
The automatically self-draining separators currently available on the market,

recommended for use in the systems described, are highly optimised on a
hydraulic level, in the separation process, as well as on a control technology
level, so that, when selected and used correctly, a balance between the
ingress and removal of impurities is maintained. A minimum requirement on
the operator, by the manufacturer of the diesel engine, is the synchronous
operation of the lube oil separator and the diesel engine.
000.04
MAN Diesel & Turbo
Oil Change
RP
OS
E
A definitive prediction of the expected useful life of the oil cannot be since the
engine manufacturers generally do not know the quality of the fuel or lubricant oil to be used, the operational conditions under which the engine runs,
and also whether proper oil maintenance can be assumed.
An oil change is necessary if the chemical-physical parameters of the oil filling

have changed in such a way that the lubrication, cleaning and neutralisation
characteristics are no longer adequate. This can only be ascertained by full
analysis.
The parameters specified in Table 1 must be observed.
6682 000.04-02 EN
General
R
FO
2007-10-25 - de
TR
AI
NI
NG
PU
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.
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Lubricating oil/Fuel
Carrying out the spot test
ON
LY
Summary
000.05
MAN Diesel & Turbo
Collating and assessing operating media parameters, maintaining the consistency 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.
RP
OS
E
Work Sequence (during the lube oil test)
Immerse a cleaned rod (glass or wire), which should taper to a point, in the
lubricating oil at the operating temperature.
Drip the oil adhering to the rod onto the filter paper and let it dry for a few
hours at room temperature.
Compare the filter paper with the tests shown on the reverse.
Evaluation of the Lube Oil Drip Test
The 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.
6682 000.05-01 EN
General
R
FO
2009-03-26 - de
TR
AI
Doped lubricating oils contain active ingredients that hold combustion residues in suspension in a finely distributed form and/or prevent these from
accumulating in the engine (effect of the dispersant). The dirt particles are
smaller than the capillaries in the paper which explains why the flow effect is
more pronounced at the outer edges. When the dispersion effect reduces,
dirt particles join together and block the capillaries. The centre of the spot
turns a dark colour. If the edge has a radial appearance, this indicates that
the lubricating oil contains water or fuel.
NI
NG
PU
The spot test on filter paper indicates the degree of contamination, the presence of water or fuel and the current dispersing power of the detergent. Conclusions can be drawn from this information on the condition of the oil filling.
The spot test must not be regarded as a substitute for an oil analysis. If the
spot test appears abnormal compared to images made using earlier oil
charges that spent the same amount of time in the engine, this indicates
irregularities, e.g. poor combustion, fuel or water leakage, insufficient oil
maintenance, etc. Fig. 1 shows what used doped (HD) oils look like. The
lubricating oil spot shown in sample 1 is slightly contaminated, the oil shown
in sample 5 shows has been used up and an immediate oil change is
required. If the oil spot has the same appearance as sample 4, a comprehensive analysis is required to establish beyond doubt the condition of the oil
filling.
1 (2)
000.05
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
NG
Figure 1: Spot tests of doped lubricating oils - Sample 1: slightly contaminated - Sample 4: analysis required - Sample
5: oil change required
Fuel drop test
AI
TR
2009-03-26 - de
R
General
FO
NI
The spot test on the filter paper indicates the type of fuel, i.e. whether distillate or mixed fuel. In the case of heavy fuels, the appearance of the spot test
indicates the compatibility of the mixed components. It is recommended to
record the spot tests for each new bunkering in a notebook.
2 (2)
6682 000.05-01 EN
Cooling water
inspecting
ON
LY
Summary
000.07
MAN Diesel & Turbo
Acquire and check typical values of the service media to prevent or limit
damage.
RP
OS
E
The fresh water used to fill the cooling water circuits must satisfy the specifications. 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)
When using chemical 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.
Abbreviated specification
Water for filling

and refilling (without additive)
Circulating water
(with additive)
Water type
Fresh water, free of foreign matter
Treated cooling water
pH value
Chloride ion content
10dGH 1)
10dGH 1)
6.5 - 8 at 20 C
7.5 at 20 C
AI
Total hardness
NI
Typical value/property
50 mg/l
50 mg/l 2)
Table 1: Quality specifications for cooling water (abbreviated version)
TR
1)
dGH
2)
1mg/l
= 10 mg/l CaO
= 17.9 mg/l CaCO3
= 0.179 mmol/L
= 1 ppm
Testing the concentration of rust inhibitors
FO
2010-02-09 - de
1dGh
German hardness
Brief specification
6682 000.07-01 EN
General
NG
Testing the typical values of water
PU
Equipment for testing the

concentration of additives
1 (2)
MAN Diesel & Turbo

Slushing oil
Concentration
Chemical additives
according to the quality specifications in Volume 010.005 Engine - Operating Instructions, Chapter 3, Page 3.3.7
Anti-freeze
according to the quality specifications in Volume 010.005 Engine - Operating Instructions, Chapter 3, Page 3.3.7
ON
LY
000.07
Table 2: Concentration of cooling water additives
Checking the concentration

of chemical additives
The concentration should be checked every week and/or in accordance with

the maintenance schedule using the testing instruments and reagents from
the relevant supplier and corresponding instructions.
RP
OS
E
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 specifications in Volume 010.005 Engine Operating Instructions, Chapter 3,
Page 3.3.7) must be complied with in all cases. These recommended concentrations may not be the same as the manufacturer's specifications.
The concentration must be checked in accordance with the manufacturer's
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.
AI
TR
2010-02-09 - de
R
General
FO
NI
NG
PU
Checking the concentration

of anti-freeze
2 (2)
6682 000.07-01 EN
Engine or components
preservation treatment
ON
LY
Summary
000.14
MAN Diesel & Turbo
Adopt measures to counteract corrosion, carry out/repeat protective measures.

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.
RP
OS
E
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
Even the best preservation provides protection for a limited period only. A
check is absolutely necessary at stipulated time intervals, so that the preservation treatment can be repeated in good time.
NG
Protection for a limited

period
PU
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 (continental, 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 preservative must have a thick continuous layer which adheres to the surface
well, displaces water and is not affected by corrosive media.
R
FO
2010-07-07 - de
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 surface 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 complete engines.
6682 000.14-02 EN
General
TR
Depending on the intended purpose and the existing conditions, there are
various different slushing oils which can be classified as follows:
Rust inhibitor
AI
NI
The addition of vapour-phase anti-corrosion oil (VCI) has proved to be effective for internal preservation. Owing to their properties, these oils continuously 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.
1 (8)
000.14
MAN Diesel & Turbo
2. Anti-corrosion grease
ON
LY
The solvents are flammable and can develop explosive vapours!
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.
RP
OS
E
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
PU
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.
Preservation of New Engines and Spare Parts
NI
NG
Before dispatch, the engines undergo preservation in the factory. This preservation treatment means that the engines can be stored outside under a tarpaulin for 12 months. If an engine is to remain in storage for longer, the preservation treatment must be repeated. This can be carried out as described
below. Preservation of the complete engine is normally only necessary for
four-stroke engines.
AI
2 (8)
Preserve the engine base, the crankshaft flange and flywheel with waxtype slushing oil Anticorit BW366.
Preserve moving uncoated parts (e.g. control linkage), tie rods and
crankshaft outlet with Dinitrol lubricant.
Preserve fins of the explosion protection covers with slushing oil Tectyl
542, replace waxed paper in case of damage.
Engine - internal preservation
Spray crankcase with slushing oil Anticorit 6120/42DFV.
Depending on the engine size, add 3-5 litres of the VCI slushing oil Branerol to the crankcase.
Spray camshaft chamber, torsional vibration damper chamber and

rocker box with corrosion protection oil Tectyl 542.
Preserve combustion chamber with 20 ml of Branerol per cylinder via

injection valve or starting valve opening.
6682 000.14-02 EN
2010-07-07 - de
TR
R
General
FO
Engine - external preservation
Turbocharger - preservation
Spray with Branerol through outlet-housing opening and washer opening
on turbine side and through washer opening on compressor side.
ON
LY
000.14
MAN Diesel & Turbo
Turning the drive gear
The engine running gear must not be turned after being closed airtight.
Preservation of Engines during Standstill
RP
OS
E
The purpose of the procedure described is to conserve engines when they

are shut down for an indeterminate period. This procedure may not always
be the same due to the design of the pipe systems and the engine room, the
engine type and auxiliary systems used.
The following temperature and humidity values in the engine room and control room must be observed to protect the mechanical and electronic equipment:
Temperature
min. 10C
Engine
The engine must be switched over from heavy fuel oil (HFO) to marine diesel
oil (MDO) operation before switching it off. The engine must be operated for
roughly 1 hour at full load or for 2 hours at 75% load in marine diesel oil
operation. In doing so, observe the instructions in Section 3.4.1 and 3.4.2
(see Volume 010.005 Engine Operating Instructions).
NG
Work steps to be carried out

before
stopping the engine
50% RH
PU
Humidity
Turbocharger
2. Operate the engine for approx. 30 min with the anti-corrosion oil, so
that all pipes and the injection system are filled with anti-corrosion oil.
Before shutting off the engine, spray a small quantity of the low-viscosity anti-corrosion oil into the intake pipe (of the exhaust gas turbocharger).
3. All lubricating oil in the cooler and filter must be drained off. Lubricating
oil lines must be blown out. The oil pan, lubricating oil tank and lubricating oil service tank must be thoroughly cleaned. The lubricating oil system must then be filled with anti-corrosion oil of the same viscosity as
6682 000.14-02 EN
General
TR
R
FO
2010-07-07 - de
1. All the fuel in the engine must be drained off. The fuel service tank must
be cleaned thoroughly. Instead of fuel, a low-viscosity anti-corrosion oil,
to SAE group 10 to 20, is poured into the service tank (e.g. Fuchs Anticorit 1), this provides sufficient internal preservation for pipes carrying
fuel and engine parts supplying fuel.
A prerequisite for effective preservation is that all internal and external parts
of the engine are thoroughly cleaned before treating with a protective agent.
Scheduled maintenance and overhaul work is to be performed in accordance
with the maintenance schedule and recorded in the operating log sheets.
AI
Work steps to be carried out

prior to
conservation
NI
The turbocharger must be cleaned on the turbine and compressor side

before shutting it down. In doing so, observe the instructions in the turbocharger documentation (see Volume 010.200 Turbocharger)
3 (8)
000.14
MAN Diesel & Turbo
the lubricating oil used. In this case, it must be ensured, by selecting an

appropriate fill level, that oil is drawn in by the lubricating oil pumps
bubble-free.
ON
LY
4. After shutting off the engine, likewise spray a small quantity of anti-corrosion oil (approx. 0.5l) into the main starter air pipe and control air pipe
Danger of explosion! Do not start the engine!
RP
OS
E
On no account must you start an engine in this condition! Danger of

explosion! Attach a warning sign and blow out the pipes before the
next start, in accordance with Work Card 000.03!
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).
PU
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
operated 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.
NG
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.
Engines, which were already in operation and where a short

commissioning for preservation is not possible, can be preserved as
described in the section "Preservation of New Engines and Spare
Parts". You must ensure, at the same time, that prior to preservation,
the fuel, lube oil and coolant are drained off. All engine parts must also
be carefully cleaned.
4 (8)
8. Spray out the crankcase with an anti-corrosion agent (e.g. Fuchs Anticorit 6120-42 DFV or Valvoline Tectyl 51111). In addition, preserve the
camshaft with an anti-corrosion agent that leaves a waxy layer (e.g. Valvoline Tectyl 542). In addition, add 5 - 6 litres of a VCI oil to the crankcase.
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.
6682 000.14-02 EN
2010-07-07 - de
AI
TR
R
General
FO
NI
Preservation of New Engines and Spare Parts
Recommended anti-corrosion agents

Anti-corrosion agent b
Anti-corrosion agent c
Multipurpose oil (with increased

corrosion protection)
Anti-corrosion oil, soluble in fuel/

oil
Anti-corrosion oil, emulsifiable
Type of coating
wash, spray, dip, coat
wash, spray, coat or spray

without air
flush
Drying time
Non-drying
Non-drying
Non-drying
Durability of corrosion 3 months

protection with roofed
storage
3 months
24 months
Compatibility with fuel/ Fuel and lubricating oil

oil
Fuel and lubricating oil
ON
LY
Anti-corrosion agent a
RP
OS
E
Cooling water that has been

treated with anti-corrosion
agent (c) is not compatible
with chemicals used for the
treatment of cooling water
Removability of coating
Diesel fuel, petroleum, neutral Same as anti-corrosion agent Neutral cleaner, diluted alkacleaner, diluted alkaline
(a)
line cleaner, solvent as liquid
cleaner, cloth
or gaseous phase
Area of application
and comments
Engine lubricating oil during

acceptance run, flushing of
lubricating oil system, speed
governor and other components with their own lubricating oil circuit
PU
Anti-corrosion agent with

roughly 10 cSt/20C:
Mounted surfaces, parts of
fuel system, e.g. pressure
test of fuel injectors
Anti-corrosion agent with

roughly 70-90 cSt/50C:
Machined or smooth surfaces, e.g. bearing surfaces
AI
Esso-Rust-Ban 335
(85 cSt/20C)
Esso-Rust-Ban 310
(for pressure test)
Esso-Nuto 460
Fuchs-Anticorit MKR
Fuchs-Anticorit 1
(9 cSt/20C)
Henkel P3-multan 70-3
Shell-Ensis Oil N
Shell oil 9156
Valvoline corrosion protection

6 SAE 30
TR
Table 1: Recommended anti-corrosion agents (Part 1)

Anti-corrosion agent e
Anti-corrosion agent f
Anti-corrosion agent with thixotropic properties (oily protective

film with low flow characteristics)
Anti-corrosion agent, soft waxy

film
Anti-corrosion agent, hard waxy

film
Type of coating
spray, dip, coat or spray

without air

without air

without air
Drying time
Non-drying
See data sheet
See data sheet
Durability of corrosion 6-12 months

protection with roofed
storage
6 months to 3 years
3 years, 12 months if stored

outdoors

oil
Insoluble in fuel and lubricating oil
Anti-corrosion agent d
FO
2010-07-07 - de
6682 000.14-02 EN
General
NG
Esso run-in oil 40

Fuchs Renolin MR40
Shell Ensis engine oil 40
Shell Helix Plus (5W-40)
NI
Preferred anti-corrosion agent
Flush cooling water system

(30), drain completely, blow
out if required as condensate
is highly corrosive. Pressure
test of cooling chambers.
000.14
MAN Diesel & Turbo
5 (8)
000.14
MAN Diesel & Turbo

Anti-corrosion agent e
Anti-corrosion agent f
Anti-corrosion agent with thixotropic properties (oily protective

film with low flow characteristics)
Anti-corrosion agent, soft waxy

film
Anti-corrosion agent, hard waxy

film
Same as anti-corrosion agent Diesel fuel and petroleum

(a)
Area of application
and comments
Turbocharger assembly, interior surfaces and bores, vertical machined surfaces, polished screws, etc.
Bantleon-Cortec VCI 369

Fuchs-Anticorit 6120-42E
(65 cSt/20C)
(solvent free)
Fuchs-Anticorit 15N
(50 cSt/20C)
Esso-Rust-Ban 391
(6.5 cSt/20C)
Anti-corrosion agent g
Esso-Rust-Ban 395
Esso-Rust-Ban 397
Shell-Ensis Fluid H
Fuchs-Anticorit BW 366
Valvoline Tectyl 502 C
Valvoline Tectyl 846
Anti-corrosion agent i
Anti-corrosion agent with waterrepelling and anti hand sweat

properties
Anti-corrosion grease
Paint colour
Type of coating

without air
Dip (in heated state), coat
Coat, spray without air
Drying time
Non-drying
Non-drying
See data sheet
Durability of corrosion 9-18 months

protection with roofed when stored in enclosed
storage
rooms
12 months to 5 years
---

oil
NI
AI
3 months to 2 years when

stored outdoors
Insoluble in fuel and lubricating oil
Same as anti-corrosion agent Same as anti-corrosion agent Stripping agent

(e)
(e), cloth
2010-07-07 - de
TR
General
FO
External machined surfaces,

tie rods and tools. The coating must be removed before
initial operation.
Anti-corrosion agent h
NG
Same as anti-corrosion agent

(e)
Internal machined surfaces in

fuel and lubricating oil system. Contains solvents! A
component must therefore
not be packaged, insulated or
have a second coating
applied until the solvent has
been fully degassed.
PU
ON
LY
Anti-corrosion agent d
RP
OS
E
6 (8)
6682 000.14-02 EN
Anti-corrosion agent h
Anti-corrosion agent i
Anti-corrosion agent with waterrepelling and anti hand sweat

properties
Anti-corrosion grease
Paint colour
Area of application
and comments
Precisely machined surfaces,

tools, measuring devices.
Contains solvents! Note
degassing requirement (see
anti-corrosion agent (e))
Moving connections to prevent seizing, e.g. connections, rolling bearings
Unmachined surfaces. Not

for machined surfaces and
internal spaces that must be
checked for leak-tightness!
Fuchs-Anticorit 6120-42DFV
(6.2 cSt/20C)
Dinitrol-Pasta 1053
Engine:
Shell-Ensis Fluid E
Shell corrosion protection

grease
Wetterwart
SL-2304 RAL6019
Valvoline Tectyl 511M
Valvoline Tectyl 858C
Wetterwart
SL-2233 RAL6019
ON
LY
Anti-corrosion agent g
RP
OS
E
Turbocharger:
Wetterwart
Silicoterm 655E

Anti-corrosion agent l
Anti-corrosion agent m
Vapour phase corrosion-inhibiting

oil
Corrosion-inhibiting oil with VCI

active substances
Type of coating
spray
spray
Drying time
---
PU
000.14
MAN Diesel & Turbo
---
18 months
NG
Durability of corrosion --protection with roofed

storage
oil
---
Cloth
6682 000.14-02 EN
General
R
FO
2010-07-07 - de
TR
AI
NI
---
7 (8)
000.14
MAN Diesel & Turbo
Anti-corrosion agent m
Vapour phase corrosion-inhibiting

oil
Corrosion-inhibiting oil with VCI

active substances
Large internal airtight spaces.

The vapour phase of the
inhibitors occurs at low temperatures and a protective
film is formed.
Quantity approx. 300 cm3/m3
Internal space
Distance between anti-corrosion agent and surface being
protected: max. 30 cm
Large individual components

(frames, springs, ...)
Branorol 32/10
Bantleon-Cortec VCI 369
Branorost VCI paper

R for ferrous metals only
N for ferrous metals only,
neutral in relation to non-ferrous metals
U for ferrous and non-ferrous
metals
C for non-ferrous metals only
Fuchs-Anticorit VCI 0-40
Shell Vapour Phase Inhibitor
PU
Valvoline Tectyl 859A (oily)
In engines instead of (f) with

low demand
ON
LY
Area of application
and comments
Anti-corrosion agent l
RP
OS
E
AI
TR
2010-07-07 - de
R
General
FO
NI
NG
8 (8)
6682 000.14-02 EN
Loctite Products
use
ON
LY
Summary
000.19
MAN Diesel & Turbo
Use of auxiliary equipment, proper processing and mounting. Loctite is a liquid 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 reassembly.
RP
OS
E
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.
PU
Within the crankcase, LOCTITE may not be used as a substitute for

screw locking devices, feather keys etc. provided by the design
process.
NG
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.
1. Carefully wash down the joint points on the parts using quick-acting
cleanser LOCTITE 706 (vaporisation time approx. 3 min) or other suitable cleaning agents, to remove dirt and grease.
2. If necessary, apply activator T from a spray bottle and allow to dry for
approx. 3 min. The filling material hardens more quickly when using the
activator (see table).
Work steps
FO
2007-09-06 - de
Work Sequence 1 - Assembly
3. Apply a thin layer of the corresponding LOCTITE product (see table) to

one of the two adherent surfaces.
6682 000.19-01 EN
General
TR
AI
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
observed!
NI
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.
1 (4)
000.19
MAN Diesel & Turbo
ON
LY
With interference fit assemblies and larger parts, both surfaces must
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!
4. Join both the parts in the correct location.
5. Wipe away and remove the filling material outside the connection while
ensuring that the position of the parts is not changed.
RP
OS
E
6. Wait for curing time (see instructions) and finish the assembly of the
parts.
7. If necessary, heat the connection point to approx. 120 C to obtain the
ultimate strength more quickly.
Work Sequence 2 - Dismantling
1. Try and see whether the connection can be released using normal tools
and manual force.
Work Sequence 3 - Reassembly
Thoroughly remove the old LOCTITE layer on both parts mechanically,

while ensuring that the bonding surfaces are not damaged. The layer
cannot be removed using chemical agents.
NG
PU
2. If this is not possible, heat the connection to approx. 200 C and then
release the parts (Caution. Danger of fire!).
Carefully degrease the parts and fit as per work sequence 1.
222
243
245
270
272
275
648
-9222
-9243
-9245
-9270
-9272
-9275
-9648
purple
blue
blue
green
redorange
green
green
Application temperature range C 150
150
150
150
200
150
175
Viscosity
(mPa. x s)
90 - 180
200 - 400 550-1000 400 - 600 400015000
550-1100 300 - 600
Gap:
favourable
M36
M36
M20-M80 M20
04.10170
TR
Ref. No.
Product colour
max.
General
for threads up to max.
2 (4)
M36-M80 M20
Strength categories: *)
6682 000.19-01 EN
M48
2007-09-06 - de
AI
Loctite Product
FO
NI
It is possible to perform a cleanliness check using the radiation from a

UV lamp. Even the smallest traces of LOCTITE will fluoresce.
2)
243
245
270
272
275
648
N/mm
3-9
6 - 14
6 - 14
11 - 20
14 - 20
10 - 20
16 - 30
Nm
8 - 20
14 - 34
13 - 33
25 - 54
18 - 28
25 - 55
30 - 55
--
--
--
45 - 70
20 - 31
35 - 65
40 - 60
24
24
24
max. continuing torque Nm

open waiting
time
for steel
max. hrs.
24
24
24
24
for non-ferrous
metal
max. min.
Handling
strength
Min.
15 - 30
15 - 30
30 - 60
15 - 30
10 - 20
3-5
12
12
12
12
12
12
KTW
approval
BAM
approval
high strength
difficult to remove
Ultimate strength max. hrs.

Special properties
low
strength
RP
OS
E
Hardening
medium strength
Table 1: Loctite Products for Securing Threads
PU
*....... 1) DIN 54452, 2) DIN 54454
Thread seal
Loctite Product
620
Surface sealing
577
586
518
-9577
-9586
-9518
04.10170.
-9620
Product colour
max. min.
green
yellow
red
red
230
150
150
150
25000 - 50000
Application temperature range C
NG
Ref. No.
(mPa. x s)
800 - 1600
4000 - 8000
4000 - 6000
Gap:
favourable
--
--
--
NI
Viscosity
--
--
--
0,5
max.
M60
M80
M60
M20
20 - 35
5 - 13
10 - 25
4 - 14
20 - 45
9 - 25
25 - 55
5 - 13
--
--
30 - 55
--
AI
for threads up to
max.
Strength categories: *)
Compression shear
strength
N/mm2
TR
1)
Breakaway torque
2)
Nm
open waiting time

max. hrs.
24
24
24
24
for non-ferrous
metal
max. min.
60
60 - 120
15 - 30
120
30
for steel
FO
2007-09-06 - de
Hardening
Handling
strength
Min.
6682 000.19-01 EN
General
Breakaway torque
222
2
Compression
shear strength
1)
ON
LY
Loctite Product
000.19
MAN Diesel & Turbo
3 (4)
000.19
MAN Diesel & Turbo

max. hrs.
Special properties
24
12
DVGW
approval
BAM
approval
Table 2: Loctite Products for Sealing Threads and Surfaces

*....... 1) DIN 54452, 2) DIN 54454
Shaft/Hub
620
307 3)
- 9620
-9307
04.10170.
- 9603
Product colour
max. min.
green
Application temperature range C
150
Viscosity
(mPa. x s)
100 - 150
Gap:
favourable
0,05
max.
0,15
max.
--
Strength categories:
*)
1)
Breakaway torque
496
-9406
-9496
yellowish
transparent
transparent
230
120
80
80
800 - 1600
800 - 3200
10 - 30
100 - 120
0,05
--
0,05
0,05
0,20
0,1
0,1
0,1
--
--
--
--
20 - 35
15 - 30 1)
12 - 25 1)
12 - 25 1)
N/mm2
16 - 25
Nm
40 - 60
20 - 45
12 - 32 2)
18 - 26 2)
20 - 30 2)
40 - 60
--
--
--
--
2)

open waiting time
NG
Hardening
406
green
PU
Compression shear
strength
Even surface
603
Ref. No.
12
RP
OS
E
Loctite Product
for threads up to
max. hrs.
24
24
24
Sec.-
Sec.
for non-ferrous
metal
max. min.
max. 5
Bond.
Bond.
12
12
NI
for steel
Ultimate
strength
Min.
20
60 - 120
10 - 20
max. hrs.
12
24
24
AI
Handling
strength
for materials
difficult to
bond
e.g. Vitron
TR
Special properties
Table 3: Loctite Products for Bonding

Tensile strength N/mm2, 2) Tensile shear strength N/mm2, 3) with activator 7471
2007-09-06 - de
1)
General
FO
24
ON
LY
Ultimate
strength
4 (4)
6682 000.19-01 EN
003
NG
PU

Machine Elements
FO
TR
AI
NI
001
002
003
004
005
RP
OS
E
ON
LY
Machine Elements
MAN Diesel & Turbo
6632 003-05 EN
1 (1)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Galvanised Bearings
assessing
ON
LY
Summary
Machine Elements
000.11
MAN Diesel & Turbo
Carry out the work in good time in accordance with the maintenance schedule; check the components quality/wear condition. Bearing shells must be
checked on a regular basis. Usually, only the loaded bearing shell is
checked. From the wear condition and appearance of the bearing shell running surface, conclusions can be drawn regarding the load conditions, the
lubricating oil maintenance etc.
RP
OS
E
The work/work steps include: Measuring of components and assessing surface/wear condition.
Corresponding Work Cards

Work card
Work card
000.10
NG
PU
General
Work card
1
2
3
4
5
Anti-corrosion layer
Running layer
Nickel dam
Bearing metal
Steel support shell
Figure 1: Galvanised Bearings - Structure
Galvanised bearings have a long service life if the lubricating oil is carefully filtered and separated. This means that cleaning the filters and separators, and
checking the oil, are very important.
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
with increasing engine load, to detect any unacceptable increase in temperature (compare to the adjacent bearings).
Undersized bearings (with smaller diameter) ready for installation can be supplied for reworked crank pins.
6682 000.11-01 EN
General
R
FO
2008-10-28 - de
TR
The soft running layer has better running in and emergency running properties than the leaded bronze or aluminium tin bronze layer. This running layer
must, therefore, remain serviceable for as long as possible and no additional
work is permitted. Since every bearing must adapt itself after refitting, bearings which are running correctly should be opened up as little as possible.
AI
NI
Galvanised bearings (compound bearings) are used for the crankshaft bearings and big-end bearings of four-stroke engines, which are made from a
steel support shell, a bearing metal layer of leaded bronze or aluminium tin
bronze and a galvanised running layer.
1 (8)
Machine Elements
000.11
MAN Diesel & Turbo
Wear Limits
RP
OS
E
ON
LY
Bearing shells, the running surface of which show wear of more than 30%
must be replaced. Bearing shells, the running surface of which show wear of
approx. 20% are also to be replaced, if, at the same time, extensive overhaul
work is being performed on the engine.
Figure 2: Degree of Wear of the Running Surface
Bearing shells which have already been in service for 30 000 operational
hours should, in general, be replaced when the engine is being overhauled.
PU
If the bearing shells already show signs of wear on the bearing metal running
layer after approx. 5000 operational hours or the running surface is worn by
about 20%, this indicates dirt accumulation and insufficient cleaning of the
lubricating oil.
Bearing Illustrations
NG
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.
AI
The mainly grey running surface in the main load area is smooth and reflects
slightly. The bearing can be used again.
General
2 (8)
Figure 4: Partially Worn Running Layer
After the running layer is worn out a reddish brown contact pattern is seen in
lead bronze bearings. With aluminium tin bronze bearings a variation is seen
between the lighter and darker zone. The lighter zone indicates a fresh con-
6682 000.11-01 EN
2008-10-28 - de
Normal Contact Pattern with Partially Worn Running Layer
TR
Figure 3: Normal Contact Pattern
FO
NI
Normal Contact Pattern with Existing Running Layer
Mirror effect on both edges of the bearing
Figure 5: Mirror effect
ON
LY
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 evident.
Machine Elements
000.11
MAN Diesel & Turbo
RP
OS
E
The bearing becomes slightly rounded by the running-in process. Slight mirroring on the edges of the bearings will normally disappear after a longer running time. The bearing can be reused, provided figure 6 (edge loading) is not
applicable.
PU
Edge Loading (on one side or both sides)
Figure 6: Edge loading
NG
A bearing which only carries load on the edges is not permitted. Possible
causes could be deviations in the pin geometry or incorrect location of the
bearing bore, which must be corrected. The bearing must be replaced if the
edge loading is significant.
R
FO
2008-10-28 - de
TR
A one sided contact pattern may be seen in the case of external bearings
and is also acceptable provided the crank web deflection is in order (cause:
Weight of the flywheel or of the vibration damper). One sided load is not permitted for intermediate bearings. In this case the causes, e.g. pin gyration,
deformation of the bearing support, uneven tie rod preload, dirt on back of
the bearing, must be remedied. If there is pronounced one-sided load then
the bearing must be changed.
Load Marks on the Bearing Shell Joint (on one side or both sides)
6682 000.11-01 EN
General
Figure 7: Load on the One Side
AI
NI
Load on the One Side
3 (8)
000.11
Figure 8: Load Marks on the Bearing Shell Joint
ON
LY
Machine Elements
MAN Diesel & Turbo
RP
OS
E
When pronounced load marks occur near the bearing joint face, there is a
danger that the crank journal on the parting lines could break away from the
lubricating film. For this reason, a bearing should be exposed by approx. 10,
calculated from the joint face. Should load marks still appear close to the
joint face, then the cause must be remedied. In the event of load marks on
only one side, the back of the bearing should be checked for dirt or oil carbon. In addition, the bearing support could be misaligned. If there are load
marks on both sides see figures 20 (cold shuts on the back of the bearing)
and 21 (bearing spread). Bearings with heavy loading close to the joint face
should be replaced.
PU
Scoring and Embedding of Foreign Bodies in the Running Layer
Figure 9: Scores and Foreign Bodies in the Running Layer
AI
TR
Cracks in the Running layer
4 (8)
2008-10-28 - de
R
General
FO
NI
NG
Hard dirt particles, carried by the circulating oil, make scores through the
running layer and often get embedded. Depending on the hardness of the
foreign bodies the bearing journal may become scored. Light scores, which
do not break through the running layer are not dangerous. The bearings can
continue to be used. Scores which are wider than 1 mm interfere with the
structure of the wedge-shaped lube oil film. Bearings with several wide
scores in the lower shells of the crankshaft bearing or the upper shell of the
big-end bearing, which reach the lead bronze or aluminium tin bronze layer,
must be changed, especially if the scores are very close to the bearing edge.
If wide scores are seen in the bearing shells, the surface of the bearing journal must be checked. Depending on the situation, the pin should be
smoothed or reworked using emery cloth or an oil stone, or mechanically
with a portable regrinding device (Specialist firms). The cause of scoring must
be remedied. The complete lube oil circuit, including separator, lube oil filter
and lube oil pipes between the filter and engine must be checked (scale,
weld beads etc.). If other bearings are supplied with oil from this bearing,
they should definitely be checked.
Figure 10: Cracks
6682 000.11-01 EN
The odd crack in the running layer is not dangerous to the bearing. The bearing should only be replaced if there is a notable build-up of cracks in the loaded zone.
ON
LY
"Bark Beetle"
Machine Elements
000.11
MAN Diesel & Turbo
Figure 11: Bark Beetle
RP
OS
E
When the accumulation of a lot of small cracks becomes recognisable in the

loaded zone of the running layer (often paving stone type) as result of material fatigue, disintegration or erosion of the crack areas (similar to the bark
beetle on trees) the bearing should be changed.
Peeling of the Running Layer
PU
Figure 12: Peeling of the Running Layer
NG
If the running layer has begun to peel at points on the surface, then the bearing must be replaced. Only in the case of small individual areas of damage
(smaller than 2 cm2) can the bearing continue to be used, provided the binding of the remaining running layer immediately adjacent to the area of damage is good condition (check carefully with a sharp tool, e.g. a pocket knife).
Rough Running of the Bearing Metal Layer
FO
2008-10-28 - de
TR
If the soft running layer is smudged over a large area (creep deformation) and
if it has possibly already been penetrated in the middle, this implies insufficient oil, which could possibly be caused by insufficient prelubrication before
the start. The cause of insufficient oil must be remedied and the bearing
must be replaced.
Figure 14: Rough Running
6682 000.11-01 EN
General
Figure 13: Smudging of the Running Layer
AI
NI
Running Layer Heavily Smudged
5 (8)
000.11
MAN Diesel & Turbo
Spallings on the bearing metal layer
Figure 15: Spallings
ON
LY
Machine Elements
Bearings with very rough bearing metal should be replaced, particularly

because of increased pin wear. Moreover, the bearing journal must be
smoothed.
RP
OS
E
Bearings with spallings on the bearing metal layer must be replaced. The
bearing journal must be checked, smoothed or reworked.
Overheating of the Bearing Metal Layer
Figure 16: Overheating of the Running Layer
NG
PU
If the bearing metal shows overheating characteristics (blue-violet) or even

net-shaped heat cracks, the bearing must be replaced. The bearing journal
must undergo a magnetic crack inspection. If any cracks are apparent, the
bearing journal must be reground until it is "crack free", taking the surface
quality, ovality and taper into account. If no cracks or hardening have been
detected, smoothing of the pin is sufficient.
NI
Electroerosion
AI
Corrosion
2008-10-28 - de
TR
R
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.
General
FO
Figure 17: Electroerosion
6 (8)
Figure 18: Corrosion
6682 000.11-01 EN
RP
OS
E
Cold shuts on the bearing shell joint
ON
LY
Signs of running surface corrosion are surface discolouration as a result of

chemical changes in the bearing material and corrosive, usually localised,
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.
Machine Elements
000.11
MAN Diesel & Turbo
Figure 19: Cold shuts on the bearing shell joint
Cold shuts or pitting rings on the joint faces of the bearing shell indicate relative movement, due to the loss of preload or inadequate bearing protrusion.
The causes of the damage must be remedied. In less serious cases, when
refitting the bearing shells, ensure that only the cold welded material which
has deposited is carefully removed. Moreover, the back of the bearing is to
be checked for cold shuts (see figure 20). In serious cases (large amounts of
material application and removal) the bearing shells must be replaced.
NG
PU
Cold shuts on the back of the bearing
Figure 20: Cold shuts on the back of the bearing
6682 000.11-01 EN
General
R
FO
2008-10-28 - de
Bearing Spread
TR
AI
NI
Large numbers of cold shuts on the back of the bearing, which are spread
over more than 5% of the total area, are not acceptable. The bearing must
be replaced. Screw pretension, bearing protrusion, bearing spread (see figure 21) and condition of the bearing locating bore must be checked. The
bearing protrusion can only be ascertained approximately on-site by loosening the bearing bolts on one side. The cold shuts in the bearing locating bore
must be checked for cracks. If cracks are detected, the engine manufacturer
must be contacted. If no cracks have been detected, before the bearing is
reassembled surplus material in the bearing locating bore must be carefully
removed and, if the bearing is to be reused, any on the back of the bearing
must also be removed carefully.
7 (8)
000.11
D Bearing diameter
S Spread
Figure 21: Bearing Spread
ON
LY
Machine Elements
MAN Diesel & Turbo
AI
TR
2008-10-28 - de
R
General
FO
NI
NG
PU
RP
OS
E
Bearing shells must have a positive spread so that once built in they are perfectly positioned in the locating hole. The spread depends on the diameter of
the bearing and, when new, can be several millimetres. Even when bearings
are worn there should still be enough remaining spread so that when installing the bearing in the bearing locating hole it is necessary to exert considerable pressure on both joint surfaces. Bearing shells which can be very easily
placed in the bore (spread zero or negative) may not continue to be used. A
"spreading out" of the shell is not permitted.
8 (8)
6682 000.11-01 EN
Deep Groove Bearing

assessing
ON
LY
Summary
Machine Elements
000.11
MAN Diesel & Turbo
Carry out the work in good time in accordance with the maintenance schedule; check the components quality/wear condition. Bearing shells must be
checked on a regular basis. Usually, only the loaded bearing shell is
checked. From the wear condition and appearance of the bearing shell running surface, conclusions can be drawn regarding the load conditions, the
lube oil maintenance etc.
RP
OS
E

Work card
Work card
000.10
General
Work card
The deep groove bearings used in the crankshaft and big-end bearings
based on aluminium or lead bronze have the structure as shown in figure 1.
PU
The soft running layer has better running in and emergency running properties than the bearing metal shell. This is why the running layer must remain
functional for as long as possible and any rework to the running layer should
be avoided. Since every bearing must adapt itself after refitting, bearings
which are running correctly should be opened up as little as possible.
NG
Deep groove bearings, with careful filtering and separating the lube oil, have
a very long useful life. This means that cleaning the filters and separators,
and checking the oil, are very important.
NI
If the bearing metal layer of the bearing shells is clearly visible after approx.
5,000 operational hours or 20% of the running surface is worn, this indicates
serious stress due to dirt particles and inadequate cleaning of the lube oil.
R
FO
2008-10-28 - de
Undersized bearings are available for reworked crankshafts. These are subject to the same evaluation criteria as normal bearings.
6682 000.11-02 EN
General
TR
After refitting worn bearing shells, or after replacement, the bearing caps
must be felt by hand, after approx. 30 min. idling and after approx. 5 hours
with increasing engine load, to detect any unacceptable increase in temperature (compare to the adjacent bearings).
AI
Bearing shells with advanced wear can be replaced individually (upper or

lower shell) or together.
1 (6)
000.11
ON
LY
Machine Elements
MAN Diesel & Turbo
RP
OS
E
1 Running layer (approx.

75%)
2 Bearing metal cross
piece (approx. 25%)
3 Nickel dam (max. 5%)
4 Steel support shell
Figure 1: Structure of a Deep Groove Bearing
Wear Criteria
PU
In new condition the running surface accounts for approx. 75% galvanised
running layer and approx. 25% bearing metal cross pieces. The decisive factor for wear in the deep groove bearing is the ratio width of the bearing metal
cross piece to the width of the groove and the extension of the worn area.
To assess the degree of wear of the running surface, a magnifying glass with
a magnifying power of 5 is required. For every assessment of the groove
condition, it is important to compare the running surface in the area with the
least load since the groove condition here is almost new.
NG
An assessment of the bearing shells can be carried out with the aid of the
image sequence. It indicates whether a bearing can be reused or whether it
must be replaced.
AI
2 (6)
Figure 2: Wear not critical
1. The groove geometry corresponds to the new condition. The running

layer is fully preserved within the grooves. Dark spots on the running
layer are mainly embedded particles of oily carbon deposits. (See figure
left)
Assessing: The ratio bearing metal cross piece to running layer is approx.
25% to 75%. Continued use!
6682 000.11-02 EN
2008-10-28 - de
TR
R
General
FO
NI
1. No or little Wear. Continued Use
ON
LY
1. The running layer is evenly worn approx. 0.005 mm out of the grooves.
The bearing metal cross piece shows no sign of wear. Dark spots on
the running layer are mainly embedded particles of oily carbon deposits.
(see figure right)
Machine Elements
000.11
MAN Diesel & Turbo
Figure 3: Wear not critical
RP
OS
E
Assessing: Because of the wear of the running layer the bearing metal cross
pieces seem slightly wider. Continued use!
1. Embedding of small impurities over the entire running surface. No major

modification of the bearing metal cross piece (see figure left)
Assessing: Continued use!
PU
1. The running layer was dragged and spread over the bearing metal
cross pieces. The bearing metal cross pieces are partially concealed
(see figure right)
Assessing: Continued use!
1. The bearing is worn to such an extent at some spots, that the ratio running layer groove to bearing metal cross pieces is approx. 50% to 50%.
The width of the bearing metal cross pieces has increased from 25%
(new condition) to 50 %. There is still running layer inside the grooves
(see figure left)
Assessing: The bearing is functional as long as the extension of the worn

parts does not reach the limits indicated in figure 6.
If wear is expected within the next maintenance interval as described in point
2, the bearing must be replaced for safety reasons.
6682 000.11-02 EN
General
R
FO
2008-10-28 - de
Figure 4: Wear of Bearing Metal Cross Pieces
TR
AI
NI
NG
2. Wear of bearing metal cross pieces. Replace depending on extent of wear
3 (6)
000.11
MAN Diesel & Turbo
Machine Elements
1. The bearing metal cross pieces are worn locally. No grooves or running
layer present (see figure right)
RP
OS
E
3. Wear on running layer. Replace depending on extent of wear
ON
LY
Assessing: If the wear reaches the limits indicated in figure 6, the bearing
must be replaced.
Figure 5: Wear on running layer
1. Running layer outbreaks in the grooves through local overload (see figure left)
PU
Assessing: The bearing is functional as long as the extension of the worn

parts does not reach the limits indicated in figure 7.
If wear is expected within the next maintenance interval as described in point
2, the bearing must be replaced for safety reasons.
NG
1. Empty grooves. In some areas, empty grooves become visible after

washing the broken running layer. Locally, the bearing metal cross
pieces may already be worn. (see figure right)
AI
TR
2008-10-28 - de
R
General
FO
NI
Assessing: If the wear reaches the limits indicated in figure 7, the bearing
must be replaced.
4 (6)
6682 000.11-02 EN
000.11
max. 30% of shell circumference

max. 70% of shell width
Wear ratio 50% to 50%
NG
A
C
E
G
PU
RP
OS
E
ON
LY
Machine Elements
MAN Diesel & Turbo
B
D
F
H

Bearing metal cross pieces worn
6682 000.11-02 EN
General
R
FO
2008-10-28 - de
TR
AI
NI
Figure 6: Extent of Wear
5 (6)
000.11

NG
I
E
K
M
O
PU
RP
OS
E
ON
LY
Machine Elements
MAN Diesel & Turbo
Running layer outbreaks
B
F
L
N

Bearing metal cross pieces worn
Empty grooves
AI
TR
2008-10-28 - de
R
General
FO
NI
Figure 7: Extent of Wear
6 (6)
6682 000.11-02 EN
Bimetal Bearings (without a third layer)

assessing
ON
LY
Summary
Machine Elements
000.11
MAN Diesel & Turbo
Carry out the work in good time in accordance with the maintenance schedule; 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.
RP
OS
E

Work card
Work card
000.10
PU
General
Work card
NG
1 Bearing metal
2 Al - Binding layer
3 Steel support shell
Figure 1: Bearing Structure
6682 000.11-03 EN
General
FO
2008-10-28 - de
Assessment of Running Behaviour and Replacement Criteria
TR
AI
NI
Roll-bonded bimetal bearings with the material combination steel/aluminium

alloy (AlSn20) are used both as main and big-end bearings and camshaft
bearings. Visible assessment of the extent of wear of a bimetal composite
bearing shell is not possible in normal wearing conditions (see figure below).
In contrast to trimetal composite bearings with galvanised running layer,
bimetal bearings contain no optical indicators which facilitate assessing the
degree of wear by the discolouration of the sliding surface. Assessment of
the extent of wear is only possible by measuring the thickness of the bearing
shell wall and comparing the current measured value with that of the initial
condition. Measuring bearing clearance does not produce any reliable indication of bearing wear, since the acceptable wear values are measured in hundredth of a millimetre.
1 (3)
000.11
Figure 2: Measuring of Wall Thickness
ON
LY
Machine Elements
MAN Diesel & Turbo
RP
OS
E
The bearing shell must be replaced when the wear limits contained in the
sheet Technical Data: Dimensions, clearances, tolerances" are reached.
The wall thickness (A) must always be measured in the area with the
main load or perpendicularly to the joint face.
NI
NG
PU
1. Contact pattern even over the entire bearing width
Assessing: If the wall thickness is within the permitted wear value, the bearing can continue to be used.
1. Running surface slightly scored. If the scores are only visible, but neither
measurable nor perceptible, the bearing can continue to be used. If the
wall thickness has reached the lowest tolerance value, the bearing shell
must be replaced (see figure 3 - right).
Assessing: If the scores are clearly perceptible or measurable, the bearing
shell must be replaced.
General
2. Contact pattern with seizure traces
2 (3)
6682 000.11-03 EN
2008-10-28 - de
TR
AI
1. Isolated, superficial dirt marks caused by foreign bodies do not influence continued operational safety (see figure 3 - left).
FO
Figure 3: Contact Pattern Normal
000.11
Figure 4: Contact pattern with seizure traces
ON
LY
Machine Elements
MAN Diesel & Turbo
RP
OS
E
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 figure 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).
NI
NG
PU
3. Bearing metal spallings
R
FO
2008-10-28 - de
6682 000.11-03 EN
General
TR
The loaded area of the bearing shell shows signs of bearing metal spallings
caused by fatigue of the sliding layer (see figure 5).
AI
Figure 5: Contact pattern with spallings
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Elastomer Seals
storage, cleaning and fitting
ON
LY
Summary
Machine Elements
000.21
MAN Diesel & Turbo
Insert/replace components, process and install professionally. Elastomer

seals (rubber products) are to be stored properly and replaced during overhaul work.
The work/work steps comprise: storage of components/auxiliary materials,
cleaning of components and correct installation.
RP
OS
E
Preliminary remarks
When servicing or carrying out overhaul work, the natural or artificial rubber
seals must be replaced. Undamaged seals, in perfect condition, may only be
reused in an emergency. It is recommended to immediately re-order seals
used, to ensure that they are to hand when needed.
The following sections are extracts from DIN 7716 and ISO 2230-1973.
Storage of Elastomer Seals
PU
The life of rubber products is influenced by oxygen, ozone, heat, light,

humidity, solvents and mechanical load. The functionality of rubber seals
when fitted is therefore dependent on correct storage, amongst other factors. The following indications should be noted in particular:
1. The store-room should be cool, dry, free from dust and adequately ventilated.
NG
2. The storage temperature should not be less than -10 C, or more than
+25 C. Neoprene items (Chloroprene rubber) should not be stored at
temperatures less than +12 C.
NI
3. Rubber items in heated storage rooms should be protected from sources of heat. The distance between the source of heat and the stored
items must be at least 1 m. If the rooms are heated by hot air a greater
distance is required (danger of drying out).
6. Rubber items should not be stored in the same storage room as solvents, fuels, anti-seize agents, slushing oils, chemicals, acids, disinfectants and similar substances.
7. Rubber items must be tension-free, i.e. stored without tension, compression 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 deformed, or of developing cracks).
6682 000.21-01 EN
General
5. Rubber items should be protected from direct sunlight and strong artificial light which has a high UV content. The effects of ozone are particularly damaging. You must therefore ensure that the storage location is
not close to fluorescent tubes or other light sources having high ultraviolet radiation. Because of the effects of ozone, rubber items should
not be stored close to electrical installations, engines and generators.
R
FO
2010-04-07 - de
TR
AI
4. Rubber items should not be stored in humid rooms. Relative humidity

should be less than 65%.
1 (3)
000.21
MAN Diesel & Turbo
ON
LY
Machine Elements
8. Rubber items of various compositions e.g. Perbunan and silicone rubber should not come into contact with each other. This is particularly
important for parts which have different colours. Also avoid contact with
copper and materials containing manganese.
9. Rubber items should be packed (shrink wrapped) in polyethylene plastic
bags or similar (foils should not contain any plasticisers). To avoid confusion, 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.
RP
OS
E
10. Newly delivered rubber items should be stored separately from those
already in storage so that the oldest are used first.
PU
In the event of fire / heating above 315 C of FKM fluoro rubber (Trade
names Viton, Fluorel, Techoflon, Dai-el) poisonous fumes are
produced.
Hydrogen fluoride vapour, in the presence of water, produces
fluorhydric 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
NG
Rubber items are cleaned in warm soapy water and dried at room temperature. If necessary, seals which have been stored for a long period can be
cleaned in a 1.5% sodium bicarbonate solution. Any cleaning solution residue should rinsed off with normal tap water (not sea water!).
NI
AI
Assembly
General
2 (3)
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
when other components pass over them. Cylinder liners must be free of
corrosion-inhibiting wax in the area where the sealing rings are installed.
The solvent used for cleaning must be allowed to dry out completely.
The installation spaces of the sealing rings must be coated with a suitable anti-seize agent.
6682 000.21-01 EN
2010-04-07 - de
TR
Basic principles that apply in You must exercise particular care when installing rubber products. Observe
the following points in particular when carrying out the installation.
general
Sealing rings can be expanded briefly by 30% of their internal diameter at
O-ring seals
FO
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.
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.
Unsuitable anti-seize agents
ON
LY
Radial sealing rings
Machine Elements
000.21
MAN Diesel & Turbo
6682 000.21-01 EN
General
R
FO
2010-04-07 - de
TR
AI
NI
NG
PU
RP
OS
E
If unsuitable anti-seize agents are used, this can cause the seals to fail
prematurely.
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Threaded inserts
use
ON
LY
Summary
Machine Elements
000.22
MAN Diesel & Turbo
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, disassembly.
RP
OS
E
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
PU
Preliminary remarks
NG
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 shaped). See the following figure.
The thread of the locating hole must only be cut using special thread drills
(see figure 3). The thread depth must correspond to the length of the threaded insert plus 0.3 ... 0.8 x P (P = pitch) (F in figure 2 too short).
of threaded insert
Length threaded insert
Carrier pin
Notch
Threaded insert type A
(inside continuously
round)
J Threaded insert type B
(1 thread pitch hexagonal on inside)
A
B
C
D
K
FO
2008-10-28 - de
TR
Thread cutting
AI
Conventional twist drills are to be used for drilling. Information regarding the
diameter and drilling depth can be taken from the manufacturer's product
range lists. Do not, under any circumstances, countersink the core hole;
slight deburring is, however, allowed.
Figure 1: Threaded insert type A - non-locking (left), type B - self-locking (right)
6682 000.22-01 EN
General
Drilling
NI
Work Sequence 1 - Installation
1 (3)
000.22
ON
LY
Machine Elements
MAN Diesel & Turbo
E Core hole diameter

F Core hole depth
(length of threaded
insert plus adapter)
RP
OS
E
Figure 2: Twist drill/hole
G Diameter of the special

thread drill, suitable for A
C Carrier pin
H Screwing-in tool
NI
NG
PU
Figure 3: Special thread drill
AI
TR
General
Installation
2 (3)
L Pin breaker/punch
M Boring tool
Figure 5: left pin breaker/punch, right boring tool
The screwing-in tool (H) is used for fitting. The threaded insert is inserted into
the preloading cartridge of the tool with the carrier pin laying in the installation
direction. The spindle carrier pin is gripped by turning the spindle and the
insert is inserted into the preloading cartridge until the first thread is located
in the last thread pitch of the cartridge. Then place the tool onto the hole in
line and continue to turn the spindle. This then fits the threaded insert into
the locating thread (see figure 4).
6682 000.22-01 EN
2008-10-28 - de
FO
Figure 4: Screwing-in tool
The threaded insert must lie 0.3 ... 0.8 x P below the surface. It can only sit in
a fully cut thread.
The carrier pin (C) is only used for the installation. Afterwards it must be
removed with a special pin breaker (figure 5) or a punch. The tool is to be
placed in the thread on the carrier pin of the fitted threaded insert. By means
of a short strong blow on the tool mandrel, the carrier pin breaks off at the
notch provided for this purpose (D).
ON
LY
Pin breaking
Machine Elements
000.22
MAN Diesel & Turbo
Breaking the pin is not absolutely necessary for blind holes. Provided the carrier pin is not removed, the maximum screw-in depth of the bolt/screw must
be observed.
Work Sequence 2 - Removal
6682 000.22-01 EN
General
R
FO
2008-10-28 - de
TR
AI
NI
NG
PU
RP
OS
E
If, in exceptional cases, the threaded insert has to be removed, this can be
done using an boring tool as illustrated in figure 6. The tool is pressed firmly
into the thread with its wedge-shaped part and turned left until the insert
releases/until it can be screwed out.
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Tightening screwed connections

Tightening torques (partial image)
ON
LY
Summary
Machine Elements
000.29
MAN Diesel & Turbo
Provide torque values for important bolted connections, ensure operational

safety. Bolted connections, which are tightened by means of hydraulic tensioners according to torque or torsion angle, must be tightened or untightened in accordance with the specified values.
Work Cards 000.29 and 000.30 contain the necessary information.
RP
OS
E
Explanations
6632 000.29-06 EN
V32/40
R
FO
2007-07-17 - de
TR
AI
NI
NG
PU
The illustrations in Work Card 000.29 serve for identification purposes concerning the position and proximity of the parts to be connected. The illustrations have identification numbers, for example 020-1, which are listed in
numerical order in Work Card 000.30. The identification numbers also indicate the tightening torques and the corresponding Work Cards.
1 (4)
V32/40
2 (4)
2007-07-17 - de
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Machine Elements
000.29
MAN Diesel & Turbo
Figure 1: Cross-section / side view of engine
6632 000.29-06 EN
000.29
6632 000.29-06 EN
V32/40
Figure 2: Crankshaft with flywheel and fitted pumps/camshafts
R
FO
2007-07-17 - de
TR
AI
NI
NG
PU
RP
OS
E
ON
LY
Machine Elements
MAN Diesel & Turbo
3 (4)
000.29
PU
RP
OS
E
ON
LY
Machine Elements
MAN Diesel & Turbo
AI
TR
2007-07-17 - de
R
V32/40
FO
NI
NG
Figure 3: Mounting of turbocharger and charge air cooler
4 (4)
6632 000.29-06 EN

Tightening torques (table)
ON
LY
Summary
Machine Elements
000.30
MAN Diesel & Turbo
Provide torque values for important bolted connections, ensure operational

safety. Bolted connections, which are tightened by means of hydraulic tensioners according to torque or torsion angle, must be tightened or untightened in accordance with the specified values.
6632 000.30-06 EN
V32/40
R
FO
2010-03-05 - de
TR
AI
NI
NG
PU
RP
OS
E
1 (12)
V32/40
2 (12)
2010-03-05 - de
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Machine Elements
000.30
MAN Diesel & Turbo
Tightening torques
6632 000.30-06 EN
6632 000.30-06 EN
V32/40
NI
AI
TR
FO
2010-03-05 - de
NG
RP
OS
E
PU
Machine Elements
ON
LY
MAN Diesel & Turbo

000.30
3 (12)
V32/40
4 (12)
2010-03-05 - de
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Machine Elements
000.30
MAN Diesel & Turbo
6632 000.30-06 EN
6632 000.30-06 EN
V32/40
NI
AI
TR
FO
2010-03-05 - de
NG
RP
OS
E
PU
Machine Elements
ON
LY
MAN Diesel & Turbo

000.30
5 (12)
V32/40
6 (12)
2010-03-05 - de
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Machine Elements
000.30
MAN Diesel & Turbo
6632 000.30-06 EN
6632 000.30-06 EN
V32/40
NI
AI
TR
FO
2010-03-05 - de
NG
RP
OS
E
PU
Machine Elements
ON
LY
MAN Diesel & Turbo

000.30
7 (12)
V32/40
8 (12)
2010-03-05 - de
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Machine Elements
000.30
MAN Diesel & Turbo
6632 000.30-06 EN
6632 000.30-06 EN
V32/40
NI
AI
TR
FO
2010-03-05 - de
NG
RP
OS
E
PU
Machine Elements
ON
LY
MAN Diesel & Turbo

000.30
9 (12)
V32/40
10 (12)
2010-03-05 - de
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Machine Elements
000.30
MAN Diesel & Turbo
6632 000.30-06 EN
6632 000.30-06 EN
V32/40
NI
AI
TR
FO
2010-03-05 - de
NG
RP
OS
E
PU
Machine Elements
ON
LY
MAN Diesel & Turbo

000.30
11 (12)
V32/40
12 (12)
2010-03-05 - de
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Machine Elements
000.30
MAN Diesel & Turbo
6632 000.30-06 EN

Tightening torques (turning moments)
ON
LY
Summary
Machine Elements
000.31
MAN Diesel & Turbo
Provide tightening torques for important bolted connections, ensure operational safety. Bolted connections should be tightened using a torque wrench
if at all possible. For especially important connections, the values are specified in Work Card 000.30. Approximate values for other bolts are stated here.
Tightening of bolted
connections according to
torque
RP
OS
E
Tightening Torques
If other bolted connections other than those listed in Work Card 000.30 are
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 , 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. Conversion factors must be used for other strength classes, by which the tightening torque taken from the table must be multiplied. The strength class
is stamped on the screw head.
Strength class
PU
NG
Conversion factor x
5.6
6.8
10.9
12.9
0,47
0,75
1,4
1,7
Table 1: Conversion factors for tightening torques depending on the strength class of
the bolts
NI
The following applies approximately for the coefficient of friction :

= 0.08
for anti-seize agent containing molybdenum disulphide (MoS2)
or lubricated using Loctite

(see Work Card 000.19)
Tightening torque in Nm
Coefficient of friction
0,08
0,14
M5
M6
M8
Thread
Rated dimension
Tightening torque in Nm
Coefficient of friction
0,08
0,14
M 24
475
690
10
M 24x2
500
750
17
25
M 27
700
1020
M 10
34
50
M 27x2
730
1100
M 12
60
85
M 30
950
1380
FO
2007-08-29 - de
Thread
Rated dimension
for surfaces without post-treatment, slightly oiled
6682 000.31-01 EN
General
TR
= 0.14
Optimoly-Paste White T)
AI
(MOLYKOTE Paste Type G-n or HSC and
1 (2)
MAN Diesel & Turbo

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
M 18
200
280
M 36x3
M 18x1.5
215
320
M 39
M 18x2
205
300
M 39x3
M 20
275
400
M 42
M 20x1.5
295
450
M 42x3
M 20x2
285
425
M 22
370
540
M 22x1.5
395
595
M 22x2
380
565
ON
LY
M 14
1640
2400
1710
2550
2115
3120
2190
3300
2630
3860
2760
4170
M 45
3260
4820
M 45x3
3415
5180
M 48
3950
5820
M 48x3
4185
6370
RP
OS
E
Machine Elements
000.31
AI
TR
2007-08-29 - de
R
General
FO
NI
NG
PU
Table 2: Tightening torques for bolts of strength class 8.8
2 (2)
6682 000.31-01 EN

General remarks
ON
LY
Summary
Machine Elements
000.32
MAN Diesel & Turbo
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.
RP
OS
E

Work card
000.29
General remarks
Work card
000.30
000.31
Different methods of tightening bolted connections are used depending on

the purpose of the connection and its significance. When there are no specifications for the tightening of screwed connections of average significance,
use normal ring spanners, socket spanneres or open-jaw wrenches without
any extensions.
PU
Tightening with standard

tools
Work card
NG
Self-locking hexagon nuts must only be used once! After use for
assembly, they must be replaced by new self-locking hexagon nuts!
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 decisive for the pre-treatment of the bolted connection and for the application of
the anti-seize agent.
Tightening to torsion angle

or torque and torsion angle
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.
Bolted connections for the tightening of which a specific torsion angle is
stipulated, must firstly be tightened with a torque wrench to the stated torque
or with an open-jaw spanner, ring spanner or socket spanner until the nut or
bolt fits tightly. Secondly, the nut or bolt must continue to be tightened by
the stipulated torsion angle.
6682 000.32-01 EN
General
R
FO
2007-03-26 - de
TR
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 circumstances. Torque wrenches must also be regularly checked for correct read-out/
setting.
AI
NI
Tightening to torque
1 (2)
MAN Diesel & Turbo

The procedure in which the screwed connections were primarily, or exclusively, tightened by reference to the elongation of the bolt/pressing of the
parts to be tensioned has been discarded in favour of other methods. Today,
the change in length/pressing is only measured as a checking dimension, in
addition to tightening with hydraulic tensioners.
Disadvantages of the
previously stated methods
The following disadvantages of tightening bolted connections with ring spanners, 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
The disadvantages listed above are not applicable to the tightening of bolted
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 regulations.
AI
TR
2007-03-26 - de
R
General
FO
NI
NG
PU
Tightening with hydraulic

tensioners
ON
LY
Tightening to the elongation

of the bolt
RP
OS
E
Machine Elements
000.32
2 (2)
6682 000.32-01 EN
Surface Test By
Penetration methods
ON
LY
Summary
Machine Elements
000.34
MAN Diesel & Turbo
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 perfect condition, or to correctly classify existing damage.
Tools/aids required
Quan- Designation
tity
RP
OS
E
The work/work steps include: Cleaning components and preparing for testing, inspecting parts/components.
Number
Status
Inventory
1 Special cleaning agent
Inventory
1 Penetrant
Inventory
Inventory
Inventory
1 Wire brush
1 Developer
PU
1 Protective clothing
Application areas
In all cases the manufacturer's instructions must be observed during use.

The following information illustrates the procedure and the main application
options.
FO
2008-10-28 - de
Work Sequence 1 - Precleaning of the Components to be Tested

Various cleaning methods can be applied, depending on the type and quality
of the component to be tested. Generally the surface to be tested must have
a polished metal finish, must be clean and free of grease. All types of coating
and deposits, such as galvanic coatings, rust and scale layers must be
removed. This is necessary so that the penetrant can fully wet the surface
and penetrate surface faults.
6682 000.34-01 EN
General
TR
Fluorescent penetrating oils are used in a similar method. These require an

additional emulsifying process. The evaluation of surface faults is carried out
under UV light.
AI
NI
NG
Surface inspections using the penetration method are based on the introduction 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 m, provided they have a connection to the test surface. The penetration method
can be used for almost all materials and at a temperature range of approx.
-5 to 50 C. With special testing equipment, this method can also be used
on surfaces having temperatures up to 175 C. Surface defects (hereafter
referred to as faults) can be displayed independently of their type and direction as well as independently of the geometry of the test object. Other nondestructive test methods can only be applied with restrictions under the
requirements stated above.
1 (7)
000.34
RP
OS
E
ON
LY
Machine Elements
MAN Diesel & Turbo
1 Mechanical (Wire brush)
3 Chemical (Degreasing using hot

steam)
2 Mechanical (e.g. sandblasting)
4 Chemical (Cleaning agent)
Figure 1: Options for the precleaning of the components to be tested (Illustration
source: Helling)
Work Sequence 2 - Introduction of the Penetrant
AI
General
2 (7)
The excess penetrant clinging to the component surface must be fully

removed. In doing so, you must ensure that the penetrant remains in position
in any faults that are detected. The cleaning method depends on the penetrant used.
6682 000.34-01 EN
2008-10-28 - de
TR
R
1 Immersion bath
3 Spraying (spray can)
2 Brushing on
4 Spraying (Compressed air gun)
Figure 2: Options for application of the penetrant
Work Sequence 3 - Intermediate Cleaning of the Component Surface
FO
NI
NG
PU
The penetrant can be applied to the component to be tested in various ways.

You must ensure that the test surface remains fully wet throughout the entire
penetration period. Adequate penetration duration depends on the characteristics of the penetrant, the test temperature and the material of the component to be tested. For castings, this is generally within a range 3 ... 5
minutes, for homogeneous metals 10 ... 20 minutes.
000.34
RP
OS
E
ON
LY
Machine Elements
MAN Diesel & Turbo
1 water soaked, non-fraying cloth

or sponge
2 Cleaning with a brush
3 Rinsing with water

4 Special cleaning agents (compatible with the penetrant)
Figure 3: Intermediate cleaning options
Work Sequence 4 - Drying of the Cleaned Component Surface
Work Sequence 5 - Development Process
FO
2008-10-28 - de
2 dry, non-fraying cloth

Figure 4: Component drying options
3 Compressed air (water and oil

free)
4 Warm air
The developer must be applied as evenly as possible in a thin layer on the

component surface to be tested. In addition to wet developers based on
water or solvent, dry developers are also used. In general, the development
duration corresponds to the penetration duration of the penetrant.
6682 000.34-01 EN
General
1 Air drying
TR
AI
NI
NG
PU
After removal of the excess penetrant, the component surface to be tested

must be dried as quickly as possible. In doing so, you must ensure that the
penetrant located in any faults does not dry in. The entire drying process can
be omitted if a wet developer with water is used as the carrying agent for the
development process.
3 (7)
000.34
RP
OS
E
ON
LY
Machine Elements
MAN Diesel & Turbo
1 Water-based wet developer

3 Solvent-based wet developer
(Immersion)
(compressed air gun)
(aerosol can)
(electrostatic/airless)
Figure 5: Options for the application of the developer
Work Sequence 6 - Results Evaluation
AI
TR
General
4 (7)
3 photograph
4 Documentation by photographs
or video recording
2008-10-28 - de
1 visual inspection
2 Documentation on transparency
film
Figure 6: Options for recording the test result
FO
NI
NG
PU
The developer (white) draws the penetrant (red) out of any faults and shows
them as coloured bleed-outs. The size, type and shape of the bleedings
allow conclusions to be drawn as to the origin of the fault. Such fault indications are shown as a schematic diagram in figure 7.
6682 000.34-01 EN
000.34
6
7
8
9
Cluster porosity
Spongy structure
Porosity (heavy bleeding)
Stress corrosion cracking
6682 000.34-01 EN
General
R
FO
2008-10-28 - de
TR
Figure 8: Valve cone with stress cracks in the fillet
AI
NI
NG
PU
RP
OS
E
1 Cold cracks
2 Hot cracks
3 Grinding cracks
4 Cracks (heavy bleeding)
5 Porosity
Figure 7: Fault indications
ON
LY
Machine Elements
MAN Diesel & Turbo
5 (7)
000.34
RP
OS
E
ON
LY
Machine Elements
MAN Diesel & Turbo
PU
Figure 9: Valve cone with cracks in the valve seat armouring
Recommended Manufacturers for Testing Chemicals (Special Cleaning Agents/

Penetrants/Developers)
Manufacturer
Developer
Tiede-PEN RL-40
Tiede-PEN PWL-1
Tiede-PEN DL-20
MR 79
MR 68 NF
MR 70
ARDROX
9PR88
ARDROX
9VF2
ARDROX
9D1B
NPU
VP 30
D 70
NI
AI
Brent GmbH
Rostocker Strae 40
D-41199 Mnchengladbach
TR
Helling KG GmbH & CO.

Sylvesterallee 2
D-22525 Hamburg
2008-10-28 - de
Table 1: Manufacturers/Testing Chemicals
General
FO
MR Chemie GmbH
Nordstrae 61-63
D-59427 Unna
Penetrant
NG
Tiede
Bahnhofstrae 94-98
D-73457 Esslingen
Special cleaning agent
6 (7)
6682 000.34-01 EN
000.34
RP
OS
E
ON
LY
Machine Elements
MAN Diesel & Turbo
6682 000.34-01 EN
General
R
FO
2008-10-28 - de
TR
AI
NI
NG
PU
Figure 10: Testing Chemicals of Various Manufacturers (Special Cleaning Agents/

Penetrants/Developers Respectively)
7 (7)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Surface Test By
Magnetic leakage flux method
ON
LY
Summary
Machine Elements
000.34
MAN Diesel & Turbo
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 perfect condition, or to correctly classify existing damage.
Tools/aids required
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
PU
Quan- Designation
tity
RP
OS
E
The work/work steps include: Cleaning components and preparing for testing, inspecting parts/components.
NG
Application areas
The magnetic field in the component to be tested can be generated in several different ways. Apart from coil magnetisation, self-magnetisation and
induced magnetisation, the most widespread magnetisation method is yoke
magnetisation. In all cases the manufacturer's instructions must be observed
during use. The following information illustrates the yoke magnetisation procedure and the basic application options.
6682 000.34-02 EN
General
R
FO
2008-10-28 - de
TR
The magnetic powder is applied to the test surface as a dry powder or in a

liquid suspension (water, oil, paraffin). These are ferromagnetic materials
such as iron, nickel and cobalt alloys. The ferromagnetic characteristics of
these materials disappear above a certain temperature, the so-called Curie
point. For most ferromagnetic materials this point is approx. 760 C.
AI
NI
Surface examinations, carried out according to the magnetic particle inspection method, cause ferromagnetic discontinuities and thus leakage fields in
the faulty areas of magnetised ferromagnetic materials which have been flooded by a magnetic field. These go beyond the component surface. The presence of a magnetic discontinuity or a leakage field is verified by the application 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.
1 (5)
000.34
RP
OS
E
ON
LY
Machine Elements
MAN Diesel & Turbo
AI
TR
R
Figure 2: Permanent magnet with special paint and magnetic powder in spray cans
(by Helling)
2008-10-28 - de
Yoke magnetisation
General
FO
NI
NG
PU
Figure 1: AC yoke magnetising device (by Helling)
2 (5)
6682 000.34-02 EN
ON
LY
Figure 3: Field line path in yoke magnetisation
Machine Elements
000.34
MAN Diesel & Turbo
In yoke magnetisation we generally differentiate between two types of magnetisation. The magnetic field can be generated using a permanent magnet
or solenoid.
A Component without
faults (homogeneous
magnetic field - no fault
display)
B Component with faults in
the field direction (homogeneous magnetic field no fault display)
C Component with faults
transverse to the field
direction (inhomogeneous magnetic leakage
field - clear fault display)
NI
NG
PU
RP
OS
E
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).
The magnetic powder can be applied in a dry or wet process. Both procedures differ in their application options and, in part, in their display sensitivity.
6682 000.34-02 EN
General
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.
Application of the magnetic powder
FO
2008-10-28 - de
TR
The component to be tested must be cleaned and freed from all types of
coatings and covering which may impede the alignment of the magnetic
powder or which may lead to incorrect fault displays.
AI
Figure 4: Field lines in the magnetised component
3 (5)
MAN Diesel & Turbo
ON
LY
Machine Elements
000.34
Figure 5: Bead formation in the magnetic powder due to magnetic leakage fields
Dry process
RP
OS
E
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 surface of the component to be tested to be absolutely dry and free from
grease. Surface roughness can be slightly higher than in the wet process. In
the dry process, relatively thick powder beads are formed, leading to a clear
fault display.
The dry process is advantageous for testing components that cannot not be
wetted with water or testing oil or on hot component surfaces.
Wet process
PU
In the wet process, the magnetic powder is flushed onto the component surface to be tested in a carrier liquid. Water or testing oil is used as the carrier
agent, depending on the application. The mobility of the individual magnetic
powder particles is substantially increased by the use of such magnetic particle suspensions. The particles "swim" to the faults. This, however, assumes
the constant movement of the carrying agent in order to prevent the magnetic powder from being deposited.
NG
The concentration of magnetic powder in the carrying agent is also decisive

for the test result. In general, magnetic particle suspensions with higher concentrations 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-fluorescent magnetic particle suspensions is between 6 ... 24 g/l and fluorescent
magnetic particle suspensions between 0.25 ... 2.5 g/l.
AI
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 flushing 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.
General
Very fine separations, such as grinding and hardening cracks, can only be
reliably detected using the wet process with less concentrated magnetic particle suspensions and a smaller grain size.
4 (5)
6682 000.34-02 EN
2008-10-28 - de
TR
Carrying Out the Magnetic Powder Test
FO
NI
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.
ON
LY
Finally, the test area is examined for powder accumulation and the possible
fault indications are evaluated, marked and fixed if necessary. Depending on
the use of the component, test agent residues are removed and the component is demagnetised.
Machine Elements
000.34
MAN Diesel & Turbo
Magnetic Powder Indications
NI
NG
PU
RP
OS
E
During the magnetic powder test, an image of the fault pattern is given by
the bead formation at the fault locations, but no information is provided as to
the fault depth. As already described, clear magnetic powder images are
provided of component surface faults, while faults underneath the component surface only result in indistinct indications.
R
FO
2008-10-28 - de
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.
6682 000.34-02 EN
General
TR
AI
False indications are a special problem in magnetic powder testing. These

are powder accumulations which occur in places that are not faulty. False
displays occur, for example, at sharp cross section transitions or in coldformed areas. A certain amount of experience is required in such cases to be
able to differentiate between a false display and a genuine fault indication.
Figure 6: Valve cone with stress cracks in the fillet
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Working and Safety Regulations

the use of load carrying equipment/slings
ON
LY
Summary
Machine Elements
000.43
MAN Diesel & Turbo
Impart the necessary knowledge, ensure safe use (of load carrying equipment).
In order to use the load carrying equipment/slings in a safe manner the regulations for use must be observed.
RP
OS
E
The following must be observed:

Danger of accidents,
Safety regulations and
Maintenance regulations.

Work card
Work card
000.34
Preliminary remarks
Work card
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
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/doubtful components.
Use the stipulated tensioning values and lubricants.
NG
The load carrying equipment must be stored in a stable condition.
In order to prevent damage and corrosion the tools must be protected

from dust, dirt, chemicals and liquids.
Always use genuine spare parts when carrying out overhaul work since
perfect function and carrying capacity depends upon this.
Check the load carrying equipment regularly for correct condition. Before
and after extensive maintenance work, a crack check (see Work Card
000.34) in the main load area of the load carrying equipment must be
carried out.
R
FO
2008-09-15 - de
TR
Basic Safety Information

Obligations and liability
Knowledge of the basic safety information and safety regulations is a basic

prerequisite for ensuring safe handling and trouble-free operation of load carrying equipment.
6682 000.43-01 EN
General
Storage and Care of Tools
AI
NI
Safety Regulations
PU
1 (4)
000.43
MAN Diesel & Turbo
Machine Elements
These Operating Instructions, particularly the safety information, must be

observed by all persons who work with load carrying equipment.
ON
LY
The applicable rules and regulations at the place of use governing the prevention of accidents must also be observed.
Intended use
The sole purpose of load carrying equipment or sling gear is to raise and
lower the Diesel engine components or assemblies specified by MAN Diesel
& Turbo SE.
Improper use
Use for any purpose other than that specified above is prohibited. Hazards
may arise as a result of improper use.
An example of improper use is the carrying of loads of unspecified components or assemblies
Although the load carrying equipment/sling gear is constructed in accordance with the latest technical standards and generally recognised safety regulations, it can still 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. Load carrying equipment or sling gear must only be used:
RP
OS
E
Hazards associated with the

handling of load carrying
equipment
for its intended purpose,
when it is perfectly safe to use.
Faults that could impair safety must be eliminated immediately.
PU
Visual inspection of load carrying equipment/sling gear
NG
Load carrying equipment/sling gear must be inspected visually to

check for damage or wear in general following every loading cycle
(change of load when lifting up or setting down).
Regular inspection of load carrying equipment/sling gear
AI
General
2 (4)
Replacing load carrying equipment/sling gear

Load carrying equipment/sling gear must be taken out of service and
replaced with new equipment once 15 years have elapsed since its
manufacturing date! A tally of the loading cycles must be kept in the
operating records!
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 are dealt with exclusively according to the provisions arising 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
6682 000.43-01 EN
2008-09-15 - de
TR
R
Warranty and liability
FO
NI
Load carrying equipment/sling gear must be inspected (general visual

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
writing!
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
ON
LY
Incorrect assembly, commissioning, operation and maintenance of the

load carrying equipment/sling gear
RP
OS
E
Organisational measures
Machine Elements
000.43
MAN Diesel & Turbo
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.
PU
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 equipment/sling gear.
NG
Safety equipment
Hot surfaces of components

Only touch the hot surfaces of components when wearing protective
gloves or protective clothing!
Allow the components to cool down before touching their surfaces
without wearing protective gloves or protective clothing.
6682 000.43-01 EN
General
TR
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
loading cycle for signs of damage and also to ensure that the safety equipment is in working order.
Particular dangers
FO
2008-09-15 - de
Safety measures to be taken

during normal operation
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
on the job may only work with the load carrying equipment/sling gear under
the supervision of an experienced person.
AI
Instruction of personnel
NI
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.
3 (4)
000.43
MAN Diesel & Turbo
Machine Elements
Damaged components
ON
LY
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.
Handling of heavy components or assemblies
RP
OS
E
Due to the weight of the components or assemblies being handled by

the load carrying equipment/sling gear as well as other factors, the
following points in particular must be observed:
Stay clear of the area below suspended loads. Keep other persons out
of the danger zone.
Observe the maximum permissible capacity of the crane or lifting
tackle.
Observe the maximum permissible load-bearing capacity of the load
carrying equipment/sling gear.
PU
Working with load carrying equipment, environmental

conditions
Carry out prescribed adjustment, maintenance and inspection work on

time.
Secure load carrying equipment/sling gear or lifting tackle to prevent it
from starting up or moving accidentally.
If the load carrying equipment/sling gear is not in perfect condition,

replace it immediately! Only use genuine spare and wear parts! It cannot
be guaranteed that parts procured from other sources are designed and
manufactured to meet the specific loading and safety requirements.
Do not modify, add to or convert the load carrying equipment/sling gear

without the manufacturer's consent.
All conversion measures require the written consent of MAN Diesel &
Turbo SE.
2008-09-15 - de
TR
AI
Constructional changes to
load carrying equipment/
sling gear
General
FO
NI
Maintenance and repairs,

troubleshooting
NG
Components may be damaged when they are removed if the space

above is limited.
Danger of crushing when setting down load carrying equipment, and
when attaching/installing components or assemblies.
Tilting moments may be exceeded, or the load could shift
unexpectedly, if the incorrect attachment point is used.
4 (4)
6682 000.43-01 EN
004
NG
PU

Machine Elements
FO
TR
AI
NI
001
002
003
004
005
RP
OS
E
ON
LY
MAN Diesel & Turbo
6632 004-05 EN
1 (1)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Working and Safety Regulations

using high-pressure tools/hydraulic tensioners
ON
LY
Summary
000.33
MAN Diesel & Turbo
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.
Preliminary remarks
RP
OS
E
The following are to be observed: Accident hazards, safety regulations and

maintenance instructions.
Hydraulic tensioners, high-pressure hoses and the high-pressure pump are

tools which can be used safely without malfunctioning, despite high operating pressures, if the following instructions are observed.
Instructions for use
Instructions for repair
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.
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 tensioners.
When unfastening bolts that have been tightened hydraulically, do not

exceed the prescribed clamping pressure by more than 5%.
When checking bolts that have been hydraulically tightened, the release
pressure must not by more than 7% below or more than 5% above the
prescribed clamping pressure (see Work Card 000.30).
6682 000.33-01 EN
General
R
FO
2007-07-19 - de
TR
AI
NI
NG
PU
Safety Regulations
1 (6)
000.33
MAN Diesel & Turbo
ON
LY
If the release pressure is too low (7% below the prescribed value at the
most), the cause should be investigated (this may be due to insufficient
attention being paid during tightening, wear or excessive settlement of screw
connection).
If the release pressure is 10% or more below the prescribed value, notify
MAN Diesel & Turbo SE in Augsburg who will help you find the best
approach for checking this.
If the release pressure is too high (bolt cannot be released by applying 5%

higher clamping pressure), the cause must be eliminated if possible (bolted
connection damaged/corroded or siezed due to paint; tensioner damaged or
incorrectly attached).
RP
OS
E
Once remedial action has been taken and the connection still cannot be
released, the clamping pressure may then only be increased until the connection releases with the consent of MAN Diesel & Turbo SE in Augsburg
which must be verifiable (as there is a danger of bolt elongation or deformation of components). Alternatively, the nut can be split and replaced with the
bolt.
Storage and Care of Tools
Store tools at 15 to 25 C if possible, so that plastic parts do not age

prematurely and the hydraulic fluid remains adequately fluid. Plastic seals
must be protected from the effects of light.
Dust, dirt, chemicals and liquids must be kept away from tools to avoid
damage to the sealing faces.
Presses and high-pressure hoses must be bled (air) for storage.
Do not kink high-pressure hoses. Couplings to be interconnected.
When carrying out overhaul work, only ever use genuine spare parts,
since perfect operation depends, for example, on the correct hardness of
the O-ring seals.
NG
PU
Check the pump pressure gauge regularly for correct read-out.
Knowledge of the fundamental safety information and safety regulations

is a fundamental prerequisite for working safely with hydraulic tensioners
without problems.
AI
General
2 (6)
Checking and logging the

loading cycles
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.
Although the hydraulic tensioner is constructed in accordance with the latest

technical standards and generally recognised safety regulations, it can still
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
hydraulic tensioner:
for its intended purpose,
when it is perfectly safe to use.
Faults that could impair safety must be eliminated immediately.

The hydraulic tensioner must undergo a general visual inspection, including
an inspection of the thread for damage and wear, following every loading
cycle (i.e. change of load when tightening or releasing).
6682 000.33-01 EN
2007-07-19 - de
TR
Hazards associated with

handling the hydraulic
tensioner
FO
Obligations and liability
NI
Basic Safety Information
ON
LY
The hydraulic tensioner must be inspected (general visual inspection,

inspection of thread for damage/wear and magnetic crack test of all
components) at regular intervals (approx. every 100 loading cycles)
and this must be documented in the operating records!
000.33
MAN Diesel & Turbo
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
RP
OS
E
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 properly installed or are not working correctly
Non-compliance with the information on transport, storage, assembly,

commissioning, operation, maintenance and setting up the hydraulic tensioner 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
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
Improper use
Use for any purpose other than that specified above is prohibited. Hazards
may arise as a result of improper use.
R
FO
2007-07-19 - de
Examples of improper use are:
Organisational measures
Any type of bolted connection which has not been specified
High-strength bolted connections in steel construction
Clamping screw connections in other areas
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
6682 000.33-01 EN
General
AI
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.
NI
NG
PU
TR
Intended use
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:
3 (6)
MAN Diesel & Turbo
All existing hydraulic equipment must be regularly checked.
Personnel who are authorised to work with the hydraulic tensioner must
receive instruction regarding use of the Operating Instructions and the
safety information contained therein.
ON
LY
000.33
Safety equipment
Each time you commission the hydraulic tensioner, make sure that all safety
equipment is properly attached and functional beforehand.
Informal safety measures
The Operating Instructions must always be kept at the hydraulic tensioner.
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.
Work on the hydraulic tensioner 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 on the job may
only work with the hydraulic tensioner under the supervision of an experienced person.
Safety measures to be taken

during normal operation
Before commissioning the hydraulic tensioner, make sure that this will not
put anyone in danger. Check the hydraulic tensioner at least once every
loading cycle for signs of damage and also to ensure that the safety equipment is in working order.
RP
OS
E
Instruction of personnel
NG
PU
When building up the pressure, pay attention to the permissible

operating/clamping pressure for the relevant hydraulic tensioner and
bolted connection being tightened!
There is no additional limit applied to the maximum operating pressure
of the pump for the hydraulic tensioner/cylinder with low operating
pressure. In this instance, the pressure gauge must be carefully
observed!
AI
General
4 (6)
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.
Hose lines may only be uncoupled once the hydraulic system is at zero
pressure.
Damaged hose lines
High-pressure hose lines are subject to an operating pressure of 1500

bar (bursting pressure >3300 bar) and are equipped with protective hosing. Check for damage prior to commissioning.
Do not bend the hose line. The minimum bending diameter of the highpressure hose line is 400 mm.
Only use hose lines approved by MAN Diesel & Turbo SE, Augsburg!
6682 000.33-01 EN
2007-07-19 - de
TR
Particular dangers
FO
NI
Observe the residual mechanical, hydraulic and pneumatic energy in

the hydraulic tensioner and take corresponding measures when
instructing the operating personnel.
000.33
MAN Diesel & Turbo
When screwing onto the bolt, do not reach into the area near the contact
surface of the tensioning cylinder and thrust piece.
Do not reach into the area near the contact surface of the tensioning cylinder and thrust piece during pressurisation!
Hot surfaces of components
ON
LY
Only touch the hot surfaces of components when wearing protective

gloves or protective clothing!
Allow the components to cool down before touching their surfaces without wearing protective gloves or protective clothing.
Breakage of bolt
Keep clear of the direction of force, i.e. the bolt axis, during pressurisation
Damaged components
RP
OS
E
Crushing of limbs between tensioning cylinder and thrust piece
Clean the threads following every tightening operation and check for
damage
Damaged and worn parts (tension screw, clamping nut, etc.) must not
be used under any circumstances whatsoever and must be replaced
immediately.
The following points in particular must be observed due to the high pressures
and forces which are present:
There is a risk of parts which are highly stressed breaking as the pressure builds up in the tensioner (during tightening, releasing and testing).
Broken parts are flung outwards in the direction of force, i.e. along the
extended axis of the bolt or press. There is a danger of this happening
during pumping, or if a fully pressurised tightening device is stressed by
being struck heavily.
Danger of needle-thin or razor-sharp jets of hydraulic oil being discharged as a result of leaks at sealing elements, bursting hoses or breakage of fixtures. These can inflict injuries to the skin and eyes at distances
of up to 1 m.
If the tightening operations are not performed according to the specifications this could cause the running gear bolts to fracture and the machine
to be seriously damaged. Possible reasons for this are: Incorrect pressure applied during pumping; a hose has not been connected; the hose
coupling has not engaged; tightening operation has not been checked
(length not measured, attention not paid to number of holes when turning
the nut).
Work on hydraulic equipment may only be carried out by persons with
special knowledge and experience of hydraulic systems!
Check all lines, hoses and threaded unions regularly for leaks and visible
signs of damage! Repair damage immediately! Oil that spurts out can
inflict injuries and cause burns.
Dump the pressure in hose lines before starting repair or assembly and
installation work in accordance with the module descriptions!
Only use hydraulic fluids prescribed by MAN Diesel & Turbo SE, Augsburg!
Route and install high-pressure hose lines correctly! Do not get connections mixed up! The fixtures, as well as the length and quality of the hose
lines, must satisfy the requirements.
6682 000.33-01 EN
2007-07-19 - de
FO
General
TR
Hydraulic tensioner system
AI
NI
NG
PU
5 (6)
MAN Diesel & Turbo

Wear safety goggles and protective gloves when working on/with the
hydraulic tensioning cylinder. Stay clear of the area directly next to the
fixture during pressurisation.
Maintenance and repairs,

troubleshooting
Carry out prescribed adjustment, maintenance and inspection work on

time.
Secure hydraulic tensioners to prevent them from being started up accidentally.
Constructional changes to
the hydraulic tensioner
Do not modify, add to or convert the hydraulic tensioner without the

manufacturer's consent.
All conversion measures require the written consent of MAN Diesel &
Turbo SE, Augsburg.
If the hydraulic tensioning tool components are not in perfect condition,

replace them immediately! Only use genuine spare and wear parts! It
cannot be guaranteed that parts procured from other sources are
designed and manufactured to meet the specific loading and safety
requirements.
ON
LY
AI
TR
2007-07-19 - de
R
General
FO
NI
NG
PU
RP
OS
E
000.33
6 (6)
6682 000.33-01 EN
High-pressure pump
use
ON
LY
Summary
Impart the necessary knowledge, ensure adequate application. The highpressure 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.
Number
Status
1 High-pressure pump
009.342
Standard
009.229
Option
Inventory
Technical data
Designation
Pressure range
NG
Test pressure
PU
1 Slushing oil (viscosity 6-16 mm/s)
Information
0 - 1500 bar
1500 bar
7 - 15 bar
Oil filling
5 Liter
Quality
Korrosionsschutzl
Dimensions
431x317x405 mm
Weight
30,5 kg
AI
NI
Compressed air connection
Structure/Mode of action
FO
TR
For tightening and releasing large bolted connections the following is needed:
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
the hydraulic tensioner is supported by the surrounding parts of the screw.
The high-pressure pump is operated by compressed air. The air is directed
through control elements to a piston. This piston can be pressurised from
both sides and is equipped with pistons of smaller diameter on both sides
6682 009.03-05 EN
General
Quan- Designation
tity
Tools/aids required
RP
OS
E
Information is imparted concerning: Technical data, commissioning, shutdown, maintenance and behaviour in the case of failures.
2007-04-25 - de
009.03
MAN Diesel & Turbo
1 (6)
009.03
MAN Diesel & Turbo
ON
LY
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
RP
OS
E
Observe safety instructions in Work Card 000.33!
Work steps
1. Check oil level indicator (5) in the high-pressure pump, open oil filler
neck (1) and add slushing oil if necessary.
PU
When adding slushing oil, pour oil through the basket strainer, since
malfunctions can be caused by foreign material.
2. Connect the high-pressure pump to hydraulic tensioner with a highpressure hose.

3. Set shut-off valve (A) to position II / OUT OF SERVICE.
NG
4. Connect the compressed air hose to hose connection (6).

5. Adjust the pressure regulating valve (C) so that pressure gauge (7)
shows approx. 1 bar.
NI
6. Open the relief valve (B) (counter-clockwise) to release the oil side of the
high-pressure pump.
AI
9. Close relief valve (B) (clockwise).
General
2 (6)
10. Gradually turn the pressure-regulating valve (C) for compressed air in a
clockwise direction until the desired pressure is indicated on the oil
pressure gauge (3) (there is a delay depending on the size of the
hydraulic tensioner).
6682 009.03-05 EN
2007-04-25 - de
When connecting the high-pressure hose and the hydraulic tensioner,

ensure that they are completely filled with slushing oil and bled.
TR
8. Put shut-off valve (A) to position I / OPERATION- High-pressure pump

starts.
FO
7. Ensure that all connection hoses are properly connected and close off
the hose connections (4) which are not in use with a blind plug (lock the
sliding sleeve of coupling with the stop ring).
ON
LY
The high-pressure pump runs up to the adjusted oil pressure, leakage

losses are automatically compensated by re-pumping.
009.03
MAN Diesel & Turbo
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.
RP
OS
E
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.
PU
Never open the quick-acting coupling while under pressure. - Risk of

accident! Oil pressure gauge (3) must indicate zero!
NG
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.
NI
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).
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
water can drain out. Tighten locking bolt afterwards. See manufacturer's
manual.
6682 009.03-05 EN
General
R
FO
2007-04-25 - de
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.
TR
Maintenance
AI
5. Disconnect high-pressure hose.
3 (6)
009.03
MAN Diesel & Turbo
In the case of operating faults

Compressed air part
ON
LY
1. High-pressure pump works only at a pressure of > 1.5 ... 2 bar

Reason: Friction of the control slide seal too high
Remedy: Lubricate or renew O-ring seals on the pilot valve
2. The pump does not run or runs only very slowly
Reason 1: Compressed air system leaking
Remedy: Replace O-ring seal
Reason 2: Venting system frozen up
Remedy: Heat the high-pressure pump to approx. 20 C
RP
OS
E
3. The pump does not generate any pressure, or remains at dead centre
Reason: Air system frozen up or functional problem
Remedy: Renew O-ring seals on the pilot valve or air piston
4. Condensate escaping from silencer of the vent
Reason: Compressed air filter full of water
Remedy: Drain the compressed air filter
Hydraulic part
1. Pump working but not feeding

Reason 1: Air in suction pipe
Remedy: Vent the hydraulic system
Reason 2: Suction filter choked
Remedy: Clean suction filter
AI
TR
2007-04-25 - de
R
General
FO
NI
NG
PU
2. Hydraulic oil escaping from the silencer

Reason: Piston seal worn and leaking
Remedy: Renew seal
4 (6)
6682 009.03-05 EN
2007-04-25 - de
FO
6682 009.03-05 EN
General
6 Hose connection (compressed

air)
2 Set of wear parts
7 Compressed air pressure gauge
3 Oil pressure gauge
A Shut-off valve
4 Hose connection (tensioner)
B Relief valve
5 Oil level indicator
C Pressure regulating valve
Figure 1: High-pressure pump, by GERUS, type HP25
TR
1 Oil filler neck with basket strainer
AI
NI
NG
PU
RP
OS
E
ON
LY
009.03
MAN Diesel & Turbo
5 (6)
009.03
RP
OS
E
ON
LY
MAN Diesel & Turbo
AI
TR
2007-04-25 - de
R
General
FO
NI
NG
PU
A Shut-off valve
C Pressure regulating valve
B Relief valve
Figure 2: Functional diagram of the high-pressure pump
6 (6)
6682 009.03-05 EN
High-pressure hoses
use
ON
LY
Summary
009.05
MAN Diesel & Turbo
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.
Quan- Designation
tity
1 High-pressure hose
Number
Status
009.330
Standard
009.306
Standard
009.305
Standard
009.304
Standard
009.026
Standard
PU
1 Opener
RP
OS
E
Tools/aids required
Make-up
NG
For the connection of the high-pressure pump with hydraulic tensioner, special pressure-resistant hose pipes are used. They consist of a steel wire-braided plastic interior hose and an external protective hose, which will catch the
emerging fluid jet in the case of leakage.
Permitted operating pressure:
1500 bar
with sudden load
900 bar
AI
Use
3,300 bar
R
FO
2009-07-06 - de
TR
For the connection of the high pressure pump there are quick-acting couplings on both sides, which have to be secured with an additional threaded
ring against unintentional loosening. After the coupling is engaged, the corrugated threaded ring must be screwed up to the stop.
Opening the check valve
Observe safety instructions in Work Card 000.33! Consider the

maximum usability quoted by the manufacturer.
After the use of high pressure hoses, i.e. after switching off the high pressure
pump and opening the release valve, the hoses must remain connected for
approx. 3 minutes. Otherwise internal pressure may remain, which would
block the hose coupling. Under certain circumstances the hose cannot be
6682 009.05-01 EN
General
Minimum burst pressure
NI
with constant load
1 (2)
009.05
MAN Diesel & Turbo
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
could occur.
RP
OS
E
ON
LY
The high pressure hoses are equipped with check valves on both sides. This
stops them from leaking when in storage.
NG
PU
Figure 1: High pressure hose with mounted opener (bottom left)
1 Hydraulic nipple on the

high pressure hose
2 Threaded piece for
clamping
3 Threaded piece to open
the valve
AI
TR
2009-07-06 - de
R
General
FO
NI
Figure 2: Using the opener
2 (2)
6682 009.05-01 EN
Hydraulic tensioner
use
ON
LY
Summary
Impart the necessary knowledge, ensure proper use.

Hydraulic tensioners are used for extending bolts with regard to the components to be connected. In this condition, nuts can be tightened or loosened
without applying force.
Quan- Designation
tity
RP
OS
E
The work/work steps include:

loosening,
tightening and
resetting the piston.
Tools/aids required
Number
Status
009.096
Standard
009.097
Standard
009.342
Standard
1 Hydraulic hand pump
009.320
Standard
009.304
Standard
009.305
Standard
009.306
Standard
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
1 Hydraulic tensioner
NI
NG
PU
009.01
MAN Diesel & Turbo
Work card
Work card
000.30
000.33
009.02
009.03
009.05
R
FO
2007-10-25 - de
Technical data
Designation
Information
Tool number
009.096/009.097
Effective piston area
72,72 cm
Effective stroke
11 mm
Nominal pressure
1200 bar
Test pressure
1300 bar
6629 009.01-02 EN
32/40
Work card
TR
AI
1 (4)
009.01
MAN Diesel & Turbo
Preliminary remarks
ON
LY
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 according 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.
RP
OS
E
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.
AI
Piston
Casing
Thrust piece
Nut
5
6
7
A
Bolt
Tommy bar
Hose connection
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
Before tightening the screwed connection, the nut must be tightened handtight. The piston of the tensioner must be screwed on such that the casing
and the thrust pad are blocked.
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
danger that the nut may be loosened, but that the bolt and the tensioner are
still tightened to such an extent that the tensioner cannot be removed.
6629 009.01-02 EN
2007-10-25 - de
TR
R
32/40
2 (4)
1
2
3
4
Tightening
FO
NI
NG
PU
Tandem tensioners are always used as a unit.
Work Sequence 1 - Releasing

Work steps
2. Place thrust piece (3) over nut (4).
ON
LY
1. Clean screw thread (5).
009.01
MAN Diesel & Turbo
3. Screw the tensioner in position, making sure that the thrust piece is
located centrically.
RP
OS
E
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).
PU
7. Close gap (A).
8. Pump the tensioner until the nut (4) can be released.
NG
Do not allow the pressure to fall below 7 % or exceed 5 % of the

tension pressure (see Work Cards 000.30 and 000.33).
NI
9. Turn nut back with tommy bar through the cut-out in the thrust piece
(turn-back angle see Work Card 000.30).
R
FO
2007-10-25 - de
TR
Work sequence 2 - Tightening
1. Tighten nut (4) with tommy bar (6) hand-tight.

2. Place thrust piece (3) over nut.
3. Screw the tensioner in position, making sure that the thrust piece is
located centrically.
4. Connect the high-pressure hose to the tensioner and high-pressure
pump/hydraulic hand pump.
009.03).
6. Tighten stud (5) with specified pressure (see Work Card 000.30).
7. Tighten nut (4) with tommy bar through the cut-out in the thrust piece
until it is in contact.
6629 009.01-02 EN
32/40
11. Remove tensioner and remove thrust piece.
AI
10. Release pressure, disconnect high-pressure hose from the tensioner

and high-pressure pump/hydraulic hand pump.
3 (4)
009.01
MAN Diesel & Turbo
8. Release pressure, disconnect high-pressure hose from the tensioner

and high-pressure pump/hydraulic hand pump.
ON
LY
9. Remove tensioner and remove thrust piece.
PU
RP
OS
E
Work Sequence 3 - Resetting the Piston
1 Casing
2 Piston
3 Thrust spindle
Figure 2: Use of the resetting device
4 Thrust piece
5 Hose nipple with non-return valve
NG
After each use of the hydraulic tensioner, the piston must be returned to its
initial position, so that the effective stroke cannot be exceeded. Danger of
sudden discharge of hydraulic fluid or leakage! Danger of tilting!
1. Turn back the two-armed resetting device (009.092) adequately, then

insert in the blind holes of the casing.
2. Turn the thrust spindle (3) forward until the matching recess in the
thrust piece (4) engages in the hole in the piston.
3. Turn on further until contact is made and then re-set the piston until
contact is made.
32/40
4. Remove the resetting device.
4 (4)
6629 009.01-02 EN
2007-10-25 - de
TR
Work steps
AI
If resetting the tensioner is performed without the high-pressure hose and

the high-pressure pump/hydraulic hand pump being coupled, the first step is
to open the non-return valve of the hose nipple with the press-open device.
FO
NI
For practical reasons, resetting always takes place with the tensioner coupled/ready for operation. The first step is to open the relief valve on the highpressure pump/hydraulic hand pump (enables displacement of the hydraulic
fluid). Re-setting the piston is made more easy if the relevant hose is connected temporarily to the return connection (only with a high-pressure pump).
Tools/aids required
Quan- Designation
tity
RP
OS
E

bleeding,
checking tightness,
disassembling and assembling and
replacing sealing rings/sealing elements.
Number
Status
009.097
Standard
009.097-1
Standard
009.097-1
2
Standard
009.096
Standard
1 Piston
009.096-1
Standard
009.096-1
2
Standard
1 Hydraulic nipple
009.096-2
0
Standard
1 Threaded piece
009.096-2
1
Standard
1 Sealing ring
009.096-2
2
Standard
1 O-ring seal
009.096-2
6
Standard
1 Backing ring
009.096-2
7
Standard
1 O-ring seal
009.096-3
0
Standard
1 Backing ring
009.096-3
1
Standard
009.342
Standard
009.320
Standard
009.306
Standard
1 Opener
009.026
Standard
1 Resetting device
009.092
Standard
1 Piston
R
FO
2007-10-24 - de
TR
AI
NI
NG
1 Casing
PU
1 Casing
6629 009.02-02 EN
32/40;V32/40PGI
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.
Summary
ON
LY
Hydraulic tensioner
bleeding, testing, renewing sealing rings
009.02
MAN Diesel & Turbo
1 (4)
009.02
MAN Diesel & Turbo

Number
Status
1 Resetting device
009.092-1
Standard
1 Spacer
009.092-1
0
Standard

Work card
Work card
009.01
Work card
RP
OS
E
Preliminary remarks
ON
LY
Quan- Designation
tity
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.
AI
22
26
27
30
31
Sealing ring
O-ring seal
Backing ring
O-ring seal
Backing ring
* Threaded piece (21) is glued into the hydraulic nipple (20) using Loctite 586
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.
6629 009.02-02 EN
2007-10-24 - de
TR
R
32/40;V32/40PGI
2 (4)
1 Piston
2 Piston
12 Casing
13 Casing
20 Hydraulic nipple
21 Threaded piece*)
Figure 1: Single tensioner, not self-resetting
Work sequence 1 - Leak testing and bleeding of the tensioner
FO
NI
NG
PU
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 dismantled. As high working pressures and critical tolerances and areas are
involved, further interventions/repairs are not recommended. Instead, we recommend you have the device overhauled by MAN Diesel & Turbo SE or an
authorised Service Centre, if necessary.
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).
ON
LY
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.
009.02
MAN Diesel & Turbo
7. Remove the push-open device and the resetting device.
Leakage checking
1. Mount tensioner on a readily accessible bolt for occasional leakage

checking. Connect high-pressure hose.
2. Pump the hydraulic tensioner with the recommended tensioning pressure for that bolt. No leakage should appear for the next 5 minutes.
RP
OS
E
3. Release pressure, disconnect high pressure pump or hydraulic hand

pump and high pressure hose. Remove tensioner.
Work sequence 2 - Dismantling and assembling the tensioner/replacing the sealing

elements
Dismantling
1. Place the hydraulic tensioner on a clean surface or clamp in a vice with

the spanner flats of the piston (1 or 2).
2. Push open the non-return valve in the hydraulic nipple (20) with the
push-open device (009.026) (see Work Card 009.05 for handling
instructions).
PU
3. Place the spacer (009.092-10) on the piston. See Fig. 2.

4. Turn back the resetting device (009.092-1) adequately, then insert in
the blind holes of the casing (12 or 13).
NG
5. Turn the thrust spindle forwards until the recess in the thrust piece
engages with the spacer.
6. Continue to turn until the piston becomes free. In the final phase do not
tilt, if possible, and make sure it does not fall out. See Fig. 2.
7. Remove O-ring seals (26 and 30) and backing rings (27 and 31).
NI
8. Clean all parts and check for damage, replace if necessary.
1. Fit new backing rings (27 and 31) and O-ring seals (26 and 30). Make
sure that the position is correct. O-ring seal always on the pressure
side, backing ring with groove towards the O-ring seal.
1. Installation takes place in the reverse order. To do this, the resetting
device (009.092-1) must be applied from the opposite side. Do not tilt
the piston (1 or 2) when inserting. If necessary, off-set the resetting
device by 180. Do not damage the O-ring seals. Use push-open
device (009.026) during the assembly as well. See Fig. 3.
2. Bleed the tensioner in accordance with work sequence 1 after assembly, perform a leak test.
6629 009.02-02 EN
32/40;V32/40PGI
R
FO
2007-10-24 - de
Assembly
TR
Replace the sealing rings
AI
9. Apply a thin coat of Belzona anti-seize agent to all fitting surfaces on the
piston and on the casing. O-ring seals/backing rings and grooves must
remain free.
3 (4)
009.02
RP
OS
E
ON
LY
MAN Diesel & Turbo
AI
4 (4)
Figure 3: Assembly of the tensioner
6629 009.02-02 EN
2007-10-24 - de
TR
R
32/40;V32/40PGI
FO
NI
NG
PU
1 Piston
12 Casing
Figure 2: Dismantling the tensioner (pushing the piston out)
Hydraulic tensioner
use
Tools/aids required
Quan- Designation
tity
RP
OS
E

loosening,
tightening and
resetting the piston.
Number
Status
030.559
Standard
009.665
Standard
009.664
Standard
009.342
Standard
009.320
Standard
009.306
Standard
1 Single-ended open-jaw spanner 50
000.569
Option
000.262
Option
1 Tension nut
NG
PU
1 Tommy bar, 8
NI
Work card
000.30
000.33
009.03
009.05
009.08
AI
Work card
R
FO
2008-12-15 - de
TR
Technical data
Work card
Designation
Information
Nominal pressure
1000 bar
Test pressure
1100 bar
Tool number
009.664/009.665
Effective piston area
41,09 cm
Effective stroke
5 mm
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 when hydraulic fluid from the high-pressure pump
6629 009.07-03 EN
L32/40;L32/40CR;V32/40;V32/40PGI
Impart the necessary knowledge, ensure proper use.

Hydraulic tensioners are used for extending bolts with regard to the components 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.
ON
LY
Summary
009.07
MAN Diesel & Turbo
1 (4)
009.07
MAN Diesel & Turbo
2 (4)
5 Thrust piece
6 Bolt
7 Tommy bar
A Hole for tommy bar

X Released
Y Under tension
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 009.08.
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.
The hydraulic tensioner is automatically set to zero position with a set of
compression springs (1). Added to this, the high-pressure pump or the
hydraulic hand pump must be connected and the relief valve must be
opened.
6629 009.07-03 EN
2008-12-15 - de
TR
AI
1 Compression spring
3 Tension nut
4 Nut
Figure 1: Hydraulic tensioner
FO
L32/40;L32/40CR;V32/40;V32/40PGI
NI
NG
PU
RP
OS
E
ON
LY
or hydraulic hand pump is pressed under the plungers. When the pressure is
high enough, the bolt nut is accessible and can be releaseed or adjusted
according to specifications.
Work Sequence 1 - Releasing

Work steps
2. Set the thrust piece (5) over the nut (4).
ON
LY
1. Clean screw thread (6).
009.07
MAN Diesel & Turbo
3. Check with a single-ended open-jaw spanner (000.569) whether the

tensioning nut (3) is screwed tightly on the tensioner (2). See Work Card
009.08.
4. Screw on tensioner (2) and ensure that the thrust piece (5) is placed
centrally.
RP
OS
E
Screwing on the tensioner
Insert tommy bar in the bore (A) to screw on the tensioner.
5. After assembly turn back the piston with the tension nut (3) by the
specified turn-back angle for each individual screwed connection. See
Work Card 000.30.
6. Connect the high-pressure hose to the tensioner (2) and high-pressure
pump or hydraulic hand pump.
PU
7. Start high-pressure pump or hydraulic hand pump. See Work Card

009.03.
8. Pump the tensioner (2) until the nut (4) can be released.
NG

TR
11. Unscrew tensioner (2) and take off thrust piece (5).
R
FO
2008-12-15 - de
Work sequence 2 - Tightening

1. Tighten the nut (4) hand-tight with the tommy bar (7).
2. Place thrust piece (5) over nut.
3. Check with a single-ended open-jaw spanner (000.569) whether the
tensioning nut (3) is screwed tightly on the tensioner (2). See Work Card
009.08.
4. Screw on tensioner (2) and ensure that the thrust piece (5) is placed
centrally.
6629 009.07-03 EN
L32/40;L32/40CR;V32/40;V32/40PGI
AI
10. Release pressure, disconnect high-pressure hose from the tensioner (2)
and high-pressure pump or hydraulic hand pump.
NI
9. Using a tommy bar (7) turn the nut (4) back through the cut-out in the
thrust piece (5). Reset angle see Work Card 000.30.
3 (4)
009.07
MAN Diesel & Turbo
Screwing on the tensioner
ON
LY
Insert tommy bar in the bore (A) to screw on the tensioner.
5. Connect the high-pressure hose to the tensioner (2) and high-pressure

pump or hydraulic hand pump.
6. Start high-pressure pump or hydraulic hand pump. See Work Card
009.03.
7. Tighten bolt (6) with specified pressure. See Work Card 000.30.
RP
OS
E
8. Tighten nut (4) with tommy bar (7) through the cut-out in the thrust
piece (5) until it is in contact.
9. Release pressure, disconnect high-pressure hose from the tensioner (2)

and high-pressure pump or hydraulic hand pump.
AI
TR
2008-12-15 - de
FO
L32/40;L32/40CR;V32/40;V32/40PGI
NI
NG
PU
10. Unscrew tensioner (2) and take off thrust piece (5).
4 (4)
6629 009.07-03 EN
Tools/aids required
Quan- Designation
tity
RP
OS
E

venting,
checking tightness,
disassembling and assembling and
replacing sealing rings/sealing elements.
Number
Status
030.539
Standard
009.664
Standard
009.664-1
Standard
009.664-2
Standard
009.664-3
Standard
009.664-4
Standard
009.664-8
Standard
1 Angle piece
009.664-1
0
Standard
1 Threaded piece
009.664-1
1
Standard
1 Hydraulic nipple
009.664-1
2
Standard
2 High-pressure seal
009.664-1
4
Standard
1 Locking ring
009.664-1
8
Standard
1 Set screw
009.664-1
9
Standard
1 Parallel pin
009.664-2
3
Standard
009.664-2
5
Standard
009.664-2
8
Standard
009.664-2
9
Standard
009.664-3
0
Standard
1 Tension nut
1 Piston
1 Casing
1 Casing
R
FO
2008-12-10 - de
TR
AI
NI
NG
1 Cover
PU
1 Piston
6629 009.08-03 EN
32/40;32/40CR;V32/40;V32/40PGI
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.
Summary
ON
LY
Hydraulic tensioner
bleeding, testing, renewing sealing rings
009.08
MAN Diesel & Turbo
1 (7)
009.08
MAN Diesel & Turbo
Quan- Designation
tity
Status
009.664-3
1
Standard
009.664-3
5
Standard
009.663
Standard
009.627
Standard
009.621
Standard
009.622
Standard
009.342
Standard
ON
LY
Number
12 Parallel pin
1 Mounting device
1 Overload valve
1 Pin extractor
1 Opener
RP
OS
E
009.320
Standard
009.306
Standard
1 Pliers for locking rings A 10-25
002.121
Option
1 Single-ended open-jaw spanner 50
000.569
Option
1 Hexagon screw driver 12
000.299
Option
1 Combination spanner (set)
Inventory
Inventory
1 Molecular gold grease (anti-seize agent)
Inventory
PU
Work card
Work card
Work card
Preliminary remarks
NG
009.07
Work Sequence 1 - Dismantling the tensioner
FO
2 (7)
The hydraulic tensioner must be dismantled if the high-pressure seals need

to be replaced, or if there is damage. All high-pressure seals should be
replaced as a matter of course if the hydraulic tensioner is dismantled. As
high working pressures and critical tolerances and areas are involved, further
interventions/repairs are not recommended. Instead, we recommend you
have the device overhauled by MAN Diesel & Turbo SE or an authorised
Service Centre, if necessary.
Work steps
1. Screw hexagon socket bolts (23) into hydraulic tensioner. See Fig. 2/I.
2. Pull out all parallel pins (12) using the pin extractor (009.621). See Fig.
2/II.
3. Unscrew tensioning nut (030539) with single ended open-jaw spanner
(000.569).
6629 009.08-03 EN
2008-12-10 - de
TR
AI
Non-return valves are fitted at both ends of the high-pressure pipes which
means they cannot run dry.
32/40;32/40CR;V32/40;V32/40PGI
NI
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.
Simultaneous rotation of the piston
ON
LY
If the piston (14) is also turned when the tensioning nut is unscrewed, it
can be held with a hexagon screwdriver (000.299). See Fig. 3/III.
4. Pull off casing (13) from piston (13). See Fig. 2/IV.
5. Pull off casing (16) from piston (14). See Fig. 2/V.
6. Remove the locking ring (5) from the piston (14) with the locking ring pliers for the locking ring (002.121).
7. Press piston (10) out of casing (13).
Starting position
Work steps
RP
OS
E
8. Remove high-pressure seals (8, 9, 11, 15 and 18). See fig. 2/VI.
Work sequence 2 - Assembling the tensioner
009.08
MAN Diesel & Turbo
All parts are cleaned, checked and renewed where necessary.

1. Apply "Molecular" lubricant to all metallic fitting surfaces of the piston
(10 and 14) or on the casing (13 and 16).
Application of the anti-seize agent!
PU
When applying the anti-seize agent, make sure that the threads, highpressure seals and grooves remain free.
NG
2. Insert new high-pressure seals (18) in angle piece (3). Ensure that they
are not twisted and the sealing lips are not damaged.
Position of the sealing lips!
NI
Attention must be paid to the correct position of the sealing lips. See
Fig. 3/I.
R
FO
2008-12-10 - de
TR
When inserting the piston do not damage the sealing lips of the highpressure seals.
4. Fit the locking ring (5) in the ring groove with the locking ring pliers for
the locking ring (002.232).
5. Place new high-pressure seals (8, 9, 11 and 15) in the casing (13 and
15) or piston (10). Ensure that they are not twisted and the sealing lips
are not damaged.
6. Assemble all parts. In doing so, make sure that the sealing lips are not
damaged.
6629 009.08-03 EN
32/40;32/40CR;V32/40;V32/40PGI
Do not damage sealing lips!
AI
3. Place the angle piece (3) on the piston (14).
3 (7)
009.08
MAN Diesel & Turbo
Position of the sealing lips!
ON
LY
Attention must be paid to the correct position of the sealing lips. See
Fig. 3/I.
7. Mount push-open device (009.622) on hydraulic nipple (1) and screw

on star knob (26). See Fig. 3/II.
8. Fit mounting device (009663). See Fig. 3/II.
9. Tighten the hydraulic tensioner by turning the nut (24).
RP
OS
E
Position of the bores!
When assembling the hydraulic tensioner, make sure the bores are
positioned correctly.
10. Detach mounting and push-open device.
11. Screw tension nut (030539) onto piston (14). See Fig. 3/III.
Securing the tension screw
PU
To prevent a later release of the tension screw, it can be tightened with

a torque of 250 Nm.
NG
12. Insert parallel pins (12) into the respective bore holes.
Installing the parallel pins
NI
When installing the parallel pins (12), make sure that they are inserted
with the thread outwards to enable repeated removal.
AI
TR
2008-12-10 - de
FO
32/40;32/40CR;V32/40;V32/40PGI
13. Unscrew and remove the hexagon socket bolts (23).
4 (7)
6629 009.08-03 EN
6629 009.08-03 EN
12
13
14
15
16
17
18
19
20
21
22
Parallel pin
casing
Piston
High-pressure seal
casing
Parallel pin
High-pressure seal
Compression spring
Ball
Pin
Threaded piece
32/40;32/40CR;V32/40;V32/40PGI
R
FO
2008-12-10 - de
TR
AI
NI
1 Hydraulic nipple
2 Threaded piece
3 Angle piece
4 Set screw
5 locking ring
6 Cover
10 Piston
Figure 1: Hydraulic tensioner
NG
PU
RP
OS
E
ON
LY
009.08
MAN Diesel & Turbo
5 (7)
009.08
AI
TR
6 (7)
6629 009.08-03 EN
16 casing
23 Hexagon socket bolt
I-VI Work steps
2008-12-10 - de
3 Angle piece
5 locking ring
12 Parallel pin
13 casing
14 Piston
10 Piston
Figure 2: Disassembling/assembling the hydraulic tensioner
FO
32/40;32/40CR;V32/40;V32/40PGI
NI
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
6629 009.08-03 EN
32/40;32/40CR;V32/40;V32/40PGI
26 Star knob
I-III Work steps
FO
2008-12-10 - de
24 Nut
25 Hexagon bolt
Figure 3: Disassembling/assembling the hydraulic tensioner
TR
AI
NI
NG
PU
RP
OS
E
ON
LY
009.08
MAN Diesel & Turbo
7 (7)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Measuring gauge (measuring device)

checking the screw elongation
ON
LY
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.
Quan- Designation
tity
RP
OS
E

correct use/application and
measuring of the elongation.
Required tools/Auxiliary equipment
Number
Status
009.665
Standard
009.664
Standard
009.446
Standard
009.444
Standard
009.342
Standard
009.320
Standard
009.306
Standard
1 Measuring device
Work card
Work card
000.30
009.01
009.07
6629 009.06-04 EN
L32/40;L32/40CR;V32/40;V32/40PGI
R
FO
2008-12-12 - de
TR
AI
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 guaranteed if the tensioner is blocked or the tension pressure is partly or fully dissipated by friction.
Preliminary Remarks
Work card
NI
NG
PU
1 Dial gauge
009.06
MAN Diesel & Turbo
1 (3)
009.06
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
NG
1 Hydraulic tensioning tool

2 Thrust piece
Figure 1: Measuring device, placed on hydraulic tensioner
Working Sequence 1 - Measuring the bolt elongation l

Bolted connection untightened, tensioning tool is placed and ready to work.
AI
NI
1. Start high pressure pump or hydraulic hand pump and tighten bolt with
tensioning tool with pre-tensioned pressure.
(for value see Work Card 000.30).
2 (3)
3. Raise tension pressure to recommended value (see Work Card 000.30).

Tighten nut with tommy bar, hand-tight.
4. Reduce pressure to "0" and raise again to pre-tension pressure.
5. Indication on the dial gauge is equivalent to screw elongation/compression of parts l. Read off the value, convert to millimetres and compare
with the target value (see Work Card 000.30).
Bolts must be tightened with the required oil pressure, not according
to l. The l measurement serves only as an additional check.
6629 009.06-04 EN
2008-12-12 - de
FO
TR
2. Mount measuring device (009.446) on the hydraulic tensioning tool (1).

Reset dial gauge (009.444) to "0".
L32/40;L32/40CR;V32/40;V32/40PGI
Starting position
Working steps
6. If deviation from the target value is too great repeat the process, otherwise check tensioner, bolted connection and pressure gauge.
6629 009.06-04 EN
L32/40;L32/40CR;V32/40;V32/40PGI
R
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2008-12-12 - de
TR
AI
NI
NG
PU
RP
OS
E
ON
LY
7. Reduce pressure to "0". Remove tensioner.
009.06
MAN Diesel & Turbo
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
005
NG
PU

Machine Elements
FO
TR
AI
NI
001
002
003
004
005
RP
OS
E
ON
LY
MAN Diesel & Turbo
6632 005-05 EN
1 (1)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Summary
ON
LY
Ignition and compression pressures

determining
Collate and assess operational data, detect problems on (influencing) subassemblies /systems.
Ignition and compression pressures are important measures 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.
Personnel and time required

Number Qualification
1 Technician
PU
Tools/aids required
RP
OS
E

Recording pressures,
Collating operational data and
Assessing results.
Preliminary remarks
Duration in h
0,5
Number
Status
1 Ignition measuring instrument by Baewert, Type

250E
419.019
Option
1 Protective gloves
Inventory
NG
Quan- Designation
tity
000.25
MAN Diesel & Turbo
Work sequence 1 - Recording pressures
FO
2010-03-02 - de
Starting position
Work steps
Engine at desired performance level in stable operation. Steady state condition of operational values is reached.
1. Before indicating, open the indicator valve and keep it open for 2-3 ignition strokes to remove carbon or combustion residues which have built
up in the indicator pipe.
6682 000.25-03 EN
General
The calibration interval for the ignition pressure measuring device should be
one year.
TR
AI
NI
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 regular intervals, in accordance with the maintenance schedule. When evaluating,
both the absolute values and the differences from cylinder to cylinder are
important.
1 (3)
000.25
MAN Diesel & Turbo
2. Close the indicator valve.
ON
LY
Do not step in front of the fire jet!
3. Screw pressure sensor of the measuring device onto the indicator

valve.
RP
OS
E
4. Record the ignition pressures according to the Operating Instructions

for the ignition pressure meter Type 250E (419.019).
The compression pressures can be recorded in a similar way to the
ignition pressures, if, during that procedure, the control rod of the
associated injection pump is set to zero against the force of the
buckling lever spring.
AI
2 (3)
Figure 1: Baewert Ignition pressure meter Type 250E
6682 000.25-03 EN
2010-03-02 - de
TR
R
General
FO
NI
NG
PU
Measurement of the compression pressure is only allowed up to a load

where the remaining cylinders still operating can take the load of the
cylinder which is switched off.
Work sequence 2 - Evaluation/Assessment

The following limit values/requirements must be observed:
measured ignition pressures at nominal output maximum value,
Deviations between cylinders average tolerance

(for corresponding limit values, refer to 010.005 Engine - Operating
Instructions, Chapter 2.5.2),
same regulating rod position with all fuel-injection pumps.
ON
LY
000.25
MAN Diesel & Turbo
RP
OS
E
For practical reasons, the diagrams/results should be compared with those

in the test run report, or those obtained during earlier measurements. If the
ignition pressures are too high, this is because fuel is being injected too early
or not enough fuel is being injected. If the ignition pressures at the individual
cylinders are too low, this may be due to one of the following malfunctions:
fuel-injection nozzle is dripping or not injecting properly,
damaged/worn fuel-injection pump and
leaking gas exchange valves.
Type and source of danger
6682 000.25-03 EN
General
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2010-03-02 - de
TR
AI
NI
NG
PU
You can analyse measured data graphically and/or arithmetically using

the PC software supplied.
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Charge air cooler/crankcase

Measuring the differential pressure
ON
LY
Summary
Collecting operating data, ensuring/restoring operating safety, enabling/supporting 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.
Tools/aids required
Quan- Designation
tity
Number
Status
1 Digital pressure gauge "Digima-Premo"
009.090
Option
1 Storage bag
009.090-1
Option
009.090-2
Option
009.090-3
Option
009.090-4
Option
4 Quick-fitting coupling
009.090-5
Option
2 Hose plug-in nipple
009.090-6
Option
2 Filter
009.090-7
Option
1 U-tube pressure gauge/ water-filled PVC hose
Inventory
1 Measuring tape
Inventory
1 9V battery
1 Plug-in charger
6682 000.40-01 EN
General
FO
TR
AI
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 recommended cleaning intervals in the maintenance schedule, the measurement of differential pressure helps to determine the most suitable time for
cleaning and to evaluate the operating data. The measurement can be done
with a digital differential pressure gauge or a U-tube pressure gauge.
NI
NG
PU
1 PVC hose
Preliminary remarks
RP
OS
E
The work includes: Measurement by means of a digital pressure gauge, and

measurement by means of a U-tube pressure gauge.
2007-11-15 - de
000.40
MAN Diesel & Turbo
1 (4)
000.40
MAN Diesel & Turbo
RP
OS
E
ON
LY
Measuring set-up/measuring devices
4 "Attenuation" push-button
1b "Off" push-button
5a Pressure connection p1
2a "" push-button (measur5b Pressure connection p2
ing range 0-2 bar)
2b "" push-button (measur6a Zero-point setting for
ing range 0-10 bar)
measuring range 0-2 bar
3 Information area (indica6b Zero-point setting for
tion of measuring range/
measuring range 0-10 bar
attenuation)
Figure 2: Measuring device "Digima-Premo" made by SI, special instruments
General
2 (4)
6682 000.40-01 EN
7 Indication of measured
value
8 Battery tray
9 Indication "lo bat" (battery
status)
10a Output for recording
instrument (+)
10b Output for printer (-)
2007-11-15 - de
AI
TR
1a "On" push-button
FO
NI
NG
PU
1 Casing before charge air cooler

4 Measuring connection
2 Charge air cooler
5 Measuring device
3 Charge air pipe
Figure 1: Measuring points/measuring set-up (figure shows engine L 40/54 with
single-stage charge air cooler)
Safety Instructions
ON
LY
Maximum pressure on the device 14 bar.
000.40
MAN Diesel & Turbo
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
the measured value is negative. With relative pressure measurements p1=
ambient pressure, p2 = measuring pressure.
Measurement with digital pressure gauge

One-off preparations
RP
OS
E
The hose couplings on the engine and on the hoses in front of the measuring
device are self-blocking.
Fit hose plug-in nipple and quick-fit coupling on both ends of the PVC hoses.
Cut the hose approx. 30 cm before the coupling and connect both ends to
the connections on the water repellent filter. Also use this hose for connection p1!
Work steps
1. Blow by the measuring connections. In order to do so, connect hose

plug-in nipple with nom. 8 mm temporarily to the coupling at the
engine side.
PU
2. Connect PVC hoses with filter to measuring points A and B. The locking
rings of the hose couplings must engage.
3. Connect measuring device and press push-button "w" for measurement of the 0 - 2 bar range. Indication at "w" will be visible in area 3.
NG
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.
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.
R
FO
2007-11-15 - de
TR
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.
Measurement with U-tube pressure gauge
Work steps
1. Blow by the measuring connections as described above.

2. Fit hose nipples, which are mounted on the measuring connections on
the engine, to both ends of the PVC hose having 8 mm inner diameter.
6682 000.40-01 EN
General
AI
7. Compare measured value with reference value and evaluate. The differential 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).
NI
6. Turn off measuring device. Remove measuring hoses from the measuring points (lift locking ring to do so).
3 (4)
000.40
MAN Diesel & Turbo
3. Fill hose with water until the water column is approx. 300 mm high on
both sides.
ON
LY
4. Grasp hose ends and connect to the couplings of the measuring points
at the same time.
5. Measure water level h and evaluate the result as described above.
RP
OS
E
h 100 mm WG = 10 mbar
differential pressure
2 Connection before
charge air cooler
3 Connection after charge
air cooler
Figure 3: Differential pressure measurement with U-tube pressure gauge
Checking the crankcase pressure
AI
General
Figure 4: Measuring point on crankcase (engine L 40/54)
4 (4)
6682 000.40-01 EN
2007-11-15 - de
TR
R
FO
NI
NG
PU
A measuring connection is also located on the crankcase (approx. in the

middle of engine on the exhaust side). The crankcase pressure can be measured here on connection p2, relative to the atmosphere. When evaluating the
measured values, the following must be considered: the wear condition of
the piston, piston rings and cylinder liners, a potential sealing air transition
from the bearings of the turbocharger to the running gear area, the function
of the crankcase air bleed valve and other factors.
RP
OS
E
ON
LY
MAN Diesel & Turbo
PU
1 Introduction

NG
blies
FO
TR
AI
NI
4 Appendix
6632 3 B2-05 EN
1 (1)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
000
TR
R
FO
6632 000-05 EN
NI
NG
PU
Torsional vibration damper
Piston/Piston rings
Camshafts/Camshaft bearings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
000
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Inlet and exhaust valves
Operating device
Speed regulation
Starting air pilot valve/Starting valve/Main starting valve
Charge air and exhaust pipe
Lubricating oil and cooling water pump
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 (2)
6632 000-05 EN
3.1
Figure 1: Cross section of engine
6632 3.1-03 EN
V32/40
R
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2008-07-08 - de
TR
AI
NI
NG
PU
RP
OS
E
ON
LY
Sub-assembly overview - longitudinal and cross-section of the engine
MAN Diesel & Turbo
1 (4)
V32/40
2 (4)
2008-07-08 - de
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
3.1
MAN Diesel & Turbo
Figure 2: Longitudinal section of engine
6632 3.1-03 EN
3.1
MAN Diesel & Turbo
Designation
0112)
Oil sump
012
Cylinder crankcase
020
Crankshaft
021
Crankshaft bearing
0231)2)
Crankshaft extension
027
030
Connecting rod
034
Piston
050
Cylinder liner with top land ring
055
Cylinder head
0571)
Safety valve on cylinder head

Coverings
072
Coverings
073a
Crankcase covering
073b
Crankcase casing with relief valve / splash oil
077
Casing of camshaft
100
101a
Injection camshaft
101b
Valve camshaft
101c1)2)
Rotary vibration damper for injection camshaft
101c
Rotary vibration damper for valve camshaft
102a
Camshaft bearing
102b
Thrust bearing
111
Rocker arm with bearings and cylinder head cover
112
Inlet and exhaust cam follower with push rod
114
120a2)
NG
NI
Exhaust valve
Control piston for injection camshaft

Control piston for valve camshaft
125
Parts for the operating device and measuring devices
120b1)2)
FO
1)
2008-07-08 - de
AI
Inlet valve
1)
140
Speed controller
1601)
Starting air pilot valve
161
Starting valve
1)
162
Main starting valve
200
Fuel injection pump with drive
1)
6632 3.1-03 EN
V32/40
113
TR
1)2)
PU
071b
1)
071a
RP
OS
E
Sub-assembly
ON
LY
Overview of components - Designation
3 (4)
3.1
Designation
203
221
280a
Charge air pipe
280b1)2)
Air bypass pipe
286a
Built-on components for turbocharger
286b
Built-on components for washing device
289a
Exhaust pipe
289b
Exhaust pipe casing
3002)
Lubricating oil pump
3021)
Lubricating oil pump for cylinder lubrication
311
Crankcase ventilation
322a
Charge air cooler with attaching parts
322b
Casing
3502)
Cooling water pump

Main bearing temperature monitoring
408
1)
Cabling on engine for splash-oil temperature monitoring
413b1)2)
Oil mist detector
419
Indicator valve
430
Piping, general
432
Starting air pipes and control pipes
434
Fuel injection pipe
4341)
Fuel pipes
440
lubricating oil lines
NG
1)
PU
413a
1)
NI
Condensate drain
442
1)
443a
Cylinder lubrication
443b1)2)
Valve seat lubrication
447
Cooling water lines
1)
489a
489b
Cable conduits with attachment
TR
1)
1)
Warning sign
1)
These sub-assemblies are not visible in the illustrations
2)
if any
2008-07-08 - de
Table 1: Sub-assembly designation
V32/40
FO
RP
OS
E
1)
ON
LY
Sub-assembly
AI
MAN Diesel & Turbo
4 (4)
6632 3.1-03 EN
009
TR
R
FO
6632 009-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
009
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 (2)
6632 009-05 EN
Position of crankshaft flange in relation to driven flange

determining/checking
ON
LY
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 installation and must be checked regularly.
Quan- Designation
tity
2 Dial gauge
1 Inside micrometer
RP
OS
E
This includes:
Checking the alignment,
recording measured values and
evaluating results.
Tools/aids required
Work card
Work card
000.10
012.01
NG
Preliminary remarks
Number
Status
Inventory
Inventory
Inventory
PU
1 External micrometer
000.09
MAN Diesel & Turbo
Work card
thermal expansion of the engine, generator or the gear,
thermal expansion of the rubber elements in the case of resilient mounting,
the settling behaviour of the resilient mounting and
shaft disalignment under pressure.
TR
R
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2010-08-24 - de
The position of both flanges is to be measured on the original equipment and

checked subsequently at regular intervals in accordance with the maintenance schedule.
Deviations from flywheel alignment diagram

If required, a special manual can be prepared for certain propulsion
systems, in which the necessary alignment measurements are given.
These can vary from those in the flywheel alignment diagram.
6682 000.09-01 EN
General
thermal expansion of the foundations,
AI
NI
The flange of the crankshaft, i.e. ultimately the engine, must show certain
axial offsets in the cold state, with respect to the driven flange so that influencing factors are compensated for under operating conditions. Such factors
are:
1 (3)
000.09
RP
OS
E
ON
LY
MAN Diesel & Turbo
C Reference mounting
G Shaft axis
dimension, coupling
2 Engine main flange
D Spacing
A Radial offset
E Spacing
A Difference, radial offset
B Axial offset
F Engine crankshaft axle
ST Control side
Figure 1: Alignment of the crankshaft flange with respect to the driven flange - measurements and terms
PU
1 Driven shaft flange
The crank web deflection complies with the regulations (see Work Card
000.10).
Prerequisites/measuring
procedure
In order to ascertain the exact alignment during assembly, it is necessary to

make a measuring clamp with two dial gauges to be fastened to the flywheel.
One measuring gauge records the radial axle misalignment (A) for the vertical
and horizontal deviations, the other gauge measures the plane parallelism or
the flange divergence (B). The measuring bracket can be used for subsequent checks, as required in resiliently mounted engines in particular.
NI
NG
Starting position
General
2 (3)
Emergency lubrication
The engine bearings must, if required, be equipped with emergency
lubrication during rotation of the crankshaft for alignment.
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 necessary, the alignment must be corrected again. Later comparison of the values
allows conclusions to be drawn concerning time sequencing, the scope and
possible causes for changes.
6682 000.09-01 EN
2010-08-24 - de
TR
AI
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 measured (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.
FO
Work sequence 1 - Measuring the flange alignment
NI
AI
TR
6682 000.09-01 EN
General
FO
2010-08-24 - de
NG
RP
OS
E
PU
ON
LY
MAN Diesel & Turbo

000.09
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Summary
ON
LY
Check foundation bolts

Aligning engine on the foundations
Check alignment, Check sub-assemblies for consistency/wear, Detect problems with (influencing) components/systems.
Foundation bolts must be checked regularly for correct pretension, adapters
and stoppers to be checked for consistency and secure location.
1 Technician
1 Assistant
Tools/aids required
4
4
Number
Status
1 Tension nut
030.539
Standard
1 Thrust piece
030.538
Standard
1 Guide tube
021.032
Standard
009.664
Standard
009.342
Option
009.320
Standard
009.306
Standard
1 Open-jaw wrench 55
000.570
Standard
1 Thickness gauges 0.05-1
000.454
Standard
000.451
Standard
1 Forcing-off bolt M32x2
Inventory
1 Depth gauge
Inventory
1 Hammer (wood/plastic-)
Inventory
2 Tommy bar, 6
000.261
Standard
TR
AI
NI
NG
PU
Quan- Designation
tity
Duration in h
FO
2008-12-15 - de

Work card
Work card
Work card
000.10
000.30
000.33
009.03
6629 012.01-03 EN
L32/40;L32/40CR;V32/40;V32/40PGI
RP
OS
E
This extends to:

Inspection of parts/components and
realign the engine.
012.01
MAN Diesel & Turbo
1 (6)
012.01
MAN Diesel & Turbo
Preliminary remarks
ON
LY
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-tightened with the specified tensioning pressure.
RP
OS
E
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 (especially 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.
PU
After a period of bad weather, after a collision or grounding (with

marine engines), or after natural catastrophes (with stationary engines),
the location of the engine should be checked accurately, and all
foundation bolts should be retightened. The foundation bolts on the
coupling side and on the free engine end are most at danger.
NG
The fixing of the engine on the foundation is executed in different ways

depending on the system (marine engine, stationary engine). Marine engines
are bolted to the top plates of the ship, stationary engines are bolted to a
foundation beam.
Work sequence 1 - Checks on the cylinder crankcase
NI
TR
AI
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 Operating Instructions.
2 (6)
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.
Work steps
Checking the foundation bolts starts on the coupling side.
6629 012.01-03 EN
2008-12-15 - de
Work sequence 2 - Checking the foundations
FO
L32/40;L32/40CR;V32/40;V32/40PGI
1. Remove protection caps (9) and clean and degrease foundation bolts
(12 or 13).
ON
LY
2. Check whether tension nut (030.539) is tightly screwed to the tensioner

(009.664).
3. Place thrust piece (030.538) over foundation bolt and screw on tensioner.
4. Rotate back the tensioner through 180.
012.01
MAN Diesel & Turbo
5. Connect high-pressure hose (009.306) onto tensioner and high-pressure pump or hydraulic hand pump.
RP
OS
E
6. Start the high-pressure pump or hydraulic hand pump (see Work Card
009.03) and close the gap between the thrust piece and tensioner that
resulted from the turning back.
7. Pump the tensioner until the nut (10) can be released. Make a note of
the release pressure and compare it to the clamping pressure.
The pressure must lie max. 7% under or 5% over the tension pressure
(see Work Cards 000.30 and 000.33).
NG
PU
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 surface of the nuts must be free from
residual plastic particles.
8. Adjust high-pressure pump to the specified clamping pressure or activate hydraulic hand pump up to the specified clamping pressure and
tighten the nut.
NI
9. Dump the pressure and detach the hydraulic tensioner.
R
FO
2008-12-15 - de
TR
12. Check adapter (14) and stopper (15) for firm seating by tapping.
6629 012.01-03 EN
L32/40;L32/40CR;V32/40;V32/40PGI
AI
11. Grease the threads of the foundation bolts for protection against rust
and cover with protection caps.
10. Check remaining foundation bolts in the same way (point 3 to 9).
3 (6)
012.01
RP
OS
E
ON
LY
MAN Diesel & Turbo
9 Protection cap
13 Foundation bolt (fitting

bolt)
14 Adapter
15 Stopper
16 Foundation
17 Washer
PU
10 Nut
18 Hexagon nut
11 Cylinder crankcase
12 Foundation bolt (undercut
A Bolt projection
bolt)
Figure 1: Mounting of the engine on the foundation plate (main engine) and fitting the hydraulic tensioner
Work sequence 3 - Aligning the complete engine
NI
4 (6)
11
14
16
19
20
Cylinder crankcase
Adapter
Foundation
Forcing-off bolt
Shim
AI
Figure 2: Arrangement of the forcing-off bolt
1. Attach hydraulic tensioner to the foundation bolt (12 or 13) and release
nut (10) (see work sequence 2, points 1 to 7).
2. Turn back nut
4. Check the remaining foundation bolts in the same manner.
5. Unscrew the nuts and remove the foundation bolts if possible.
6. Remove the protection caps over the forcing-off thread and screw the
forcing-off bolts (19) in position, placing packer plates (20) underneath
to provide protection for the foundations.
6629 012.01-03 EN
2008-12-15 - de
TR
R
FO
L32/40;L32/40CR;V32/40;V32/40PGI
NG
Work steps
ON
LY
7. Lift the engine with the forcing-off bolts, remove the location pieces (14)
and align the engine so that the web deflection is within acceptable limits (see Work Card 000.10).
012.01
MAN Diesel & Turbo
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.
RP
OS
E
8. Determine the thickness of the spacers and, if necessary, make new

spacers.
Only one uniform material may be used for packers! A mixture of cast
resin and steel spacer plates is not allowed!
9. Install spacers, check proper seating using the feeler gauge (000.451).
10. Fit the foundation bolts (with fitting bolts do not forget washer (17)) and
screw nuts in position hand-tight. Check bolt projection (A) = 79 mm.
PU
11. Remove forcing-off bolts and shims and store with the tool. Grease
forcing-off threads and cover with protective caps.
12. Check whether tension nut (030.539) is tightly screwed to the tensioner
(009.664).
NG
13. Place thrust piece (030.538) over the foundation bolt and screw the
tensioner in position, for sequence see figure 4 or 5.
14. Connect high pressure hose (009.306) onto tensioner and high pressure pump or hydraulic hand pump.

17. Tighten the remaining foundation bolts in the same way (point 13 to 16).
18. Check crank web deflection again and record in operating log sheets
(see Work Card 000.10).
19. Grease the threads of the foundation bolts for protection against rust
and cover with protection caps.
6629 012.01-03 EN
L32/40;L32/40CR;V32/40;V32/40PGI
R
FO
2008-12-15 - de
TR
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
residual plastic particles.
AI
NI
15. Set high-pressure pump or hydraulic hand pump in operation (see Work
Card 009.03) and tighten foundation bolt with specified clamping pressure (see Work Card 000.30). Manually tighten nut using tommy bar
(000.261).
5 (6)
012.01
RP
OS
E
ON
LY
MAN Diesel & Turbo
NG
PU
1-8 Marking the tightening sequence

Figure 3: Tightening sequence of the foundation bolts (in-line engine)
NI
AI
TR
2008-12-15 - de
FO
L32/40;L32/40CR;V32/40;V32/40PGI

A1- Cylinder bank A
A6
B1- Cylinder bank B
B6
Figure 4: Tightening sequence of the foundation bolts (V engine)
6 (6)
6629 012.01-03 EN
012
TR
R
FO
6632 012-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
012
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 (2)
6632 012-05 EN
Safety requirements
RP
OS
E

determining pressure release and evaluating
tightening connection with target pressure.
Drive shaft secured against rotating
Tools/aids required
Quan- Designation
tity
Number
Status
021.256
Standard
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
009.342
Standard
009.320
Standard
009.306
Standard
009.097
Standard
009.095
Standard
2 Measuring device
009.051
Standard
2 Angle piece
009.028
Standard
000.451
Option
2 Tommy bar, 10
000.263
Standard
2 Tommy bar, 8
000.262
Standard
1 Ring spanner (cranked) 24x27
000.247
Standard
1 Depth gauge
Inventory
2 Setting gauge
R
FO
2007-10-09 - de
TR
AI
NI
NG
PU
2 Tension screw

Work card
Work card
Work card
000.30
000.32
000.33
009.01
009.03
6632 012.02-01 EN
V32/40
Tightening and releasing important screwed connections with the correct values, ensure correct execution of work.
Crankshaft bearing bolts and cross tie rods
Summary
ON
LY
Crankshaft bearing bolts and cross tie rods

inspection, loosening and tightening
012.02
MAN Diesel & Turbo
1 (8)
012.02
MAN Diesel & Turbo
Work sequence 1 - Checking the cross tie rods

Starting position
Work steps
1. Clean threads of the cross tie rods (6).
ON
LY
Protection caps removed from cross tie rods.

2. Assemble the hydraulic tensioners on both cross tie rods of a crankshaft bearing, thereby tightening the tension screw (021.253) hand-tight
up to the stop.
RP
OS
E
Before installing the tensioning cylinder ensure that the pistons are
completely pressed in.
3. Turn the tensioning cylinder (009.097) back by 270.

4. Connect the high-pressure hoses (009.306) to the tensioning cylinder
and the high-pressure pump or hydraulic hand pump.
5. Start the high-pressure pump or the hydraulic hand pump (see Work
Card 009.03) and close the gap between the thrust piece (021.252)
and ring (4) that resulted from the turning back.
PU
6. Pump up the tensioning cylinder until the nuts (5) can be released.
NG

Make a note of the release pressure and compare it to the clamping pressure.
NI
AI
2. Release the pressure and remove the hydraulic tensioners.

3. Place protection caps over the cross tie rods.
2007-10-09 - de
TR
4. Reset the pistons of the tensioning cylinders (see Work Card 009.01).
V32/40
FO
1. Adjust high pressure pump to the specified tension pressure or activate

hydraulic hand pump up to the specified tension pressure and tighten
both nuts.
2 (8)
6632 012.02-01 EN
012.02
RP
OS
E
ON
LY
MAN Diesel & Turbo
5 Nut
4 Ring
6 Cross tie rod
Figure 1: Attach the hydraulic tensioner to the cross tie rod
Work sequence 2 - Checking the crankshaft bearing bolts

Starting position
Crankcase is opened, running gear is turned so that the main bearing cap is
easily accessible.
6632 012.02-01 EN
V32/40
3 Main bearing cap

Figure 2: Attaching the hydraulic tandem tensioner to the crankshaft bearing bolt
during releasing
R
FO
2007-10-09 - de
TR
AI
NI
NG
PU
3 (8)
012.02
MAN Diesel & Turbo
Work steps
1. Clean the thread of the crankshaft bearing bolts (8).

2. Screw on tension screws (021.255) up to the stop of the tensioning cylinder (009.095).
ON
LY
3. Place thrust pieces (021.254) over nuts (7) and screw tensioning cylinder a few turns onto the crankshaft bearing bolts.
4. Insert setting gauges (021.256) between thrust pieces and crankshaft
bearing cap (3) and turn tensioning cylinder so far that the thrust pads
lie directly on the setting gauges.
5. Fit intermediate rings (021.250) and tensioning cylinder (009.097).
6. Place angle pieces (009.028) on the tensioning cylinder.
RP
OS
E
7. Connect four high-pressure hoses (009.306) to the tensioning cylinder

and to the high-pressure pump or the hydraulic hand pump.
8. Remove setting gauges.
9. Start the high pressure pump or the hydraulic hand pump (see Work
Card 009.03) and close the gap between the thrust piece and crankshaft bearing cap.
10. Pump the tensioning cylinder until the nuts can be released.
PU

11. Make a note of the release pressure and compare it to the clamping
pressure.
NG
both nuts.
13. Release pressure and remove tandem tensioner.
NI
14. Close crankcase.
AI
TR
2007-10-09 - de
R
V32/40
FO
4 (8)
6632 012.02-01 EN
012.02
RP
OS
E
ON
LY
MAN Diesel & Turbo
PU
3 Main bearing cap

9 Dial gauge
7 Nut
8 Crankshaft bearing bolt
A Bolt projection
Figure 3: Arrangement of the hydraulic tandem tensioner on the main bearing bolt
Starting position
Work steps
NG
Work sequence 3 - Unloading the cross tie rods
Remove protection caps from the cross tie rods.

1. Attach hydraulic tensioner and release nuts (5) (see work sequence 1,
point 1 to 6).
NI
2. Turn back both nuts

(turn-back angle, see Work Card 000.30).
TR
Work sequence 4 - Releasing the crankshaft bearing bolts
R
FO
2007-10-09 - de
Starting position
Work steps
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
must be untightened.
1. Fit hydraulic tandem tensioners to both main bearing bolts (8) and
release the nuts (7).
(see Work Card 2, point 1 to 10)
V32/40
AI
4. Retract pistons of the tensioning cylinders (009.097)

2. Turn back both nuts (turn-back angle, see Work Card 000.30).
6632 012.02-01 EN
5 (8)
012.02
MAN Diesel & Turbo
3. Release pressure and remove tandem tensioners.
ON
LY
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
The tightening process is performed in several steps. Attention must be

paid to the correct torque sequence. Before tightening the main bearing
bolts ensure that the bolt projection A = 174 1.8 mm is maintained.
Work steps
RP
OS
E
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 tightening the tension screws (021.253) hand-tight up to the stop.
PU
NG
5. Screw on tension screws (021.255) up to the stop of the tensioning cylinder (009.095).
NI
7. Place the intermediate rings (021.250) over the tension screws on the
tensioning cylinder, insert the tommy bars through the holes in the intermediate rings in the tension screws.
By inserting the tommy bars, the intermediate rings do not have to be
fitted and removed when changing the tensioning cylinders (009.097).
2007-10-09 - de
TR
AI
V32/40
FO
6. Place thrust piece (021.254) over nuts (7) and screw tension cylinder
onto the crankshaft bearing bolts (8).
6 (8)
6632 012.02-01 EN
012.02
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 Crankshaft
Figure 4: Mounting the hydraulic tensioner to the cross tie rod
3 Main bearing cap
1. Connect high pressure hoses (009.306) onto tensioning cylinder of the

cross tie rods and high pressure pump or hydraulic hand pump.
2. Set high-pressure pump or hydraulic hand pump in operation (see Work
Card 009.03) and tighten cross tie rod with a pressure of 300 bar.
Tighten both nuts using the tommy bar, hand-tight.
PU
3. Release pressure, uncouple high-pressure hoses, unscrew tensioning

cylinder.
NG
5. Screw the tensioning cylinder (009.097) onto the main bearing bolts,
remove the tommy bars from the tension screws.
6. Place angle pieces (009.028) on the tensioning cylinder.
7. Connect high-pressure hoses to the tensioning cylinder of the main
bearing bolts.
10. Retract pistons of the tensioning cylinders.

11. Screw the tensioning cylinder back onto the cross tie rod
12. Connect high-pressure hoses to the tensioning cylinder of the cross tie
rods.
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.
6632 012.02-01 EN
V32/40
R
FO
2007-10-09 - de
TR
AI
9. Release the pressure, uncouple the high-pressure hoses and angle

pieces, insert the tommy bars through the intermediate rings in the tensioning bolts again and unscrew the tensioning cylinder (009.097).
NI
8. Set high-pressure pump or hydraulic hand pump in operation and

tighten main bearing bolts with a pressure of 300 bar. Tighten both nuts
using the tommy bar, hand-tight.
7 (8)
012.02
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 Crankshaft
Figure 5: Attaching the hydraulic tandem tensioner to the crankshaft bearing bolts
3 Main bearing cap
1. Release pressure, uncouple high-pressure hoses and remove hydraulic

tensioner from the cross tie rods.
2. Retract pistons of the tensioning cylinders.
PU
3. Screw the tensioning cylinder onto the main bearing bolts, remove the
tommy bars from the tension screws.
4. Place angle pieces on the tensioning cylinder.
5. Connect high-pressure hoses to the tensioning cylinder of the main
bearing bolts.
NG
6. Start high pressure pump or hydraulic hand pump and tighten crankshaft bearing bolts with a pressure of 300 bar.
7. Set measuring devices (009.051) onto the tensioning cylinder (009.097)
and set the dial gauges (9) to "Zero".
NI
8. Tighten crankshaft bearing bolts with the specified final pressure (see
Work Card 000.30). Tighten both nuts using the tommy bar, hand-tight.
V32/40
8 (8)
Tighten crankshaft bearing bolts with the specified tension pressure,

not according to the 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.
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.
6632 012.02-01 EN
2007-10-09 - de
TR
AI
10. Tighten main bearing bolts with a pressure of 300 bar again. Read off
elongation L on the dial gauges and compare with the specified value
FO
9. Release the pressure.
Cylinder head bolts

removing and drawing in
ON
LY
Summary
Install/replace components, ensure proper use

, cylinder head bolts must be dismantled, if cylinder liners have to be dismantled at a low deinstallation height. Cylinder head bolts must also be dismantled if their sealing rings are damaged.
Number
Status
009.089
Option
009.089-1
Option
009.089-2
Option
000.266
Standard
000.243
Standard
1 Grease (acid-free)
Inventory
1 Ring nut
1 Ring nut
PU
1 Tommy bar, 16
Work card
000.30
055.02
NI
Work card
Work card
Designation
Information
Cylinder head bolt
32,5 kg
AI
Technical data
NG
TR
Work sequence 1 - Removing the cylinder head bolt
R
FO
2009-09-10 - de
Starting position
Work steps
Cylinder head removed.

1. Mount bolt extractor (009.089) on the cylinder head bolt (1) (observe
projection A = 53 mm - see figure 1).
2. Release and unscrew cylinder head bolt.
3. Dismantle the other cylinder head bolts in the same way.
4. Clean cylinder head bolts and check for damage.
5. Check ring (3) for damage, (if necessary, replace).
Work sequence 2 - Drawing in the cylinder head bolt
Starting position
Bore and thread in the cylinder crankcase as well as the cylinder head bolts
well cleaned and degreased.
6629 012.03-01 EN
32/40;L32/44CR
1 Bolt extractor
Quan- Designation
tity
RP
OS
E

removing components,
installing components.
Tools/aids required
012.03
MAN Diesel & Turbo
1 (3)
012.03
MAN Diesel & Turbo
Working steps
1. Push new O-ring seals (2) and possibly renewed ring (3) over the thread
of the cylinder head bolts.
ON
LY
2. Mount Bolt extractor (009.089) on the cylinder head bolt (1) (observe
projection 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.
RP
OS
E
8. Install cylinder head (see work card 055.02).
Before the subsequent hydraulic tensioning of the cylinder head bolts

ensure that the temperature between cylinder crankcase and cylinder
head bolts is the same. This is especially important when replacing
cylinder head bolts when the engine is at operating temperature.
NI
AI
TR
2009-09-10 - de
R
32/40;L32/44CR
FO
NG
PU
9. ighten cylinder head bolts (see work card 055.01).
2 (3)
6629 012.03-01 EN
012.03
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
6629 012.03-01 EN
32/40;L32/44CR
R
FO
2009-09-10 - de
TR
AI
NI
1 Cylinder head bolt

5 Hexagon nut
2 O-ring seal
6 Stud
3 Ring
7 O-ring seal
A berstand
Figure 1: Cylinder head bolt in the crankcase/installation of the bolt extractor (upper
right)
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
020
TR
R
FO
6632 020-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
020
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 (2)
6632 020-05 EN
Crankshaft
Measuring crankshaft deflection
ON
LY
Summary
Check alignment, detect problems (having an influence) on components/systems, 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.
RP
OS
E
The work includes:

checking the alignment,
recording measured values and
evaluation of results.
Engine stopped

PU
1 Technician
Duration in h
1 Assistant
NG
Tools/aids required
Status
1 Guide tube
021.032
Standard
009.229
Option
1 Web deflection measurement unit (mechanical)
008.171
Option
000.454
Standard
1 Felt-tip pen/marker pen
Inventory
AI
TR
0,15
Number
NI
Quan- Designation
tity
0,15

Work card
Work card
Work card
000.09
FO
2010-03-03 - de
Preliminary remark
The crank web deflection is the difference in the measured values between
two crank web positions offset by 180. The crank web deflection indicates
the alignment of the main bearings and the bearing of the driven shaft. If the
measured values (table 2 and 3) exceed the maximum values (table 4)
allowed, the cause should be eliminated and the crankshaft realigned. Possible causes are:
Unequal wear on crankshaft bearing,
6682 000.10-05 EN

32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;
51/60DF;V28/33D
Safety requirements
000.10
MAN Diesel & Turbo
1 (7)
MAN Diesel & Turbo
Changes of the position of the driven shaft or
Changes in the fixing of the engine on the foundations or of the foundation.
Work sequence 1 - Measuring the crank web deflection
ON
LY
The results of the measurement of the crank web deflection are correlated
with the check of the alignment of the crankshaft flange to the driven shaft.
The measuring gauge is to be read at the RBDC and LBDC points when the
connecting rod is installed. If the connecting rod is installed, then it is to be
read in the BDC position.
The position of the crankshaft pin, not that of the measurement unit, is decisive for the designation.
RP
OS
E
000.10
The designation of the crankshaft's sides and sense of rotation must be

made when looking at the crankshaft from the coupling flange (coupling
side).
For the subsequent work steps, the measurement must be made with the
connecting rods installed (normal case).
Work steps
1. Dismantle the covers on the running gear apertures.
PU
2. Turn crankshaft cylinder 1 to the starting position, depending on the

normal rotation direction of the engine, either in the LBDC or RBDC
position.
Initial position
NG
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.
NI
Incorrect values due to not fully supported crankshaft
2 (7)
4. Select suitable extension rods and mount them on measurement unit.

5. Locate the measurement unit in the measuring points (2).
Measuring points
The measuring points for the measurement with fitted running gears
are in the balance weights! Exception: Engine 58/64, the measuring
points are in the crank webs!
6682 000.10-05 EN
2010-03-03 - de
TR
AI
If the crankshaft ist not fully supported, the values of the web deflection
measurement will be incorrect.
FO

32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;
51/60DF;V28/33D
3. Check whether the crankshaft is lying on the lower bearing shells using
the feeler gauges (000.454).
Measurement when engine is hot
ON
LY
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.
000.10
MAN Diesel & Turbo
6. Set the dial gauge approximately at the centre of the measuring range
to "0" as initial value.
RP
OS
E
7. Turn crankshaft in the normal rotation direction to the intended measuring 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).
Turning the crankshaft
PU
Take care not to damage the measurement unit with the big-end
bearing bolts when turning the crankshaft!
When turning over a V-engine, ensure that the measurement unit is not
damaged by the slave connecting rod!
8. Measure the other crankshaft webs in the same way.
NG
9. After measuring all webs, disassemble the measurement unit, clean it

and store it in the wooden case.
Work sequence 2 - Recording measured values

Measurement value and direction of deviation (fig. 3, table 1),
Assembly condition (e.g. piston/connecting rod installed/removed),
Coupling type (rigid, resilient),
Engine mounting (rigid, resilient, semi-resilient),
Other relevant conditions (e.g. ship in dock or floating)
Oil and coolant temperatures if the measurements are taken at engine

operating temperature, and
Engine's main direction of rotation.
TR
AI
NI
FO
2010-03-03 - de
Work sequence 3 - Evaluation/Assessment

Crank position
Hand crank number

1
...
Hand crank at
RBDC1)
...
Hand crank at
RTDC
-2
+1
+2
+1
-1
...
6682 000.10-05 EN

32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;
51/60DF;V28/33D
The measurement report must include the following information:
3 (7)
MAN Diesel & Turbo

-5
+3
+5
+6
+1
-3
...
Hand crank at
LTDC
+1
+2
+4
+3
-3
-2
...
Hand crank at
LBDC1)
+2
+2
ON
LY
Hand crank at
TDC
-1
-1
...
Table 1: Recording of measured values (example) - measured values in 1/100 mm

1)
Measurement with connecting rod removed = BDC
Crank web deflection
Hand crank number

1
...
vertical av
-6
+3
+4
+6
+1,5
-2,5
...
av = TDC - 1/2 (LBDC+RBDC)
horizontal ah
-3
-1
-4
-1
+4
+1
...
ah = RTDC - LTDC
RP
OS
E
000.10
Table 2: Recording of measured values (example) - crank web deflections in 1/100 mm
PU
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:
av = (-3) - 0.5 ((-1) + 0) = -2.5
horizontal ah hand crank no.

6:
ah = (-1) - (-2) = +1
NG
vertical av hand crank no. 6:
4 (7)
NI
1 to 2
2 to 3
3 to 4
4 to 5
5 to 6
6 to ...
...
...
...
AI
Difference
Hand crank number
The absolute difference between the TDC values of adjacent cranks (calculated in table 3) must not exceed the absolute values of the permissible crank
web deflection.
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
and 3:
6682 000.10-05 EN
2010-03-03 - de
TR
Table 3: Evaluation of TDC measured values of adjacent cylinders (example) - absolute differential values in 1/100 mm
FO

32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;
51/60DF;V28/33D
Crank web deflection, with the corresponding algebraic sign, must not
exceed the maximum permissible value.
L 32/44
CR
V 32/44
CR
40/54
L 48/60
L 48/60
B
L 48/60
CR
L 51/60
DF
V 48/60
V 48/60 B
V 48/60
CR
V 51/60
DF
58/64
with cold
engine
15
142)
182)
182)
18
23
26
23
with warm
engine
15
+14
-20
+18
-25
+18
-25
18
23
26
23
320
460
540
550
505
580
580
560
Measuring
point distance (A)
RP
OS
E
Crank web
deflection
32/40
ON
LY
Engine type 28/33 D
000.10
MAN Diesel & Turbo
Table 4: Maximum permissible crank web deflection (differential values) with the running gear installed and
corresponding 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
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!
1)
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.
AI
R
FO
2010-03-03 - de
TR
Figure 1: Measuring the crank web deflection
6682 000.10-05 EN

32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;
51/60DF;V28/33D
1 Crank web
2 Measuring range (centre
punch)
3 Crank pin
A Measuring point distance
NI
NG
PU
2)
5 (7)
000.10
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
5 Balance weight
LTDC Left Top Dead Centre
LL Sense of engine rotation
RTDC Right Top Dead Centre
left
3 Crank pin
RL Sense of engine rotation
LBDC Left Bottom Dead Centre
right
4 Connecting rod
TDC Top Dead Centre
RBDC Right Bottom Dead Centre
Figure 2: Crank web deflection measurement (with connecting rod) - seen from the coupling side - in-line engine 48/60
B shown
6 (7)
NI
2010-03-03 - de
TR
AI
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)
FO

32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;
51/60DF;V28/33D
NG
1 Crank web
2 Measuring range
6682 000.10-05 EN
R
FO
2010-03-03 - de
TR
AI

32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;
51/60DF;V28/33D
NI
NG
PU
RP
OS
E
ON
LY
TD Top Dead Centre

C
LT Left Top Dead Centre
D
C
RT Right Top Dead Centre
D
C
B Bottom Dead Centre
D
C
LB Left Bottom Dead CenD tre
C
R Right Bottom Dead CenB tre
D
C
Figure 4: Designation of crank positions - seen from the coupling side
000.10
MAN Diesel & Turbo
6682 000.10-05 EN
7 (7)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
RP
OS
E

Safety requirements
Engine stopped
Tools/aids required
Quan- Designation
tity
Number
Status
030.243
Standard
2 Tensioning screw
021.251
Standard
2 Intermediate ring
021.250
Standard
009.342
Standard
009.320
Standard
009.306
Standard
009.097
Standard
009.096
Standard
1 Tommy bar, 10
000.263
Standard
NI
NG
PU
2 Thrust piece
Work card
Work card
Work card
000.30
000.32
009.01
009.03
FO
2007-07-17 - de
TR
AI
6632 020.01-01 EN
V32/40
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.
Summary
ON
LY
Balance weight bolts

inspecting
020.01
MAN Diesel & Turbo
1 (3)
020.01
MAN Diesel & Turbo
RP
OS
E
ON
LY
Work sequence 1 - Checking the balance weight bolts
Figure 1: Illustration and installation of the hydraulic tensioner
Starting position
2 Balance weight
PU
Crankcase is open, crankshaft is arranged in such a way that the balance

weight is vertical (see figure 1).
Work steps
1. Clean thread of studs (4).
2. Screw on tension screws (021.251) until they abut on the tensioning

cylinder (009.096).
NG
3. Place the thrust pieces (030.243) over the nuts (3) and screw the tensioning cylinder onto the studs.
NI
5. Fit intermediate rings (021.250) and tensioning cylinder (009.097).
V32/40

both nuts.
10. Release pressure and remove tandem tensioner.
11. Close crankcase.
2 (3)
6632 020.01-01 EN
2007-07-17 - de

TR
AI
7. Start the high-pressure pump or the hydraulic hand pump (see Work
Card 009.03) and close the gap between the thrust piece and the balance weight (2).
FO

ON
LY
020.01
MAN Diesel & Turbo
RP
OS
E
2 Balance weight
3 Nut
4 Stud
6632 020.01-01 EN
V32/40
R
FO
2007-07-17 - de
TR
AI
NI
NG
PU
Figure 2: Arrangement of the hydraulic tandem tensioner
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Crankshaft oil bore

closing
ON
LY
Summary
Ensure correct execution of work, enable emergency operation.

If the engine has to continue to run in an emergency despite a removed running gear (piston with connecting rod), the oil bores of the respective crank
pin are to be closed.
RP
OS
E
Engine stopped
Tools/aids required
Quan- Designation
tity
Number
Status
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
000.243
Standard
NG
PU
1 Locking device
Work card
Work card
112.01
200.01
Work card
AI
NI
Preliminary remarks
R
FO
2007-05-10 - de
TR
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.
It is only in an emergency that the engine should continue to run when

the running gear is removed and, as such, when the performance and
speed is reduced. See detailed description in the user manual, section
3.6.
6629 020.02-01 EN
32/40

proper assembly
and if necessary
disassembly.
Safety requirements
020.02
MAN Diesel & Turbo
1 (2)
020.02
MAN Diesel & Turbo
Work sequence 1 - Closing the oil bore

Starting position
Work steps
ON
LY
Piston with connecting rod, big-end bearing and push rod are removed.
1. Place a sealing plug (020.050-5) on the threaded rod (020.050-1) and
insert in the oil bore (3).
2. Place a second sealing plug on the threaded rod, screw on castle nut
(4), tighten and secure with cotter pin (5).
3. Attach complete cylinder head, do not insert push rods. Shut down
exhaust and inlet cam follower (fix outside of the cam range), close
lubrication holes.
RP
OS
E
4. Take injection pump of the concerned cylinder out of operation (pull

control rod to zero filling and lock with pipe clamp, see Work Card
200.01).
5. Close oil pipe to the rocker arm lubrication.
NG
PU
6. Close starting control air pipe to the cylinder out of operation.
NI
AI
TR
2007-05-10 - de
R
32/40
FO
1 O-ring seal
4 Castle nut M8
2 Crank pin
5 Cotter pin
3 Oil bore
Figure 1: Close the oil bore in the crank pin (figure shows L32/40)
2 (2)
6629 020.02-01 EN
Gearwheel on the crankshaft

removal and installation
Tools/aids required
Quan- Designation
tity
RP
OS
E

Number
Status
008.017
Standard
002.452
Standard
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
Inventory
4 Threaded rod M22/Dia22
Inventory
2 Wood (to support underneath)
Inventory
1 Lubricant (containing molybdenum disulphide)
Inventory
1 Torque wrench
2 Shackle A0.6
NI
NG
PU
1 Adapter 12.5x20
AI
Work card
Work card
000.30
000.32
100.01
TR
Work card
Designation
Information
Crankshaft gearwheel
66 kg
Preliminary remarks
FO
2007-11-05 - de
Technical data
It is recommended to have overhaul work on the camshaft drive on marine

engines done in a customer service locations (ship's safety/degree of difficulty).
6632 020.03-01 EN
V32/40
Check assembly parts for state/wear condition; prevent operational problems/damage.

If the gearwheel on the crankshaft shows damage, then the gear rim is to be
replaced, i.e. renewed.
ON
LY
Summary
020.03
MAN Diesel & Turbo
1 (6)
020.03
MAN Diesel & Turbo
Work sequence 1 - Removing the crankshaft gearwheel

Starting position
Work steps
1. Release hexagon bolts (27) and unscrew.
ON
LY
Covering of the coupling side and crankshaft outer bearing are dismantled.
Marks on the gearwheels coincide (see figure 4).
2. Screw in four threaded rods (29) through crankshaft gearwheel (23) in

the crankshaft (22).
3. Pull crankshaft gearwheel so far towards the front until it is outside the
crankcase. Prop the crankshaft gearwheel with a wooden support.
4. Screw two lifting eye bolts (000.142) into the gearwheel upper part (24).
RP
OS
E
5. Attach the cables (28) with the shackles (002.452) to the ring screws
and hook them onto the lifting tackle.
6. Release hexagon socket bolts (32) and unscrew.
7. Unscrew both upper threaded rods.
8. Lift gearwheel upper part, remove over the crankshaft and place on the
support.
PU
Do not lay gearwheel upper part on cylindrical pins (31).
9. Detach shackle from lifting eye bolts and remove from ropes.
NG
10. Lay ropes around the gearwheel lower part (25) and mount on the lifting
tackle.
11. Unscrew lower threaded rods.
NI
12. Lift gearwheel lower part, replace wooden support for flat wooden support, lower gearwheel lower part onto this and pull out from under the
crankshaft.
AI
TR
2007-11-05 - de
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
FO
13. Remove ropes, place gearwheel lower part on the support.
2 (6)
6632 020.03-01 EN
020.03
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
6632 020.03-01 EN
31 Parallel pin
V32/40
22 Crankshaft
28 Rope
24 Gearwheel upper part
29 Threaded rod
25 Gearwheel lower part
30 Wooden support
Figure 2: Attaching the gearwheel upper part and lifting the gearwheel lower part
R
FO
2007-11-05 - de
TR
AI
NI
NG
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)
3 (6)
020.03
MAN Diesel & Turbo
Work sequence 2 - Fitting the crankshaft gearwheel

Starting position
ON
LY
Replace damaged crankshaft gearwheel with a new one. Contact faces on

the crankshaft and crankshaft gearwheel as well as parting lines between
gearwheel upper part and lower part have been cleaned. Marks on the gearwheels coincide (see figure 4).
Marking the tightening

sequence
Parallel pin
Hexagon socket bolt
Coupling side
PU
RP
OS
E
14
23
31
32
K
S
Figure 3: Torque sequence for the radial fastening screws
Work steps
NG
1. Place two ropes (28) around the gearwheel lower part (25), hook onto
the lifting tackle, push onto flat wooden support under the crankshaft
(22) and lift. Push wooden support (30) for propping under the gearwheel lower part. Remove ropes.
NI
AI
TR
2007-11-05 - de
R
V32/40
FO
Before installing the gearwheel lower part pay attention to the position
of the holes for the cylindrical pins (31).
4 (6)
6632 020.03-01 EN
020.03
RP
OS
E
ON
LY
MAN Diesel & Turbo
33 Camshaft gearwheel
34 Spur wheel (intermediate wheel)
Figure 4: Marks on the gearwheels
35 Double spur wheel (intermediate

wheel)
36 Injection camshaft gearwheel
M Mark
PU
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 lifting tackle.
NG
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.
NI
4. Apply MoS2-lubricant on threads and resting surface of the hexagon

socket bolts (32), screw in and tighten with the specified torque (see
Work Card 000.30), see figure 3 for sequence.
7. Push crankshaft gearwheel (23) up to the stop on the crankshaft in the

crankcase, paying attention to the offset on the crankshaft and position
of the parallel pin (26) bore.
Check that the marks (M) of the camshaft drive gearwheels coincide
(see figure 4).
8. Unscrew threaded rods and remove.

bolts (27), screw in and tighten with the specified torque (see Work
Card 000.30), see figure 5 for sequence.
6632 020.03-01 EN
V32/40
R
FO
2007-11-05 - de
TR
AI
6. Remove ropes from lifting tackle, remove shackle from the lifting eye
bolts and unscrew lifting eye bolts from the gearwheel upper part.
5. Screw in upper threaded rods through the gearwheel upper part in the
crankshaft.
5 (6)
020.03
MAN Diesel & Turbo

sequence
Crankshaft
Hexagon bolt
RP
OS
E
520
22
23
27
ON
LY
10. Attach the main outer bearing and covering on the coupling side (see
Work Card 021.04 and 071.01).
NI
AI
TR
2007-11-05 - de
R
V32/40
FO
NG
PU
Figure 5: Torque sequence for the axial fastening screws
6 (6)
6632 020.03-01 EN
Coupling bolts
inspecting
ON
LY
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.
Quan- Designation
tity
RP
OS
E
The work includes:

checking the bolted connections.
Tools/aids required

000.32
Preliminary remarks
Work card
Number
Status
009.229
Option
Inventory
Work card
PU
Work card
020.04
MAN Diesel & Turbo
NG
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).
TR
R
FO
2007-10-31 - de
When checking or retightening the coupling bolts, hold the hexagon

nuts (9) in position with an open-jaw wrench.
2. When fitting the coupling (1) make sure that the thread and resting surface of the hexagon bolts (10) are coated with MoS2 lubricant, are
screwed in position and tightened with the prescribed torque (see flywheel arrangement drawing of the individual installation) and that there
are washers between the hexagon bolts and the coupling (11).
6629 020.04-01 EN
32/40
1. Check the tightness of the coupling bolts with the prescribed torque
(see flywheel arrangement drawing of the individual installation), if necessary tighten the hexagon nuts (7).
Coupling (1) on coupling side removed.
AI
Starting position
Work steps
NI
Work sequence 1 -Checking the coupling bolts
1 (2)
020.04
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
2007-10-31 - de
TR
AI
NI
Coupling*
7 Hexagon nut
Flywheel*
8 Coupling bolt
Hexagonal socket bolt
9 Hexagon nut
Crankshaft
10 Hexagon bolt
Casing
11 Washer
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
32/40
FO
1
2
3
4
5
6
*
2 (2)
6629 020.04-01 EN
Summary
ON
LY
Balance weight
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.
Engine secured against starting
Engine shut down

1 Technician
PU
1 Assistant
Tools/aids required
Status
2 Wire rope
030.255
Option
2 Thrust piece
030.243
Standard
2 Tensioning screw
021.251
Standard
2 Intermediate ring
021.250
Standard
009.342
Standard
009.320
Standard
009.306
Standard
009.097
Standard
009.096
Standard
1 Measuring device
009.121
Standard
1 Bolt extractor
009.089
Option
1 Ratchet tool
008.023
Standard
1 Torque wrench
008.017
Standard
1 Ratchet hoist
002.552
Option
2 Shackle A1.0
002.453
Standard
1 Tommy bar, 10
000.263
Standard
000.143
Standard
1 Lifting tackle
Inventory
NI
AI
TR
R
FO
2007-10-09 - de
Number
NG
Quan- Designation
tity
Duration in h
6632 020.05-01 EN
V32/40
Safety requirements
RP
OS
E

020.05
MAN Diesel & Turbo
1 (5)
020.05
MAN Diesel & Turbo

Number
Status
1 Rope
Inventory
1 Socket spanner (set)
Inventory
Inventory
ON
LY
Quan- Designation
tity

Work card
000.30
009.03
Technical data
Designation
Work card
009.06
RP
OS
E
Work card
Information
Balance weight
145 kg
NI
AI
Work steps
2 Balance weight
3 Nut
Figure 1: Opened crankcase
Crankcase is opened, crankshaft is turned so that the balance weight is vertical.

2. Screw on tension screws (021.251) up to the stop on the hydraulic tensioner (009.096).
3. Place the thrust pieces (030.243) over the nuts (3) and screw the tensioners (009.096) onto the studs (see figure 2).
V32/40
2 (5)
4 Stud
7 Crankshaft deflection
8 Threaded hole
6632 020.05-01 EN
2007-10-09 - de
TR
Starting position
FO
NG
PU
Work sequence 1 - Removing the balance weight
3 Nut
4 Stud
PU
2 Balance weight
Figure 2: Fitting the tensioners
RP
OS
E
ON
LY
Before fitting the tensioners ensure that the pistons are fully retracted.
Once the tensioners have been fitted the crankshaft must not be
turned again.
020.05
MAN Diesel & Turbo
1. Turn the tensioners (009.096) back by 250.

2. Fit intermediate rings (021.250) and tensioners (009.097).
NG
3. Connect four high-pressure hoses (009.306) onto tensioners and highpressure pump or hydraulic hand pump.
4. Start the high-pressure pump or hydraulic hand pump (see Work Card
009.03) and close the gap between the thrust piece (030.243) and balance weight (2) which arises from turning backwards.
6. Turn back nuts.

8. Screw two lifting eye bolts (000.143) into the threaded holes (8) in the
side of the balance weight (see 1 and 4).
6632 020.05-01 EN
V32/40
R
FO
2007-10-09 - de
TR

AI
NI
5. Pump the tensioners until the nuts (3) can be released. Make a note of
the release pressure and compare it to the specified locking pressure.
3 (5)
020.05
ON
LY
MAN Diesel & Turbo
RP
OS
E
2 Balance weight
4 Stud
Figure 3: Extraction and fitting the studs on the balance weight
1. Hang balance weight with ropes (030.255) onto the ratchet hoist
(002.552) and suspend from lifting tackle and tighten ropes.
2. Unscrew a nut (3), undo stud (4) with bolt extractor (009.089) and
unscrew (see Fig. 3).
Repeat procedure to remove second nut with stud.
3. Lower balance weight evenly until the parallel pin (6) and clamping
sleeve (5) are free.
PU
4. Pull the balance weight carefully from the crankcase (see figure 4) by
alternately slackening and tightening the ratchet hoist or lifting tackle.
NI
AI
4 (5)
4 Stud
2 Balance weight
5 Clamping sleeve
3 Nut
6 Parallel pin
Figure 4: Removing and installing the balance weight
6632 020.05-01 EN
7 Crankshaft deflection
2007-10-09 - de
TR
R
V32/40
FO
NG
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 sequence 2 - Installing the balance weight
ON
LY
Installing the balance weight is carried out in reverse order from the removal.
In doing so, observe the following points:
020.05
MAN Diesel & Turbo
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).
RP
OS
E
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 highpressure pump or hydraulic hand pump.
009.03) and tighten balance weight bolts with a pressure of 50 bar.
Reset measuring gauge to "zero".
PU
9. Tighten balance weight bolts with specified final pressure (see Work
Card 000.30) and tighten both nuts hand-tight. Release the pressure.
NG
10. Tighten balance weight bolts with a pressure of 50 bar again. Read
screw elongation L on the dial gauge and compare with the specified
value (see Work Card 000.30).
6632 020.05-01 EN
V32/40
R
FO
2007-10-09 - de
TR
AI
11. Release pressure and remove tensioners. Remove lifting eye bolts on
the balance weight.
NI
Tighten balance weight bolts with specified tensioning pressure,

notaccording to the screw elongation l. Elongation specifications
serve only for checking purposes. Repeat tensioning process in the
case of great deviations and check the measuring devices or pressure
gauges.
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
021
TR
R
FO
6632 021-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
021
ON
LY
RP
OS
E
PU
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
NG
111
112
113/114
120
125
140
160-162
FO
MAN Diesel & Turbo
2 (2)
6632 021-05 EN
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.
RP
OS
E
Safety requirements
Engine stopped
PU
1 Technician
1 Assistant
NG
Tools/aids required
Number
Status
6 Tommy bar
021.523
Standard
1 Raising and lowering fixture
021.336
Standard
2 Support
021.260
Standard
1 Cross bar
021.259
Standard
2 Guide tube
021.258
Standard
1 Guide tube
021.032
Standard
1 Scissor-type jack
009.085
Standard
000.454
Standard
1 Tommy bar, 10
000.263
Option
Inventory
Inventory
FO
TR
AI
NI
Quan- Designation
tity
2010-04-23 - de
Duration in h
6632 021.01-03 EN
V32/40;V32/40G

dismantling the cross tie rods,
lowering the bearing cap,
checking the bearing shell and
restoring the starting position.
Summary
ON
LY
Main bearing cap with lower bearing shell

lowering and checking
021.01
MAN Diesel & Turbo
1 (5)
021.01
MAN Diesel & Turbo

Work card
000.10
000.11
Work card
ON
LY
Work card
012.02
Technical data
Designation
Information
Main bearing cap
118 kg
RP
OS
E
Work sequence 1 - Lowering the main bearing cap - checking the lower crankshaft
bearing shell
Starting position
5
9
10
11
12
Cylinder crankcase
Cross tie rod
Nut
Ring
O-ring seal
NG
PU
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 (special tool) is placed in the oil sump or the oil sump has been cleaned using an
appropriate agent. Temperature sensor removed (if fitted).
AI
1. Unscrew nuts (10) from cross tie rods (9), and remove rings (11) and Oring seals (12).
V32/40;V32/40G
2 (5)
3. Screw guide tubes (021.258) into main bearing bolts (16), tighten fingertight.
4. Place the cross tie (021.259) into the oil sump (17), slide under the
guide tube, lift and fix in position by inserting a tommy bar (021.523)
into each centre hole (3) in the guide tubes.
(see figure 2 A)
5. Fit two supports (021.260) on cross tie and clamp in the crankcase by
turning the hexagon nuts (18). The cross tie will be pressed against the
tommy bars by doing this.
6. Slide the scissor-type jack (009.085) into the groove in the cross tie and
insert the locking mechanism (20) into the cross tie. Screw the scissortype 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.
6632 021.01-03 EN
2010-04-23 - de
TR
2. Unscrew both cross tie rods and dismantle.
FO
Work steps
NI
Figure 1: Illustration of the cross tie rod
ON
LY
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 Fig. 2 B).
021.01
MAN Diesel & Turbo
With a hot engine it may be necessary to unload the cross tie rods of
the adjacent main bearing.
RP
OS
E
Do not remove the crankshaft bearing shell for inspection purposes to

avoid disturbing the fit as far as possible.
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).
PU
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.
6632 021.01-03 EN
V32/40;V32/40G
R
FO
2010-04-23 - de
TR
AI
NI
Replace crankshaft bearing shell if damaged or if there is severe

scoring caused by dirt. Insert new crankshaft bearing shell in the main
bearing cap, paying attention to the bearing shell fixation (back of
bearing shell free from oil). New crankshaft bearing shells are delivered
ready for installation and should not be rescraped or adapted in any
way. The bearing points are numbered. If new crankshaft bearing
shells are installed, the corresponding numbers should be transferred
to new shells.
NG
15. Check the condition of the running surface, (see Work Card 000.11).
3 (5)
021.01
4 (5)
11 Ring
12 O-ring seal
13 Ratchet tool
15 Hexagon bolt M12x45

16
17
18
19
20
(A)
Crankshaft bearing bolt

Oil pan
Hexagon nut M24x2
Locating pin
Retainer
Step 1...4
Cross tie inserted
(B) Step 5...8
Bearing cap partially lowered
(C) Step 9...11
Cross tie relocated
(D) Step 12...13
Bearing cap lowered
14 Nut
Figure 2: Crankshaft bearing and attached lifting and lowering device
Work sequence 2 - Lifting the main bearing cap
Work steps
1. Oil the running surface of the crankshaft bearing shell (8) well.
6632 021.01-03 EN
2010-04-23 - de
NI
1-4 Identification of the bores in the

guide tube
6 Crankshaft
7 Crankshaft bearing cover
8 lower crankshaft bearing shell
9 Cross tie rod
10 Nut
AI
TR
R
V32/40;V32/40G
FO
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
ON
LY
2. Lift the crankshaft bearing cap (7) using the scissor-type jack, making
sure that it does not become jammed. If needed, slightly loosen the
hexagon bolts (15) so that the crankshaft bearing cap can self-align
itself. Remaining procedure in reverse order (work sequence 1 points 3
- 13), i.e. lift the bearing cap in two stages.
021.01
MAN Diesel & Turbo
3. Screw nuts (14) onto crankshaft bearing bolts (16) and screw on handtight until they touch the crankshaft bearing cap.
4. Detach or remove the entire lifting and lowering device.
5. Apply MoS2-lubricant to the screw threads of the cross tie rods (9) and
screw into the crankshaft bearing cap hand-tight until it comes to rest.
RP
OS
E
6. Place O-ring seals (12) and rings (11) over the cross tie rods, screw
nuts (10) hand-tight up to the stop.
7. Tighten main bearing bolts and cross tie rods (see Work Card 012.02).
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.
PU
8. Check the crankshaft bearing clearance using a thickness gauge

(000.454) (see operating instructions section 2.5), in doing so, insert the
feeler gauge approx. 10 mm deep from the coupling side and the free
engine end.
9. Measure the crank web deflection (see Work Card 000.10) and note in
the operating log sheets.
NG
10. Remove the foot board (if fitted) from the oil sump.
11. Mount the temperature sensor (if available).
6632 021.01-03 EN
V32/40;V32/40G
R
FO
2010-04-23 - de
TR
AI
NI
For the running-in of the new main bearing shells, see run-in
instructions in section 3 of the Operating Instructions.
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Upper crankshaft bearing shell

removing and installing/checking
ON
LY
Summary
ensure the operational safety of bearings.
The upper crankshaft bearing shell must be removed and checked, if damage or severe scoring from dirt is detected upon checking the lower crankshaft bearing shell.
Tools/aids required
Quan- Designation
tity
Number
Status
021.268
Standard
021.266
Standard
1 Turning block
021.265
Standard
1 Eye bolt M6
000.023
Standard
1 Turning block
NG
Work card
000.11
021.01
Information
AI
Designation
Work card
upper crankshaft bearing shell
2,5 kg
TR
Work sequence - Checking the crankshaft bearing shell (removal and fitting)
R
FO
2007-10-09 - de
Starting position
Work steps
Main bearing cap is lowered, lower bearing shell is removed.

1. Insert turning block (021.265) in the oil hole in the crankshaft (6), the
crankshaft may have to be turned slightly.
Turning block must be completely in contact with the crankshaft.
2. Carefully turn out upper main bearing shell (20), do not damage it whilst
doing so (see figure 1).
6632 021.02-01 EN
V32/40
Technical data
Work card
NI
PU
1 Centring template
RP
OS
E
The work includes:

checking the bearing shell.
Safety requirements
021.02
MAN Diesel & Turbo
1 (4)
021.02
MAN Diesel & Turbo
ON
LY
Observe position of bearing shell fixation (bent-up nose). The

crankshaft must be turned in such a way that the fixing is released. It
must not be pulled into the bearing casing.
3. Pull out turning block with eye bolt (000.023).
4. Carefully clean running surface of the crankshaft bearing shell and do

not damage whilst doing so.
5. Check the condition of the running surface, (see Work Card 000.11).
RP
OS
E
Work steps (part 2:

Installation)
Damaged or worn-out crankshaft bearing shells must be replaced. New

crankshaft bearing shells are delivered ready for installation and should
not be rescraped or adapted in any way. The bearing points are
numbered (see Operating Instructions section 5). If new crankshaft
bearing shells are installed, the corresponding numbers should be
transferred to new shells.
PU
1. Set centring template (021.266) on cylinder crankcase (5). Insert the

centring 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).
NG
3. Place crankshaft bearing shell on the centring template and push in as

far as possible by hand.
NI
V32/40
2 (4)
In order to avoid warping the thin crankshaft bearing shell when

inserting. Place the turning block in position as close as possible to the
parting line in the crankshaft bearing.
5. Turn in crankshaft bearing shell in several steps (depending on the hole

spacing). Pull out the turning block after the first turn, turn crankshaft
one 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.
6632 021.02-01 EN
2007-10-09 - de
TR
AI
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.
FO
Before pushing in make a note of the position of the bearing shell

fixation.
ON
LY
Ensure even final position of the bearing shell joint faces.
021.02
MAN Diesel & Turbo
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).
6632 021.02-01 EN
V32/40
R
FO
2007-10-09 - de
20 Crankshaft bearing shell
6 Crankshaft
21 O-ring seal
Figure 1: Removal of the upper crankshaft bearing shell
TR
AI
NI
NG
PU
RP
OS
E
For the running-in of the new main bearing shells, see Operating
Instructions, section 3.4.
3 (4)
021.02
RP
OS
E
ON
LY
MAN Diesel & Turbo
NI
AI
TR
2007-10-09 - de
R
V32/40
FO
NG
PU
6 Crankshaft
20 Crankshaft bearing shell
Figure 2: Fitting the upper crankshaft bearing shell
4 (4)
6632 021.02-01 EN
Main thrust bearing

Measure axial clearance/check locating bearing rings
ON
LY
Summary
021.03
MAN Diesel & Turbo
measure components, assess surface/wear condition.
The axial clearance and the locating bearing rings must be checked at regular intervals.
Tools/aids required
Quan- Designation
tity
RP
OS
E

measuring components and
assessing the wear surface appearance / wear condition.
Number
Status
008.023
Standard
008.011
Standard
001.911
Option
001.755
Option
1 Crow bar
001.391
Option
000.451
Option
1 Magnetic post
Inventory
1 Dial gauge
Inventory
Inventory
1 Ratchet tool
NG
PU
1 Torque wrench
NI
Work card
Work card
Work card
Locating bearing ring
3,0 kg
Work sequence 1 - Measuring the crankshaft axial clearance
FO
2007-10-31 - de
Work steps
1. Move the crankshaft using the crow bar (001.391) axially in one direction up to the contact surface.
Using a hydraulic press with a support mechanism between the
crankcase wall and balance weight is strictly prohibited!
6629 021.03-01 EN
32/40
Information
TR
Designation
Technical data
AI
000.11
1 (3)
021.03
MAN Diesel & Turbo
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
location. Reset measuring gauge to "zero".
ON
LY
3. Slide the crankshaft axially as far as it will travel in the opposite direction. The dial gauge measures the distance travelled.
4. Take note of the axial clearance and compare it to the permitted clearance (see Operating Instructions, section 2.5). Record the axial clearance in the operation notes.
RP
OS
E
If the permitted clearance is exceeded, remove the crankshaft locating

bearing rings and check them (see work sequence 2).
5. Remove the magnetic post and dial gauge.
Work sequence 2- Checking the crankshaft locating bearing rings

Starting position
Work steps
Crankcase cover removed
1. Anchor the crankshaft (4) with suitable fixtures so that the crankshaft
locating bearing rings (2) are uncovered.
PU
2. Remove the stop piece (6). See Fig. 1.
NG
Ensure that the crankshaft locating bearing rings do not fall out.
NI
3. Unscrew both crankshaft locating bearing rings in the direction of rotation.
AI
5. Check the condition of the running surfaces (see Work Card 000.11).
6. Slightly lubricate the crankshaft locating bearing rings (2).
7. Apply MoS2-lubricant to threads and contact face of hexagon bolt (5).
8. Screw in the crankshaft locating bearing rings, mount the stop piece (6)
and screw in the hexagon bolts hand-tight.
Ensure that both sides correspond to the specification dimension A.
See Fig. 1.
2 (3)
6629 021.03-01 EN
2007-10-31 - de
TR
R
4. Clean crankshaft locating bearing rings carefully, without damaging it.
32/40
FO
Do not turn the crankshaft.
9. Tighten the hexagon bolts with prescribed torque. (see Work Card
000.30)
10. Remove the crankshaft axial anchoring (see point 1).
12. Fit the crankcase cover.
ON
LY
11. Measure the crankshaft axial clearance (see Work Card 1) and record
the results in the operation notes.
021.03
MAN Diesel & Turbo
RP
OS
E
2 Crankshaft locating
bearing ring
5 Hexagon bolt
6 Stop piece
A Specification dimension
= 1.0 mm (Interval
between crankshaft locating bearing ring stop piece
6629 021.03-01 EN
5 Hexagon bolt
6 Stop piece
32/40
FO
2007-10-31 - de
1 Bearing body
2 Crankshaft locating bear4 Crankshaft
ing ring
Figure 2: Axial crankshaft anchor (adjusting bearing)
TR
AI
NI
NG
PU
Figure 1: Securing the crankshaft locating bearing ring
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Crankshaft flange bearing/Bearing shells

removing, fitting and checking
Tools/aids required
Quan- Designation
tity
RP
OS
E

inspecting the bearing shells,
refitting components.
Number
Status
1 Guide tube (V engine)
021.258
Standard
1 Guide tube
021.032
Standard
008.017
Standard
001.923
Option
001.911
Option
1 Cross handle
001.891
Option
2 Socket spanner insert 36x20
001.771
Standard
000.454
Standard
1 Lifting tackle
Inventory
Inventory
Inventory
1 Hexagon nut M10
Inventory
1 Rope
Inventory
Inventory
1 Torque wrench
AI
NI
NG
PU
1 Adapter 20x12.5
TR
Work card
Work card
Work card
000.10
000.11
000.30
FO
2008-01-08 - de
Technical data
Designation
Information
Flange bearing complete
165 kg
Flange bearing - upper part
77 kg
Flange bearing - lower section
76,5 kg
lower crankshaft bearing shell
3,0 kg
upper crankshaft bearing shell
2,5 kg
6629 021.04-01 EN
32/40;V32/40PGI
ensure the operational safety of the bearings.
The crankshaft bearing shells on the outer crankshaft bearing must be
checked at regular intervals.
ON
LY
Summary
021.04
MAN Diesel & Turbo
1 (6)
021.04
MAN Diesel & Turbo
Work sequence 1- Checking the crankshaft bearing shells

Starting position
36
37
38
39
NI
Coupling bolt
Crankshaft
Hexagon bolt
Flange bearing
Hexagon bolt
Rope
Hexagon bolt
Hexagon nut
41
42
43
44
40 Wooden support
Parallel pin
Casing
Taper pin
lower crankshaft bearing
shell
Work sequences (part 1) Inspecting the bearing shells
32/40;V32/40PGI
2 (6)
Danger of death when lifting and moving loads!

Unless absolutely necessary, do not enter or remain in the area below
suspended loads!
1. Pull out four taper pins (43).

2. Unscrew and remove the hexagon bolts (31).
3. Clean and lubricate the crankshaft.
4. Pull the flange bearing (32) forward and support it with the wooden support (40). See Fig. 1.
5. Loosen the hexagon nuts (39) and unscrew, remove the hexagon bolts
(36 and 38).
6629 021.04-01 EN
2008-01-08 - de
TR
AI
35 upper crankshaft bearing

shell
Figure 1: Main outer bearings
FO
29
30
31
32
NG
PU
RP
OS
E
ON
LY
Crankcase cover and covering on the coupling side removed, flywheel and
coupling supported, temperature sensor (if available) removed.
ON
LY
6. Suspend the flange bearing upper part (33) with the rope (37) in the lifting tackle, lift it up, remove it over the crankshaft (30) and place it onto
the wooden support. Remove rope.
021.04
MAN Diesel & Turbo
When removing the flange upper part, ensure that the crankshaft
bearing shell does not fall out and is damaged in the process.
RP
OS
E
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).
Do not remove the crankshaft bearing shells for inspection purposes,
otherwise realignment will be necessary.
PU
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.
NG
Replacing the bearing shells
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.
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)
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 attention to the parallel pins (41).
6629 021.04-01 EN
32/40;V32/40PGI
TR
R
FO
2008-01-08 - de
2. Lubricate the running surface of the bottom crankshaft bearing shell

(44) well.
1. Clean and lubricate the crankshaft bearing journals (30).
AI
Work sequences (Part 2) Assembling the crankshaft

external bearing
NI
New crankshaft bearing shells are delivered ready for installation and
should not be rescraped or adapted in any way. The bearing points are
numbered (see Operating Instructions section 5). If new crankshaft
bearing shells are installed, the corresponding numbers should be
transferred to new shells.
3 (6)
021.04
MAN Diesel & Turbo
ON
LY
When attaching the flange upper part, ensure that the crankshaft
bearing 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.
RP
OS
E
9. Push the flange bearing (32) until it abuts the covering (42) in the direction 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.
PU
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).
NG
16. Mount the crankcase cover and the covering on the coupling side.
NI
AI
TR
2008-01-08 - de
R
32/40;V32/40PGI
FO
For the running-in of the new crankshaft bearing shells, see Section 3.
4 (6)
6629 021.04-01 EN
ON
LY

sequence
Flange bearing
Hexagon bolt
Hexagon bolt
Hexagon nut
Coupling side
RP
OS
E
14
32
36
38
39
K
S
021.04
MAN Diesel & Turbo
Work sequence 2 - Removing the flange bearing
FO
2008-01-08 - de
Starting position
Crankcase cover and covering on the coupling side removed, flywheel and
coupling supported, temperature sensor (if available) removed.

suspended loads!
6629 021.04-01 EN
32/40;V32/40PGI
TR

34 Flange bearing - lower section
31 Hexagon bolt
43 Taper pin
33 Flange bearing - upper part
Figure 3: Torque sequence for the axial fastening screws
AI
NI
NG
PU
Figure 2: Torque sequence for the radial fastening screws
5 (6)
021.04
MAN Diesel & Turbo
Work steps
1. Remove the flange bearing (32) (see work sequence 1, Points 1 to 6).
ON
LY
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 sequence 3 - Installing the flange bearing

Starting position
RP
OS
E
The contact face on the covering and the flange bearing, as well as the parting line between the upper and bottom part of the flange bearing are clean.

suspended loads!
Work steps
PU
1. Place the lower section of the flange bearing (34) onto a flat wooden
support 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.
NI
AI
TR
2008-01-08 - de
R
32/40;V32/40PGI
FO
NG
3. Fit the flange bearing (32) (see work sequence 1, Points 10 to 25).
6 (6)
6629 021.04-01 EN
Check components for condition/degree of wear, ensure/re-establish operating reliability.

The inspection of the external bearing of the crankshaft extension is not mentioned as such in the service schedule, but it should take place at the same
service interval as the rest of the crankshaft bearings.
Operating media systems closed/depressurised

1 Technician
PU
1 Assistant
Tools/aids required
Status
1 Ratchet tool
008.023
Standard
1 Torque wrench
008.017
Standard
1 Torque wrench
008.011
Standard
1 Power amplifier
008.030
Standard
2 Shackle A1.0
002.453
Standard
1 Adapter 12.5x20
001.927
Standard
001.911
Standard
001.858
Standard
000.451
Option
2 Ring nut M16
000.188
Standard
Inventory
2 Washer
Inventory
Inventory
1 Hexagon nut M10
Inventory
1 Washer
Inventory
Inventory
Inventory
NI
AI
TR
R
FO
2007-11-06 - de
Number
NG
Quan- Designation
tity
Duration in h
6632 023.01-01 EN
V32/40
Safety requirements
RP
OS
E
The work / work steps include:

Removing components,
Checking parts/ components,
Installing components.
Summary
ON
LY
Crankshaft extension
removing, fitting and checking with external bearing
023.01
MAN Diesel & Turbo
1 (5)
023.01
MAN Diesel & Turbo
Inventory
Inventory
Inventory
Inventory
3 Taper pin
13 Hexagon bolt
4 Parallel pin
14 Covering (two-part)
5 Hexagon bolt
15 Stud
6 Hexagon bolt
16 Hexagon nut
8 Hexagon bolt
17 Splash ring
9 Hexagon bolt
18 Casing (two-part)
11 Hexagon nut
19 Shaft end
12 Seal
20 Seal
Figure 1: Crankshaft extension with external bearing
1 Securing compound, Loctite 243

1 Sealing compound
Work card
000.11
000.30
Work card
RP
OS
E
Work card
ON
LY
Status
Number
Quan- Designation
tity
V32/40
Starting position
2 (5)
Work steps
21
23
24
26
27
28
Drain pipe
Sealing cord
Lower bearing shell
Upper bearing shell
Shaft seal
Washer (two-part)
Coupling supported, lube oil pipes removed, if mounted lube oil pumps
present, oil from pressure pipe drained, pressure pipes and lubricating oil
pump removed, any cooling water pumps and inlet and outlet pipes
removed.
1. Unscrew drain pipe (21) and remove.
6632 023.01-01 EN
2007-11-06 - de
FO
TR
AI
NI
NG
PU
Work sequence 1 Removing the covering with external bearing
2. Loosen cylinder screws of the two-piece casing (18) and screw in again
hand-tight.
4. Support casing with suitable means.
ON
LY
3. Unscrew hexagon head screws (8) and pull out casing (18) from the offset of the covering (14) without damaging splash collar (17).
023.01
MAN Diesel & Turbo
5. Unscrew the hexagonal bolts (9) and remove two-piece washer (28).
6. Unscrew cylinder screws of the two-piece casing (18), remove upper

and lower part of casing, then remove shaft seal (27).
7. Unscrew cylinder screws in the splash collar (17) and remove splash
collar.
RP
OS
E
8. Attach top half of covering (14) to the eye with shackle (002.453) and
attach rope to lifting tackle. Tension rope.
A ratchet hoist can also be used to lift the two halves of the covering.
This is attached to the cooling water pipes.
9. Remove the hexagon bolts (5) and bolted connections (11, 13).
Unscrew the hexagon bolts (6) (only upper half of the covering).
PU
10. Manually guide the top half of the covering (14) and use the lifting tackle
to pull it vertically upwards off the parallel pins (4). In doing so, ensure
that the top bearing shell (26) is not damaged by falling out.
11. Set the covering half down on a wooden support.
NG
12. Insert two hexagon bolts M16 (29) with washer (30) into the through
holes of the bottom half of the covering from below and screw on lifting
eye nuts (000.188) (see figure 2).
6632 023.01-01 EN
V32/40
4 Parallel pin
14 Casing
30 Washer
Figure 2: Attaching the bottom half of the covering
R
FO
2007-11-06 - de
TR
AI
NI
13. Attach the bottom half of the covering to the lifting tackle with two
shackles (002.453) and a rope. Tension rope.
3 (5)
023.01
MAN Diesel & Turbo
1. Screw hexagon bolt M10 with nut and washer into taper pins (3).
Tighten the hexagon nut, thereby extracting the taper pin.
2. Unscrew the hexagon bolts (6) (lower half of the covering).
ON
LY
3. Manually guide the bottom half of the covering (14), lower it with the lifting tackle and set it down on a wooden support.
Work sequence 2 Checking the bearing shells and bolted joint of the crankshaft
extension
Work steps
1. Check the tightening torque of the bolted connections (15, 16) (see
Work Card 000.30).
RP
OS
E
2. Check the bearing shells (24, 26) (see Work Card 000.11).
Under no circumstances should you attempt to reduce the clearance by

filing away or mechanical machining of the bearing shell joint faces, or
to scrape the bearing surfaces. New bearing shells are supplied ready
for fitting and must not be rescraped or machined in any way.
PU
Work sequence 3 - Removal of the crankshaft extension
NG
For normal maintenance work it is necessary to remove the crankshaft

extension.
Work steps
1. Attach the shaft end (19) to the lifting tackle with ropes and tighten the
ropes.
NI
TR
AI
3. Detach the gearwheel and use suitable means to support it on shaft

end.
4. Unscrew the hexagon socket bolts. Pull the shaft end (19) out of centring and set it down on a wooden support. Pay attention to the gearwheel in doing so.
Work steps
V32/40
4 (5)
Installation is basically in the reverse order of how it was removed. In doing

so, observe the following points.
1. When installing the shaft end (19), pay attention to the centring arrangement and the marking (OT1).
2. First of all, do up the hexagon nuts (16) hand-tight, then tighten them in
a diagonally opposite sequence with the first torque stage.
3. Subsequently tighten the nuts across the diagonals with the second
torque stage. Check all the nuts a second time.
6632 023.01-01 EN
2007-11-06 - de
Work sequence 4 - Installation of the crankshaft extension
FO
2. Undo and remove hexagon nuts (16) with torque wrench (008.017) and
torque multiplier (008.030).
Work sequence 5 Installation of the covering with external bearing
ON
LY
Installation is basically in the reverse order of how it was removed. In doing

so, observe the following points.
023.01
MAN Diesel & Turbo
Work steps
1. Coat the contact face of the covering (14) to the cylinder block and
crankcase and separating joint between the top part and bottom part of
the covering with SILICONE RHODORSIL CAF 730 sealing compound.
Do not coat area (A) and the sealing cord (23).
RP
OS
E
2. When installing the bottom half of the covering (14), loosely screw in the
hexagon bolts (6) hand-tight to begin with and tighten up with the prescribed torque (see Work Card 000.30) crosswise only after the taper
pins have been inserted.
3. Lock the bolts and screwed connections (5,6,8,13) with LOCTITE 243
and tighten up with the prescribed torque (see Work Card 000.30).
6632 023.01-01 EN
V32/40
R
FO
2007-11-06 - de
TR
AI
NI
NG
PU
All bolted connections having full length threaded holes must be oiltight (use LOCTITE). After complete fitting of the crankshaft extension
and covering, check the concentricity of the shaft end (19) and the
crank web deflection (see Work Card 000.10).
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
ON
LY
RP
OS
E
TR
R
FO
6632 027-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
Crankshaft
027
MAN Diesel & Turbo
1 (2)
MAN Diesel & Turbo
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
Crankshaft
027
2 (2)
6632 027-05 EN
RP
OS
E

removing the components,
refitting the components.
Safety requirements
Engine stopped
Tools/aids required
Quan- Designation
tity
Number
Status
027.033
Option
1 Screw-on plate
027.033-1
Option
1 Suspension plate
027.033-7
Option
2 Pipe
027.033-1
3
Option
1 Bracket
027.033-1
5
Option
2 Swivel ring bolt
027.033-2
7
Option
1 Power amplifier
008.030
Standard
1 Torque wrench
008.017
Standard
1 Shackle A2.0
002.455
Standard
2 Shackle A1.0
002.453
Standard
1 Shackle A0.6
002.452
Standard
001.912
Option
001.859
Standard
001.785
Standard
1 Ratchet tool
001.521
Option
000.141
Standard
1 Lifting tackle
Inventory
Inventory
2 Rope
Inventory
1 Socket spanner insert (set)
Inventory
Inventory
R
FO
2008-01-08 - de
TR
AI
NI
NG
PU
1 Removal and fitting fixture
6632 027.03-02 EN
Crankshaft
V32/40
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 specified intervals according to the maintenance schedule.
Summary
ON
LY
Torsional vibration damper of the crankshaft

removing and refitting
027.03
MAN Diesel & Turbo
1 (6)
MAN Diesel & Turbo

Work card
Work card
000.30
Technical data
Designation
Work card
ON
LY
Crankshaft
Information
Cover
28 kg
1295 kg
RP
OS
E
027.03
Preliminary remarks
NI
AI
4 Stud
6 Nut
8 Cover
V32/40
Work sequence 1 - Removing the torsional vibration damper
2 (6)
Starting position
The crankcase cover and the covering on the free engine end have been
removed.
6632 027.03-02 EN
2008-01-08 - de
TR
1 Crankshaft
3 Torsional vibration damper
Figure 1: Torsional vibration damper
FO
NG
PU
Each torsional vibration damper is a special component specifically designed

for an individual piece of equipment. Improper installation can lead to damage of the equipment or to the torsional vibration damper.
ON
LY

suspended loads!
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.
RP
OS
E
4. Unscrew and remove the nuts (6) from the stud bolts (4).
Crankshaft
027.03
MAN Diesel & Turbo
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
hexagon bolts (15) or nuts (16) onto suspension plate (see figure 3).
PU
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.
NG
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
suspend ropes from lifting tackle.
6632 027.03-02 EN
V32/40
R
FO
2008-01-08 - de
TR
15. Guide the torsional vibration damper outwards using the lifting tackle
and place it on the surface.
AI
NI
14. Slightly lift the torsional vibration damper. Remove supporting beam
(10), suspension plate (027.033-7) and bracket (027.033-15) and tubes
(027.033-13).
3 (6)
MAN Diesel & Turbo
NG
PU
RP
OS
E
ON
LY
Crankshaft
027.03
Hexagon socket bolt

Supporting beam
Hexagon bolt M16x100
Hexagon bolt M16x100

15 Rope
2008-01-08 - de
TR
AI
NI
9
10
11
12
V32/40
FO
1 Crankshaft
4 Stud
Figure 2: Attached removal and fitting fixture
4 (6)
6632 027.03-02 EN
RP
OS
E

Figure 3: Screwing-on and suspension plate
Crankshaft
ON
LY
027.03
MAN Diesel & Turbo

16 Hexagon nut M16

suspended loads!
6632 027.03-02 EN
V32/40

15 Rope
a max. 60
Figure 4: Lifting and transporting the torsion vibration damper
R
FO
2008-01-08 - de
TR
AI
NI
NG
PU
Work sequence 2 - Transporting the torsional vibration damper
5 (6)
MAN Diesel & Turbo

The torsional vibration damper may only be transported in a horizontal position. Use only the slings (027.033-27) provided for the purpose. Both during
removal and during transport, the torsional vibration damper must be suspended from at least two attachment points (see figure 4).
Work sequence 3 - Mounting the torsional vibration damper
ON
LY
Crankshaft

suspended loads!
RP
OS
E
027.03
The mounting of the torsional vibration damper is done in reverse sequence.

In doing so, observe the following points:
1. Remove all corrosion preventative from the new rotation vibration
damper before fitting.
2. When fitting take note of the centring and marking on the crankshaft
rotation vibration damper and do not damage it.
PU
3. Apply MoS2 lubricant on threads and contact face of the studs (4) and
nuts (6) and tighten the nuts hand-tight. Hold the internal nuts in position with a ring spanner and tighten the external nuts with a power
amplifier (008.030) and torque wrench (008.017), crosswise (see Work
Card 000.30).
NG
To achieve the specified torque, follow the Operating Instructions

supplied with the power amplifier (008.030) and set the torque wrench
(008.017) accordingly.
NI
AI
5. Before commissioning the engine the rotary vibration damper must be

supplied with pressurised oil using the priming pump until oil comes out
of the circulation holes in the side discs.
2008-01-08 - de
TR
4. Dismantle the complete removal and fitting tool.
V32/40
FO
Use caution when tightening the bolted connections with a torque

wrench and force amplifier in order to avoid slipping off the nuts (6).
6 (6)
6632 027.03-02 EN
RP
OS
E
The work/ work steps include:

Disassembling components,
Assembling components,
Checking components.
Quan- Designation
tity
Status
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
Inventory
2 lifting eye bolt (high-strength design)
Inventory
2 Shackle
Inventory
1 Lifting tackle
Inventory
2 Rope
Inventory
1 Hammer
Inventory
1 Rubber mallet
Inventory
1 Centre-punch
Inventory
1 Brass wedge
Inventory
Inventory
Inventory
Inventory
1 Lubricating oil, clean
Inventory
1 Silicone grease
Inventory
R
FO
2009-01-23 - de
TR
AI
NI
PU
Number
NG
Tools/aids required
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.
6682 027.04-01 EN
Crankshaft
General
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.
Summary
ON
LY

inspecting
027.04
MAN Diesel & Turbo
1 (10)
MAN Diesel & Turbo

The manufacturer's instructions must be followed when carrying out work on
the torsional vibration damper.
Crankshaft
RP
OS
E
ON
LY
Lifting eye bolts, shackles and lifting tackle must be appropriately selected
for the respective torsional vibration damper.
NI
AI
TR
15 Bearing bush
750 Hexagon bolt
810 Cup spring
9 Inner star
850 O-ring seal
General
2 (10)
Figure 1: Torsion vibration damper*
6682 027.04-01 EN
851 O-ring seal

I Torsional vibration damper
without bearing bush
II Torsional vibration damper
with bearing bush
2009-01-23 - de
1 Spring pack
5 Flange
7 Side plate
FO
NG
PU
027.04
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.
ON
LY
Starting position
Do not stand under suspended loads unless absolutely necessary!
Work steps
RP
OS
E
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.
Crankshaft
Work sequence 1 - Disassembling and checking torsional vibration damper
027.04
MAN Diesel & Turbo
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 support. See Fig. 2/II.
6. Remove slings.
PU
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 permissible wear limit.
NG
Exchange of the complete torsion vibration damper
NI
Replace the torsion vibration damper when the threshold values

indicated on the data sheet are exceeded.
R
FO
2009-01-23 - de
TR
tackle. See Fig. 3/V.
12. Carefully lift inner star (9) from spring pack (1) and place on wooden
support. Do not tilt inner ring or damage adjacent components in the
process. See Fig. 3/V.
13. Remove slings.
14. Check sealing surfaces of the inner star (9). Refer to data sheet for permissible wear limit.

15. Screw lifting eye bolts into spring packet (1). See fig. 3/VI.
6682 027.04-01 EN
General
AI
10. Screw lifting eye bolts into inner star (9). See Fig. 3/V.
9. Checking the permissible wear limit with measuring wedge or sliding

calliper. See work sequence 2 - Measuring the wear limit.
3 (10)
MAN Diesel & Turbo

tackle. See fig. 3/VI.
Crankshaft
17. Lift spring pack (1) and place on wooden support. See fig. 3/VI.
ON
LY
18. Remove slings.
19. Check sealing surfaces of the flange (5). Refer to data sheet for permissible wear limit.

RP
OS
E
027.04
20. Remove O-ring seals (850 and 851) from flange (5) and spring packet
(1). See Figure 3/VII.
21. Clean all the components.
Work sequence 2 - Measuring the wear limit
Number of measuring points:
PU
Approximately every fourth spring pack shall be checked.
Measuring wedge
1. Place measuring wedge between spring-leaf tips at the base of groove.
NG
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.
NI
General
4 (10)
1. Place brass wedge between the spring-leaf tips approx. 10 mm above

the base of groove.
2. Press brass wedge down (manually or using a rubber mallet) until both
sides of the spring-leaf tips are in contact with the groove flanks.
3. Measure dimension between the spring-leaf tips and enter results into
measurement log.

6682 027.04-01 EN
2009-01-23 - de
TR
Sliding calliper
AI
The torsional vibration damper must be replaced when the measuring

wedge can be inserted between the spring leaf end up to the parallel
end (max. marking).
FO
All parts cleaned and lightly oiled with clean lubricating oil.
ON
LY
Starting position
Work steps
1. Insert a new O-ring seal (850) wetted with clean lubricating oil in the
sealing ring groove of the flange (5). Make sure that it is evenly tensioned along the entire circumference and is not twisted.
2. Screw lifting eye bolts into spring packet (1).
tackle.
4. Lift spring pack (1) over flange (5). In doing so, pay attention to the
marking.
RP
OS
E
lower sealing ring groove of the spring packet (1). Make sure that it is
evenly tensioned along the entire circumference and is not twisted.
Apply silicone grease to the O-ring seal at several points to prevent it
from falling out during the assembly.
Crankshaft
Work sequence 3 - Assembling the torsionial vibration damper
027.04
MAN Diesel & Turbo
6. Screw two hexagon bolts (750) into the guide. See Fig. 4.
7. Lower spring pack (1) over flange (5).
PU
8. Use a dial gauge with magnetic post or sliding calliper to align spring
packet (1) with the flange (5). Take the maximum permissible radial runout into account (see drawing).
9. Remove slings.
10. Use two hexagon bolts (750) and old cup springs (810) as spacer
washers to screw down the spring packet (1) on the flange (5). See Fig.
4.
NG
11. Unscrew the guide bolts from work step 6.

12. Screw lifting eye bolts into inner star (9).
13. Attach rope with shackle to lifting eye bolt and suspend from lifting
tackle.
R
FO
2009-01-23 - de
TR
16. Remove slings.

17. Unscrew fixing screws from spring pack.
sealing ring groove of the spring packet (1). Make sure that it is evenly
tensioned along the entire circumference and is not twisted.
19. Screw lifting eye bolts into side plate (7).
tackle.
21. Lift side plate (7) over the spring pack (1). In doing so, pay attention to
the marking.
6682 027.04-01 EN
General
AI
15. Align inner star (9) with the spring pack (1). Provide even clearance
between inner ring and spring packet in the process.
NI
14. Carefully insert inner star (9) into spring pack (1). Do not tilt inner ring or
damage adjacent components in the process.
5 (10)
MAN Diesel & Turbo
ON
LY
lower sealing ring groove of the side plate (7). Make sure that it is evenly
tensioned along the entire circumference and is not twisted. Apply silicone grease to the O-ring seal at several points to prevent it falling out
during the assembly.
Crankshaft
23. Carefully lower side plate (7) over the spring pack (1).
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 permissible radial run-out into account (see drawing).
25. Remove slings.
26. Place new cup springs (810) coated with Loctite on both sides over the
holes in the side plate (7).
RP
OS
E
027.04
27. Apply MoS2 lubricant to threads and contact faces of hexagon bolts
(750). Screw in hexagon bolts, tighten with contact torque (see table)
until cup springs are completely pressed down. Subsequently tighten
up with the prescribed torsion angle (see data sheet).
cup springs must have flat contact!
PU
If the cup springs do not have flat contact, the tightening torque of the
hexagon bolts becomes distorted.
Correct tightening of the hexagon bolts
NI
AI
TR
2009-01-23 - de
R
General
FO
NG
First of all, tighten four hexagon bolts in a diagonally opposed

sequence. Tighten the remaining bolts in a circle. In the case of
torsional vibration dampers with two hole circles, the inner one must be
tightened first and then the outer one.
6 (10)
6682 027.04-01 EN
6682 027.04-01 EN
I-IV Work steps
Crankshaft
General
1001 Measuring wedge
1 Spring pack
750 Hexagon bolt
5 Flange
810 Cup spring
7 Side plate
850 O-ring seal
9 inner star
851 O-ring seal
Figure 2: Dismantling and assembling the torsional vibration damper
FO
2009-01-23 - de
TR
AI
NI
NG
PU
RP
OS
E
ON
LY
027.04
MAN Diesel & Turbo
7 (10)
MAN Diesel & Turbo
NI
AI
General
8 (10)
6682 027.04-01 EN
851 O-ring seal

V - VII Work steps
2009-01-23 - de
TR
R
1 Spring pack
9 inner star
5 Flange
850 O-ring seal
FO
NG
PU
RP
OS
E
ON
LY
Crankshaft
027.04
ON
LY
RP
OS
E
Crankshaft
027.04
MAN Diesel & Turbo
NG
M8
8 Nm
13 Nm
M 12
21 Nm
M 14
30 Nm
M 16
40 Nm
M 18
50 Nm
M 20
70 Nm
M 22
100 Nm
M 24 - with 2.5 mm cup-spring width
105 Nm
M 24 - with 3.6 mm cup-spring width
125 Nm
M 27 - with 3 mm cup-spring width
177 Nm
M 27 - with 4 mm cup-spring width
160 Nm
M 30
205 Nm
M 33
345 Nm
M 36
350 Nm
AI
NI
M 10
TR
R
FO
2009-01-23 - de
Contact torque
Table 1: Contact torque for cup springs*

*
The values only apply when the specified installation specifications for bolts
are complied with: "Thread lubricated or treated with Molykote and Loctite
applied to both sides of cup springs."
See drawing by Co. Geislinger
6682 027.04-01 EN
General
Nominal width of cup spring
PU
1 Spring pack
750 Hexagon bolt
5 Flange
810 Cup spring
9 (10)
MAN Diesel & Turbo
NI
AI
Shape and size of the torsion vibration damper may differ from the illustration in the figures
General
10 (10)
6682 027.04-01 EN
2009-01-23 - de
TR
R
Figure 5: Sample of a data sheet
FO
NG
PU
RP
OS
E
ON
LY
Crankshaft
027.04
030
TR
R
FO
6632 030-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
030
ON
LY
RP
OS
E
PU
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
NG
111
112
113/114
120
125
140
160-162
FO
MAN Diesel & Turbo
2 (2)
6632 030-05 EN
Summary
ON
LY
Conrod shank bolts

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.
Engine stopped
PU
1 Technician
Duration in h
1 Assistant
Tools/aids required
Status
2 Tension nut
030.539
Standard
2 Thrust piece
030.538
Standard
009.664
Standard
2 Measuring device
009.446
Standard
2 Dial gauge
009.444
Standard
009.342
Standard
009.320
Standard
009.306
Standard
000.451
Option
1 Tommy bar, 6
000.261
Standard
NI
AI
TR
R
FO
2008-12-16 - de
Number
NG
Quan- Designation
tity
Work card
Work card
Work card
000.30
000.32
009.03
Work sequence 1 - Checking the conrod shank bolts

Starting position
Crankcase is open, running gear of the corresponding cylinder is at BDC.
6629 030.01-02 EN
L32/40;L32/40CR;V32/40;V32/40PGI
Safety requirements
RP
OS
E

030.01
MAN Diesel & Turbo
1 (5)
030.01
MAN Diesel & Turbo
Work steps
1. Clean the threads of the conrod shank bolts (8).
ON
LY
2. Mount the hydraulic tensioners onto the conrod shank bolts (1 and 3).
See Fig. 1.
When hydraulic tensioners are installed, the running gear may not be
turned.
3. Turn the tensioners (009.664) back by 290.
RP
OS
E
4. Connect the high-pressure hoses (009.306) to the hydraulic tensioners

5. Set the high-pressure pump or the hydraulic hand pump in operation
(see Work Card 009.03) and close the gap created while it was being
turned back between the thrust piece (030.538) and the tensioner.
Make a note of the release pressure and compare it to the clamping
pressure.
PU
NG
7. Adjust high-pressure pump to the specified clamping pressure or activate hydraulic hand pump up to the specified clamping pressure and
tighten both nuts.
8. Release the pressure and detach the Hydraulic tensioners.
NI
9. Repeat the process (points 2 to 8) in the same way for the conrod
shank bolts (2 and 4).
3. Rotate the nuts (7) back (for turn back angle see Work Card 000.30).
4. Release the pressure and detach the hydraulic tensioners.
Work sequence 3 - Tightening the conrod shank bolts

Starting position
Work steps
Running gear is in BDC, connecting rod shank is attached to the big-end

bearing (see Work Card 034.01). Nuts are screwed on
1. Tighten the nuts (7) of the conrod shank bolts with the tommy bar
2. Check that the overall circumference of the parting line between the
connecting rod shank (5) and the big-end bearing (6) is < 0.05 mm.
6629 030.01-02 EN
2008-12-16 - de
TR
2. Untighten the conrod shank bolts (1 and 3) (see work sequence 1,

points 2 to 6).
FO
2 (5)
1. Clean the threads of the conrod shank bolts (8).
AI
Work steps
L32/40;L32/40CR;V32/40;V32/40PGI
Work sequence 2 - Untightening the conrod shank bolts
3. Mount the hydraulic tensioner onto the conrod shank bolts (1 and 3).
See Fig. 2.
ON
LY
4. Connect the high-pressure hoses (009.306) to the hydraulic tensioners

(009.664) and to the high-pressure pump or the hydraulic hand pump.
5. Mount measuring devices (009.446) on tensioners using measuring
gauge (009.444).

(see Work Card 009.03) and tighten the conrod shank bolts (8) with a
50 bar pressure. Set measuring gauges to "Zero".
7. Tighten the conrod shank bolts (8) to the specified pressure (see Work
Card 000.30). Tighten both nuts (7) hand-tight.
RP
OS
E
030.01
MAN Diesel & Turbo
9. Tighten the conrod shank bolts (8) again using 50 bar pressure. Read
off elongation L on the dial gauges and compare with the specified
value (see Work Card 000.30).
PU
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
deviations and check the measuring devices or pressure gauges. As a
result of irregular circumstances, the conrod shank bolts can be
permanently elongated. The conrod shank bolt, having an as-new
dimension of 253 +/- 0.1 mm may only be permanently extended by 0.5
mm, i.e. if the length of 253.6 mm (untensioned) is exceeded the
conrod shank bolt must be replaced.
NG
10. Release the pressure and detach the Hydraulic tensioners.
6629 030.01-02 EN
L32/40;L32/40CR;V32/40;V32/40PGI
R
FO
2008-12-16 - de
TR
AI
NI
3 (5)
030.01
NI
AI
TR
2008-12-16 - de
1 - 4 Marking the tightening

6 Big-end bearing
10 Balance weight
sequence
5 Connecting rod shank
8 Conrod shank bolt
Figure 1: Arrangement of the tensioners/running gear adjustment. Tightening sequence (figure shows in-line engine)
FO
L32/40;L32/40CR;V32/40;V32/40PGI
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
4 (5)
6629 030.01-02 EN
PU
RP
OS
E
ON
LY
030.01
MAN Diesel & Turbo
6629 030.01-02 EN
L32/40;L32/40CR;V32/40;V32/40PGI
R
FO
2008-12-16 - de
TR
AI
NI
NG

Figure 2: Arrangement of the hydraulic tensioner and the measuring device with
measuring gauge
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Summary
ON
LY
Big-end bearing bolts

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.
Engine stopped
PU
1 Technician
Duration in h
1 Assistant
Required tools/Auxiliary equipment
Status
2 Thrust piece
030.243
Standard
2 Magnetic measuring stand
009.446
Standard
2 Dial gauge
009.444
Standard
009.342
Standard
009.320
Standard
009.306
Standard
009.097
Standard
000.451
Option
1 Tommy bar, 10
000.263
Option
NI
AI
TR
R
Number
NG
Quan- Designation
tity
FO
2010-01-12 - de

Work card
Work card
Work card
000.30
000.32
009.01
009.03
6629 030.02-02 EN
32/40;32/40DF;V32/40PGI
Safety requirements
RP
OS
E

030.02
MAN Diesel & Turbo
1 (4)
030.02
MAN Diesel & Turbo
Work sequence 1 - Checking the big-end bearing bolts

Starting position
PU
RP
OS
E
ON
LY
Crankcase is open, crank pin of the relevant cylinder is vertically at the top on
in-line engines (running gear at TDC), on V engines vertically at the bottom.
The foot board (special tool) is placed in the oil sump or the oil sump has
been cleaned using an appropriate agent.
1 Big-end bearing body

2 Big-end bearing cap
Figure 1: Attaching the hydraulic tensioners to the big-end bearing bolts
Work steps
1. Clean the threads of the big-end bearing bolts (5).
NG
2. Mount hydraulic tensioners on both big-end bearing bolts (5), whilst

doing so take the centring into account (see figures 1 and 2).
NI
AI
2 (4)

(see Work Card 009.03) and close the gap created while it was being
turned back between the thrust pieces (030.243) and the big-end bearing cap (2).
Make a note of the release pressure and compare it to the clamping
pressure.
6629 030.02-02 EN
2010-01-12 - de
FO
TR
32/40;32/40DF;V32/40PGI
When hydraulic tensioners are installed, the running gear must not be
turned. Before mounting the tensioning cylinder, ensure that the
pistons are fully pressed in.
ON
LY
030.02
MAN Diesel & Turbo
7. 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 the nuts (3).
9. Remove the foot board (if available) from the oil sump.
RP
OS
E
Work sequence 2 - Releasing the connecting rod bearing bolts

Work steps
1. Release big-end bearing bolts (see work sequence 1, points 1 to 6).

2. Rotate the nuts (3) back (for turn back angle see Work Card 000.30).
Work sequence 3 - Tightening the connecting rod bearing bolts
Starting position
Work steps
Big-end bearing is pre-assembled (see Work Card 030.03); in in-line engines,

the crank pin of the relevant cylinder points vertically upwards (running gear
at TDC), and points vertically downwards in V-engines.
1. Tighten the nuts (3) of the big-end bearing bolts with the tommy bar
6629 030.02-02 EN
32/40;32/40DF;V32/40PGI

5 Big-end bearing bolt
3 Nut
Figure 2: Sectional view of the hydraulic tensioner/Positioning of the dial gauge
R
FO
2010-01-12 - de
TR
AI
NI
NG
PU
3 (4)
030.02
MAN Diesel & Turbo
2. Check that the gap where the big-end bearing body (1) meets the bigend bearing cap (2) is equal on both sides.
ON
LY
3. Mount the hydraulic tensioners on the big-end bearing bolts (5) (see Fig.
1).
RP
OS
E

(009.097) and high-pressure pump or hydraulic hand pump.
5. Offer up the magnetic measuring stand (009.446) to the tensioning cylinder (see Fig. 2).
009.03) and tighten big-end bearing bolts with a pressure of 500 bar.
Set the dial gauges (009.444) to "zero".
7. Tighten big-end bearing bolts to prescribed pressure (see Work Card
000.30). Tighten both nuts (3) hand-tight.
PU
9. Retighten big-end bearing bolts with a pressure of 500 bar. Read off
elongation L on the dial gauges and compare with the specified value
NI
AI
11. Remove the foot board (if available) from the oil sump.
12. Retract the piston of the tensioning cylinder (see Work Card 009.01).
FO
2010-01-12 - de
TR
32/40;32/40DF;V32/40PGI
NG
Tighten the big-end bearing bolts using the specified clamping

pressure, 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
permanently 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
conrod shank bolt must be replaced.
4 (4)
6629 030.02-02 EN
RP
OS
E

Safety requirements
Tools/aids required
Number
Status
030.319
Standard
1 Wire rope
200.067
Standard
1 Rope guide
030.321
Standard
1 Screw-on plate
030.320
Standard
1 Rope clamp
030.319-7
Standard
1 Support fixture
030.271
Standard
2 Extension pipe
030.269
Standard
2 Guide tube
030.268
Standard
1 Rope guide
030.262
Standard
1 Rope guide
030.261
Standard
2 Bracket
030.250
Standard
2 Thrust piece
030.243
Standard
009.342
Standard
009.320
Standard
009.306
Standard
009.097
Standard
1 Bolt extractor
009.089
Option
1 Ring nut
009.089-1
Option
1 Ring nut
009.089-2
Option
1 Ratchet tool
008.023
Standard
1 Torque wrench
008.011
Standard
2 Shackle A0.6
002.452
Standard
R
FO
2007-10-24 - de
TR
AI
NI
NG
PU
Quan- Designation
tity
6632 030.03-02 EN
V32/40
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.
Summary
ON
LY
Lowering big-end bearing cap/Removing big-end bearing bolt/

checking lower big-end bearing shell
030.03
MAN Diesel & Turbo
1 (7)
030.03
MAN Diesel & Turbo

Number
Status
1 Feeler gauge (set)
000.451
Option
Inventory
Inventory
1 Depth gauge

Work card
000.11
030.02
Technical data
Designation
Work card
030.04
RP
OS
E
Work card
ON
LY
Quan- Designation
tity
Information
Bearing shell
Big-end bearing cap
Preliminary remarks
2,5 kg
44,5 kg
NG
PU
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 bearing shell be taken out (see Work Card 030.04). Bearing shells can be
replaced as half-shells.
V32/40
2 (7)
AI
Big-end bearing bolts are released (see Work Card 030.02 and figure 1 A).
Drive gear is turned so that the crankshaft balance weight of the relevant cylinder points vertically upwards.
1. Affix two supports (030.250) to the big-end bearing cap (6) and the bigend bearing body (10).
2. Unscrew the nuts.
3. Only remove the big-end bearing bolts (4) as follows, if, subsequent to
checking the lower bearing shell, removal of the upper bearing shell in
accordance with Work Card 030.04 is intended. Otherwise continue at
step 8.
4. Mount the bolt extractor (009.089) onto the big-end bearing bolts (pay
attention to projection A in figure 2).
5. Release the big-end bearing bolts, unscrew them and remove.
6. Remove bolt extractor.
7. Turn the crankshaft by 20 25 (in the direction of the big-end bearing
to be removed) (see figure 3).
6632 030.03-02 EN
2007-10-24 - de
TR
Work steps
FO
Starting position
NI
Work sequence 1 - Lowering the big-end bearing cap/Removing the big-end bearing
bolts
8. Affix two rope guides (030.261 and 030.262) to balance weights (8) so
that these can still be moved.
ON
LY
9. Screw the rope guide (030.321) to the cylinder crankcase (2) (see figure
3, View Y).
030.03
MAN Diesel & Turbo
The engine must no longer be allowed to turn as from this assembly

step (rope guides).
RP
OS
E
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 (030.319-7)
(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 (030.271) to the screw-on plate depending
upon the relevant cylinder bank
(see figure 3, View X).
PU
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).
NG
16. Remove the rope guides between the balance weights and the wire
rope.
6632 030.03-02 EN
V32/40
R
FO
2007-10-24 - de
TR
AI
NI
17. Clean the running surface of the big-end bearing shell (13).
3 (7)
030.03
NI
AI
TR
V32/40
4 (7)
Crankshaft
Big-end bearing cap
Balance weight
Big-end bearing body
2007-10-24 - de

5
6
3 Oil pan
8
10
Figure 1: Removing the big-end bearing bolts
FO
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
6632 030.03-02 EN
ON
LY
Big-end bearing bolt

Big-end bearing cap
O-ring seal
Stud M10
Hexagon nut
Projection A = 53 mm
RP
OS
E
4
6
10
17
18
19
A
030.03
MAN Diesel & Turbo
PU
Figure 2: Image of the assembled bolt extractor and the big-end bearing bolt
Work sequence 2 - Checking the lower big-end bearing shell

Big-end bearing cap is lowered into the oil sump.
NG
Starting position
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).
Damaged or worn-out big-end bearing shells must be replaced.
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.
6632 030.03-02 EN
V32/40
R
FO
2007-10-24 - de
TR
Work steps
AI
NI
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,
especially in the event that damage has been detected on the upper
bearing shell.
5 (7)
030.03
MAN Diesel & Turbo
ON
LY
New bearing shells are delivered ready for installation. Neither the joint face
for bearing shells in use nor new ones should be filed off or mechanically processed in order to achieve a clearance reduction since this would lead to a
smaller clearance, whereas the bearing shells would no longer be able to be
clamped into the big-end bearing body and cap with sufficient hold. Likewise, under no circumstances should any additional scraping be performed
to the running surface.
1. Insert the lower big-end bearing shell into the big-end bearing cap (the
back of the big-end bearing shell is oil dry).
Work sequence 3 - Fitting the big-end bearing cap
Bearing shell has been cleaned, running surface is well lubricated, big-end
bearing bolts have been cleaned and threads are dry, running gear is positioned as shown in figure 3.
Work steps
The installation procedure is the same as the removal procedure but in

reverse. In doing so, observe the following points:
RP
OS
E
Starting position
1. When joining the big-end bearing cap (6) to the big-end bearing body
(10) take note of the locating pins.
2. When installing the big-end bearing bolts (4), proceed as follows:
3. Crankshaft (5) turned so that the balance weight (8) is vertical (see figure 1 B).
PU
4. Manually screw in the inner big-end bearing bolts from below through
the big-end bearing cap into the big-end bearing body until the contact
surface of the big-end bearing bolts abut the big-end bearing body (see
figure 2).
NG
5. Screw the nuts on manually until they abut the contact surface of the
big-end bearing cap.
NI
6. Once you have tightened the big-end bearing bolts, measure the bearing clearance by inserting a feeler gauge (000.451) to a depth of roughly
10 mm from the coupling side and free engine end.
AI
TR
2007-10-24 - de
R
V32/40
FO
Record the values in the operating log sheets.
6 (7)
6632 030.03-02 EN
R
FO
2007-10-24 - de
TR
AI
Figure 3: Lower the big-end bearing cap

11 Hexagon bolt
13 lower big-end bearing
shell
6632 030.03-02 EN
V32/40

7 Hexagon nut
8 Balance weight
NI
3 Oil pan
5 Crankshaft
NG
PU
RP
OS
E
ON
LY
030.03
MAN Diesel & Turbo
7 (7)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Upper big-end bearing shell

ON
LY
Summary
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.
RP
OS
E
Engine stopped
PU
1 Technician
1 Assistant
NG
Tools/aids required
Number
Status
030.319
Standard
1 Bracket
030.322
Standard
1 Supporting device (for easy-running piston)
030.516
Standard
1 Support (for easy-run piston)
030.515
Standard
1 Carrier (upper)
030.515-1
Standard
1 Carrier (lower)
030.515-2
Standard
Inventory
AI
NI
Quan- Designation
tity
TR
Duration in h
FO
2007-10-25 - de

Work card
Work card
000.11
030.03
Work card
Technical data
Designation
Information
Bearing shell
2,5 kg
6632 030.04-03 EN
V32/40

Safety requirements
030.04
MAN Diesel & Turbo
1 (4)
030.04
MAN Diesel & Turbo
Work steps
The big-end bearing bolts have been removed, the big-end bearing cap has
been placed in the support fixture, the running gear is positioned in BDC.
1. Wire rope and rope guides (see Work Card 030.03) removed or dismantled.
2. Removing the extension pipes (030.269) from the guide tubes
(030.268) and putting to one side.
3. Turn the drive gear so that the crank pins on the crankshaft (5) are horizontal.
4. Screw a support (030.515) for the easy-running piston (24) on to cylinder liner (15) (see figure 2, View X).
V32/40
5. Carefully turn the pistons downwards until they touch the surface.
2 (4)
6632 030.04-03 EN
2007-10-25 - de
TR
Starting position
AI
NI
15 Cylinder liner
3 Oil pan
22 Connecting rod
24 Easy-running piston
8 Balance weight
A Cylinder bank A
B Cylinder bank B
Figure 1: Attached tools for checking the upper big-end bearing shell
FO
NG
PU
RP
OS
E
ON
LY
Work sequence 1 - Removing the upper big-end bearing shell
ON
LY
While turning the pistons, ensure that the big-end bearing body follows
the crankshaft.
030.04
MAN Diesel & Turbo
6. Attach the support (030.322) to the cylinder crankcase (2).
7. Fasten the big-end bearing body (10) using the hexagon bolt (1) to the
holder (see figure 2).
RP
OS
E
8. Turn the crank pin downwards as far as possible until the big-end bearing shell (16) can be easily accessed (see figure 2).
When turning the crank pin away, observe the big-end bearing shell to
ensure that it does not fall out or is damaged.
9. Remove the big-end bearing shell.
7 Hexagon nut M12
5 Crankshaft
8 Balance weight
15 Cylinder liner
Figure 2: Fitted tool and turning out the crank pin
6632 030.04-03 EN
16 Upper big-end bearing

shell
24 Easy-running piston
V32/40
R
FO
2007-10-25 - de
TR
AI
NI
NG
PU
10. Check the big-end bearing shell (see Work Card 000.11), if necessary,
replace it.
3 (4)
030.04
MAN Diesel & Turbo
Work sequence 2 - Installing the upper big-end bearing shell

Starting position
ON
LY
The big-end bearing shell has been cleaned, the rear is oil dry, the running
surface is well lubricated.
RP
OS
E
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.
New bearing shells are supplied ready to install. Neither the joint faces
for bearing shells in use nor new ones should be filed off or
mechanically processed in order to achieve a clearance reduction since
this would lead to a smaller clearance, and the bearing shells would no
longer be able to be clamped into the big-end bearing body and cap
with sufficient hold. Likewise, under no circumstances should any
additional scraping be performed to the running surface.
PU
The installation procedure is the same as the removal procedure but in

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.
NI
AI
TR
2007-10-25 - de
R
V32/40
FO
NG
When turning the crankshaft into the BDC position, ensure that the
support (030.515) has been removed and that the connecting rod with
the pistons follows the movement of the crankshaft.
4 (4)
6632 030.04-03 EN
Ensure correct execution of work, allow emergency mode.

Big-end bearings do not need to be removed when performing normal maintenance work. This is necessary only in special cases, e.g. emergency operation of the engine with dismantled running gear and closed oil hole.

1 Technician
PU
1 Assistant
Tools/aids required
030.313
Standard
1 Screw-on plate
030.320
Standard
1 Slide piece
030.313-1
0
Standard
030.313-2
0
Standard
1 Support
030.313-3
0
Standard
1 Guide rod
030.313-4
0
Standard
1 Plate
030.313-4
5
Standard
1 Strap
030.244
Standard
1 Turning stirrup
030.260
Standard
1 Shackle A0.6
002.452
Standard
000.451
Option
1 Tommy bar, 10
000.263
Option
000.141
Standard
1 Lifting tackle
Inventory
NI
AI
TR
R
FO
Status
1 Bracket
2008-01-08 - de
Number
NG
Quan- Designation
tity
Duration in h
6632 030.05-03 EN
V32/40
Safety requirements
RP
OS
E

Summary
ON
LY
Big-end bearing
030.05
MAN Diesel & Turbo
1 (11)
030.05
MAN Diesel & Turbo

Number
Status
Inventory
1 Rope
Inventory

Work card
Work card
030.02
034.01
Designation
Work card
RP
OS
E
Technical data
ON
LY
Quan- Designation
tity
Information
Big-end bearing cap

44,5 kg
48,5 kg
Work sequence 1 - Removing the big-end bearing

Starting position
PU
Big-end bearing bolts released, big-end bearing with turning stirrup (030.260)
fixed to the balance weight, piston and connecting rod shank removed.
NG

suspended loads!
Work steps
1. Turn the crankshaft (5) until the big-end bearing is horizontal (see figure
1).
NI
AI
3. Fit the sliding block (030.313-10) to the big-end bearing cap (6) (see figure 1).
V32/40
2 (11)
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
position.
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 sliding block (see figure 3).
6632 030.05-03 EN
2008-01-08 - de
TR
4. Remove turning stirrup (030.260) whilst holding the big-end bearing

with the slide piece.
FO
2. Unscrew the nut (3) from the lower connecting rod bolt (4).
8. Unscrew a conrod shank bolt (7) at the bottom of the big-end bearing
body (10).
ON
LY
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).
030.05
MAN Diesel & Turbo
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).
11. Mount the bracket (030.313-20) on the screw-on plate.
12. Unscrew the nut (3) from the upper connecting rod bolt (4).
RP
OS
E
13. Carefully pull the big-end bearing body outwards (see figure 5).
When extracting, make sure the big-end bearing shell (15) does not fall
out and therefore become damaged.
14. Take out big-end bearing shell (15).
15. Fix the strap (030.244) onto the big-end bearing body. Screw the lifting
eye bolt (000.141) into the strap.
PU
16. Fasten the rope (17) with shackle (002.452) to the lifting eye bolt. Hook
the rope onto the lifting tackle and tighten.
17. Pull the big-end bearing body out completely taking care not to damage the big-end bearing bolts (4).
NG
18. Lift the big-end bearing body and place onto a wooden support.
Remove the strap from the big-end bearing body.
TR
20. Pull the big-end bearing cap outwards (see figure 6).
R
FO
2008-01-08 - de
When extracting, make sure the big-end bearing shell (14) does not fall
out and therefore become damaged.
21. Take out big-end bearing shell (14).

22. Fix the strap (030.244) onto the big-end bearing cap.
23. Fasten the rope (17) with shackle (002.452) to the lifting eye bolt. Hook
the rope onto the lifting tackle and tighten.
24. Lift big-end bearing cap and place on wooden support. Remove the
strap from the big-end bearing cap.
25. Clean individual parts.
6632 030.05-03 EN
V32/40
AI
19. Remove the bracket and screw-on plate and fit on the opposite side
(see figure 6).
NI
When putting down the big-end bearing body, make sure that the bigend bearing bolts and the conrod shank bolts are not damaged.
3 (11)
030.05
RP
OS
E
ON
LY
MAN Diesel & Turbo
NI
AI
TR
2008-01-08 - de
R
V32/40
FO
NG
PU

3 Nut
8 Balance weight
5 Crankshaft
11 Stud
Figure 1: Big-end bearing fixed onto balance weight, slide piece fitted to big-end
bearing cap
4 (11)
6632 030.05-03 EN

9 Cylinder crankshaft

11 Stud
6632 030.05-03 EN
V32/40
R
FO
2008-01-08 - de
TR
AI
NI
NG
2 Hexagon bolt
5 Crankshaft
Figure 2: Installation of support in crankcase
PU
RP
OS
E
ON
LY
030.05
MAN Diesel & Turbo
5 (11)
030.05
RP
OS
E
ON
LY
MAN Diesel & Turbo

NI
AI
TR
2008-01-08 - de
R
V32/40
FO
NG
PU
3 Nut
5 Crankshaft
Figure 3: Big-end bearing placed on support
6 (11)
6632 030.05-03 EN
7 Conrod shank bolt

11 Stud
12 Hexagon nut M12
6632 030.05-03 EN
V32/40
R
FO
2008-01-08 - de
TR
AI
NI
NG

5 Crankshaft
Figure 4: Big-end bearing with tool attached
PU
RP
OS
E
ON
LY
030.05
MAN Diesel & Turbo
7 (11)
030.05
7 Conrod shank bolt

13 Locating pin
15 Upper big-end bearing

shell
17 Rope
NI
AI
TR
2008-01-08 - de
R
V32/40
FO
NG
5 Crankshaft
Figure 5: Big-end bearing body removed
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
8 (11)
6632 030.05-03 EN
RP
OS
E
ON
LY
030.05
MAN Diesel & Turbo
11 Stud
12 Hexagon nut M12
14 lower big-end bearing
shell
Figure 6: Big-end bearing body removed

17 Rope
PU

5 Crankshaft
Work sequence 2 - Installing the big-end bearing
Individual parts cleaned, back of big-end bearing shells oil dry, running surfaces well oiled, threads on the big-end bearing bolts dry, drive gear located
approx. 99 before/after TDC (see figure 3). Support (030.313-30) placed in
the drive casing, bracket (030.313-20) fixed to cylinder crankcase for fitting
the big-end bearing cap.
R
FO
2008-01-08 - de
Work steps
TR

suspended loads!
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).
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.
6632 030.05-03 EN
V32/40
AI
NI
NG
Starting position
9 (11)
030.05
MAN Diesel & Turbo
ON
LY
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.
RP
OS
E
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.
PU
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
damaged when introducing the big-end bearing cap (see figure 4).
NG
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).
NI
15. Screw the nut (3) onto the upper big-end bearing bolt until it makes
contact with the big-end bearing cap.
V32/40
10 (11)
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.
19. Remove the support from the crankcase.

20. Turn the crankshaft back by 90 (crankshaft with balance weight is horizontal, see figure 1)
6632 030.05-03 EN
2008-01-08 - de
TR
AI
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).
FO
16. Remove the bracket, guide rod and plate.
21. Fix the big-end bearing with turning stirrup (030.260) onto the balance
weight (8) (see figure 1).
22. Remove the slide piece.
ON
LY
23. Screw the nut (3) onto the lower big-end bearing bolt until it makes contact with the big-end bearing cap.
030.05
MAN Diesel & Turbo
24. Turn the engine until the crank pin is at TDC. Tighten the big-end bearing bolts (see Work Card 030.02).
25. Once you have tightened the big-end bearing bolts, measure the bearing clearance by inserting a feeler gauge (000.451) to a depth of roughly
10 mm from the coupling side and free engine end. Record the values
in the operating log sheets.
6632 030.05-03 EN
V32/40
R
FO
2008-01-08 - de
TR
AI
NI
NG
PU
7 Conrod shank bolt

Figure 7: Conrod shank bolt
RP
OS
E
26. Turn the engine until the crank pin is at BDC. Fit piston with connecting
rod shank and top land ring. (see Work Card 034.01).
11 (11)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
034
TR
R
FO
6632 034-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
Piston/Piston rings
MAN Diesel & Turbo
1 (2)
034
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
Piston/Piston rings
MAN Diesel & Turbo
2 (2)
6632 034-05 EN
Summary
ON
LY
Piston
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.
Engine stopped

PU
1 Technician
1 Assistant
Tools/aids required
Status
1 Tapered sleeve for inserting the piston rings
034.100
Standard
1 Tap wrench
034.097
Standard
1 Tap
034.096
Standard
1 Suspension device
034.142
Standard
1 Carrier
034.142-1
Standard
1 Pilot rod
034.006
Standard
1 Shackle A1.0
002.453
Standard
030.265
Standard
2 Guide tube
030.263
Standard
2 Slide piece
030.264
Standard
1 Turning stirrup
030.260
Standard
1 Tommy bar, 5
000.507
Option
000.451
Option
Inventory
Inventory
Inventory
NI
AI
TR
R
FO
2007-11-06 - de
Number
NG
Quan- Designation
tity
Duration in h
6632 034.01-02 EN
V32/40
Safety requirements
RP
OS
E

Piston/Piston rings
034.01
MAN Diesel & Turbo
1 (5)
Piston/Piston rings
034.01
MAN Diesel & Turbo

Work card
030.03
034.02
Technical data
Designation
Work card
ON
LY
Work card
Information
NI
V32/40
2 (5)
Balance weight
Conrod shank bolt
Big-end bearing cap
Crankshaft

General
11
13
15
16
17
Before removing the piston, the top land ring must be removed, because it
has a smaller diameter than the piston.
Starting position
Top land ring has been removed, crankcase is open, foot board (special tool)
has been placed in the oil sump or the oil sump has been cleaned for this
purpose with a suitable agent, conrod shank bolts are released, running gear
at TDC.
Work steps
1. Clean the threaded holes in the piston crown with a manual tap
(034.096).
6632 034.01-02 EN
2007-11-06 - de
AI
TR
5 Rope
7 Piston
8 Backing ring
9 Cylinder liner
Figure 1: Removing and installing the piston
FO
NG
PU
Work sequence 1 - Removing the piston
234 kg
RP
OS
E
Piston with connecting rod shank
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).
ON
LY
3. Turn the pistons exactly to BDC and hook the rope to the lifting tackle.
Piston/Piston rings
034.01
MAN Diesel & Turbo
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).
RP
OS
E
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.
PU
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.
NG
10. Place the pistons with the connecting rod shank (10) onto a wooden
surface.
11. Close the lube oil hole in the connecting rod shank and the big-end
bearing body to protect it from any dirt penetration.
Work sequence 2 - Installing the piston
FO
2007-11-06 - de
Starting position
Work steps
Piston cleaned, checked and attached to the connecting rod shank. Cylinder
liner and the joint faces at the big-end bearing body and the connecting rod
shank have been cleaned. The big-end bearing has been fastened to the balance weight using a turning stirrup and turned exactly to BDC.
1. Screw two guide tubes (030.263) onto the inner conrod shank bolts
(13) until they abut (see figure 1).
2. Remove cover on cylinder liner opening.
3. Set the tapered sleeve (034.100) on the cylinder liner (9), lubricate the
interior surface well.
6632 034.01-02 EN
V32/40
TR
AI
The big-end bearing may only be attached to the balance weight with
the turning stirrup when the engine is at rest, when turning the running
gear with the piston removed and in some other maintenance tasks.
The engine must not be taken back into operation in this condition!
NI
12. Cover the opening that has been made in the cylinder liner.
3 (5)
034.01
MAN Diesel & Turbo
ON
LY
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 surface of piston.
6. Arrange piston ring joints as shown in Fig. 2.
Position of the piston

ring joint
Coupling side
RP
OS
E
13
K
S
K
G
S
Free engine end
Figure 2: Position of the piston ring joint
1. Open lubricating oil bore in the big-end bearing body (15) and connecting rod shank (10).
PU
2. Guide the piston using the lifting tackle over the cylinder liner and carefully lower it into the liner. In doing so, manually guide the connecting
rod and the piston with the pilot rod until the piston skirt slides into the
cylinder liner (see figure 1).
V32/40
4 (5)
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
figure 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 circumference 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
shank bolts.
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.
6632 034.01-02 EN
2007-11-06 - de
TR
AI
NI
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.
FO
NG
During the insertion process, ensure that the conrod shank foot does
not damage the cylinder liner running surface.
034.01
MAN Diesel & Turbo
6632 034.01-02 EN
V32/40
R
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2007-11-06 - de
TR
AI
NI
NG
PU
RP
OS
E
ON
LY
11. Remove the tread plate (if installed) from the oil sump, close the crankcase.
Piston/Piston rings
10. Install the top land ring (see Work Card 050.01).
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Piston/Piston rings
inspecting
ON
LY
Summary
Piston/Piston rings
034.02
MAN Diesel & Turbo
The pistons and piston rings are to be checked with regard to the appearance of their contact faces as well as the lubricating and wear condition.
1 Technician
Tools/aids required
Number
Status
1 Piston ring expander
034.110
Standard
1 Thickness gauge (set)
000.451
Standard
Inventory
1 Dial gauge
Inventory
Work card
Work card
Work card
034.01
034.05
034.07
AI
NI
NG
PU
Quan- Designation
tity
Duration in h
Work sequence 1 - Checking the piston

Piston has been removed and placed on a suitable wooden support.
R
FO
2007-10-19 - de
TR
Starting position
Work steps
1. Check the condition of the piston and piston rings.
The piston running surface should have a uniform wear surface

appearance 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
lubrication or the ingress of impurities between the piston and cylinder
liner.
2. Clean piston of carbon residues, without roughening the surface of the
piston floor. Clean the running surface carefully.
6629 034.02-02 EN
32/40
RP
OS
E

1 (5)
034.02
MAN Diesel & Turbo
NI
AI
1. Measure and note down axial clearance of the piston rings in the
grooves, compare with the maximum permissible clearance and record
the results in operating log sheets. To do this, use a feeler gauge
(000.451) determine the axial clearance at four points (exhaust side,
exhaust counter side, coupling side and free engine end) at a quarter of
the piston ring groove depth (see Fig. 2).
2 (5)
6629 034.02-02 EN
2007-10-19 - de
TR
R
8 Guide shoe
15 Locking ring
9 Hexagon bolt
16 Clamping sleeve
10 Piston crown
17 Compression ring
11 Spring plate
18 Compression ring
20 Oil control ring
13 Sleeve
22 Piston skirt
14 Locking ring
Figure 1: Piston (connecting rod and piston pin removed)
32/40
FO
NG
PU
RP
OS
E
ON
LY
Piston/Piston rings
Do not damage the graphitated coating on the piston lower part (22)
when cleaning.
PU
RP
OS
E
ON
LY
For assessment of piston rings see Work Card 034.05 and 034.07.
Piston/Piston rings
034.02
MAN Diesel & Turbo
NG
10 Piston crown
22 Piston skirt
17 Compression ring
18 Compression ring
A Piston ring groove depth
20 Oil control ring
B Measuring point (A)
Figure 2: Measuring the axial clearance of the piston rings
Work sequence 2 - Removing and installing the piston rings
AI
1. Remove piston rings (17, 18, 20) individually using the piston ring pliers
(034.110), clean them and mark them using a marking pen (cylinder no.
and piston ring groove number).
R
FO
2007-10-19 - de
TR
It is necessary to mark the piston rings to prevent them from getting

mixed up (used piston rings must be reinstalled in the same piston and
in the same piston ring groove).
6629 034.02-02 EN
32/40
Work steps
When checking the pistons, the piston rings are not usually to be removed,
since they would be under heavy strain during removal and fitting. In the
event that piston rings are removed because of their wear condition or dirt:
NI
Starting position
3 (5)
034.02
ON
LY
Piston/Piston rings
MAN Diesel & Turbo
RP
OS
E
17 Compression ring
18 Compression ring
23 Locking lever
Figure 3: Piston ring pliers with inserted piston ring
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.
PU
1. Inspect the piston rings thoroughly, if necessary, replace them.
NI
Piston crown
Dial gauge
Piston ring groove depth
Measuring point (A)
AI
10
30
A
B
32/40
4 (5)
If the piston ring grooves are conically worn, this is an indication of

excessive cylinder liner wear. Worn piston ring grooves can be
reworked. We recommend you consult MAN Diesel & Turbo in this
regard. Install suitable replacement piston rings in the reworked piston
ring grooves, and record the new height of the piston ring in the
operating records.
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
axial clearance of the piston rings in the grooves and record this in the
operation notes (see work sequence 1, point 3).
6629 034.02-02 EN
2007-10-19 - de
TR
Figure 4: Measuring the piston ring groove (determining wear)
FO
NG
2. Carefully clean the ring grooves in the piston and determine their wear.
To do so, use an appropriate dial gauge (30) to measure at four points
(exhaust side, exhaust counter side, as well as the coupling side and
free engine end) in quarter piston ring groove depth and to determine
wear (see figure 4).
ON
LY
If a piston that has already been in use is installed into a different

cylinder liner, the compression rings and the oil control rings must be
replaced and the cylinder liner will need to be rehoned. The engine
must be run in again (see Operating Instructions, section 3).
Piston/Piston rings
034.02
MAN Diesel & Turbo
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.
RP
OS
E
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.
6629 034.02-02 EN
32/40
R
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2007-10-19 - de
TR
AI
NI
NG
PU
The oil control ring (20) with tubular spring must always be installed so that
the ring flank with the marking "TOP" faces upward.
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Piston pin and piston pin bush

ON
LY
Summary
Piston pin and piston pin bush are to be checked at regular intervals and, are
hence to be dismounted.
Quan- Designation
tity
RP
OS
E

Tools/aids required
Number
Status
034.109
Option
1 Retaining bow
034.109-1
Option
002.452
Standard
002.453
Standard
1 Pliers for locking ring
002.165
Standard
000.143
Standard
Inventory
1 Shackle A0.6
NG
PU
1 Shackle A1.0
Work card
Piston/Piston rings
034.03
MAN Diesel & Turbo
Work card
Work card
Connecting rod shank
93,5 kg
Piston pin
31,5 kg
2007-07-18 - de
FO
6629 034.03-01 EN
32/40
Information
TR
Designation
AI
Technical data
NI
034.01
1 (3)
Piston/Piston rings
034.03
MAN Diesel & Turbo
Rope
Connecting rod shank
Piston pin
Piston
Wooden support
Locking ring
Piston pin bush
PU
RP
OS
E
1
2
3
4
5
6
7
ON
LY
Work sequence 1 - Removing the piston pin (and the piston pin bush)
Figure 1: Removing and installing the piston pin
Starting position
NG
Piston with connecting rod shank removed and placed on a wooden support
together with the piston crown (see Figure 1). The connecting rod is secured
against tilting. Piston inside free of oil and oil coke residue.
Work steps
1. Screw the lifting eye bolt (000.143) into the connecting rod shank (2).
NI
2. Attach the rope (1) with the shackle (002.453) to the lifting eye bolt.
Attach rope to lifting tackle.
AI
4. Remove the tilting protection from the connecting rod shank (2).
32/40
2 (3)
In the event of a temperature difference of 30 to 40C as compared to

the piston, the piston pin is to be pulled out slightly. To do so, carefully
heat up the piston, for example by using a gas burner, around the
piston pin area by applying the torch in circular movements and
ensuring that the flame does not come too close to the piston.
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.
7. Install the retaining bow (034.109-1) into the piston pin (3) (see figure).
6629 034.03-01 EN
2007-07-18 - de
TR
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.
FO
3. Slightly lift the connecting rod shank (2) so that the load is released from
the piston pin (3).
8. Attach the rope (1) with the shackle (002.452) to the retaining bow.
Attach rope to lifting tackle.
9. Carefully pull out the piston pin (3) fully.
ON
LY
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).
Piston/Piston rings
034.03
MAN Diesel & Turbo
Work sequence 2 - Installing the piston pin

Work steps
RP
OS
E
If it is necessary, the piston pin bush should be replaced in a service

workshop, since for installation purposes, it must be supercooled. In
the meantime, a replacement connecting rod shank can be installed.
No additional scraping should be performed on either the running
surface of the new piston pin bush or the run-in bush.
1. Check how well the guide shoe can be moved in the piston skirt.
6629 034.03-01 EN
32/40
R
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2007-07-18 - de
TR
AI
NI
NG
PU
2. Installation of the piston pin (3) is basically in reverse order of how it was
removed. In doing so, ensure that the piston (4) with the retaining bow
(034.109-1) is not damaged when it is being pushed in and that when
installing the connecting rod shank (2) the marking (AS) on the piston
and the connecting rod shank match.
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Piston
dismantling and assembling
ON
LY
Summary
check the components as to their state / extent of their wear.
Pistons are to be dismantled within the scope of maintenance and repair
work.
1 Assistant
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
001.797
Standard
1 Extension piece 20x400
001.914
Standard
1 Emery paper
Inventory
1 Oil stone
Inventory
1 Honing stone
Option
Inventory
1 Depth gauge
Inventory
1 Special anti-seize agent (Molykote G Rapid, Moly- kote G-n)
Inventory
TR
AI
NI
PU
Quan- Designation
tity
NG
Tools/aids required
FO
2007-09-25 - de

Work card
Work card
000.30
034.03
6629 034.04-03 EN
Work card
32/40
1 Technician
Duration in h
RP
OS
E

disassembling components,
assembling components.
Piston/Piston rings
034.04
MAN Diesel & Turbo
1 (4)
Piston/Piston rings
034.04
MAN Diesel & Turbo
Technical data
Information
ON
LY
Designation
Piston with piston rings, complete
118 kg
Work sequence 1 - Dismantling the piston

Starting position
NI
AI
2 (4)
Work steps
8
9
10
11
12
13
14
Guide shoe
Hexagon bolt
Piston crown
Spring plate
Compression spring
Sleeve
Locking ring
15
16
17
18
20
22
A
Locking ring
Clamping sleeve
Compression ring
Compression ring
Oil control ring
Piston skirt
Total length of the hexagon bolts
(9)
Figure 1: Piston (connecting rod and piston pin removed)
6629 034.04-03 EN
2007-09-25 - de
TR
R
32/40
FO
NG
PU
RP
OS
E
The piston has been placed on the wooden support (the piston skirt is positioned upward). The piston pin and the connecting rod have been removed
or disassembled. Piston cleaned externally.
ON
LY
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)).
Piston/Piston rings
034.04
MAN Diesel & Turbo
When lifting up the piston skirt, pay attention to the seating and
contact surfaces between the piston crown and the piston skirt and do
not damage them.
3. Check mobility of guide shoe and replace if necessary.
RP
OS
E
4. Clean the piston crown (10) and piston skirt (22) carefully. The cooling
chambers (internally) should be cleaned to produce a polished metallic
surface (with rotating wire brushes or emery belts). Blow the oil bores
out using compressed air. Check the parts for damage (cracks).
5. Check the contact surface between the piston crown (10) and skirt (22),
and smooth out any lifting of the material (see work sequence 2).
Work sequence 2 - Smoothing out the contact surface between the piston crown and the
piston skirt
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
Work steps
The piston is dismantled and has been cleaned.
NG
PU
Preliminary remark
1. Check the contact surface of the piston crown (10) and the piston skirt
(22) for raised points in the material.
NI
2. Remove any raised points in the material using several work steps,
using emery paper with increasingly fine grain size (100 - 180).
Starting position
FO
2007-09-25 - de
Work sequence 3 - Assembling the piston

Work steps
Piston components are cleaned, checked and replaced if required, piston

crown is placed on wooden supports.
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 crown.
6629 034.04-03 EN
32/40
TR
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.
AI
3. Smooth the contact surfaces using oil stone or a honing stone.
3 (4)
034.04
MAN Diesel & Turbo
ON
LY
Piston/Piston rings
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.
RP
OS
E
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.
PU
5. Tighten the hexagon bolts (9) with torque 200 Nm in two stages alternately 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.
NG
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 torque 90 Nm.
1. Check the guide shoe (8) mobility.
NI
AI
TR
2007-09-25 - de
R
32/40
FO
2. Install the connecting rod shank and the piston pin (see Work Card
034.03).
4 (4)
6629 034.04-03 EN
Piston rings
assessing
ON
LY
Summary
Carry out the work in good time in accordance with the maintenance schedule; 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.
RP
OS
E
Piston/Piston rings
034.05
MAN Diesel & Turbo
Work card
Work card
034.07
Preliminary remarks
Work card
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.
PU
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
Groove 1
Chrome-ceramic coated
net of cracks later
Groove 2
chrome coated
uniformly grey
chrome coated
uniformly grey
NG
Compression rings
Oil control ring
NI
Groove 3
As a result of the shape of the running surface, new compressing rings do

not wear along the entire running surface, but only along running pattern area
A. As the wear increases, the running pattern area becomes wider and
wider.
6682 034.05-03 EN
General
The ring version can be identified by the item number stamped on the upper
side of the piston rings.
Wear patterns of chrome or chrome ceramic coated piston rings
FO
2007-10-24 - de
TR
AI
In the case of chrome plated rings, the appearance of the coating only
shows minor or slight change during continuous wear. This is not the case
for chrome ceramic coated rings. The running surface of these rings when
not worn has a smooth metallic appearance and has a uniform grey colour.
After several hundred operating hours, a net of cracks becomes visible. This
is normal. This is the result of hard metal-oxide ceramic particles burying
themselves into the network structure of the chrome coat.
Table 1: Piston rings/Surface coating
1 (3)
034.05
ON
LY
Piston/Piston rings
MAN Diesel & Turbo
RP
OS
E
A Running pattern height

B Ring height
Figure 1: Running surface of chrome plated piston rings (operating hours > 1000 h)
Figure 2: Network of cracks in chrome ceramic coated piston rings (operating hours >
8,000 h)
PU
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
NG
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 running 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.
NI
AI
Coated compression rings and oil control rings must also be replaced once
the coating has been worn off in one location.
2007-10-24 - de
TR
Figure 4: Piston ring with burn marks in the running surface
General
FO
Burn marks (C) can be identified by local discolouration on the running surface. Rings in this condition must be replaced. Figure 4.
2 (3)
Figure 5: Piston ring with coating worn away
6682 034.05-03 EN
Figure 5 shows a chrome plated compression ring. The layer of chrome has
been partially worn away at (D).
ON
LY
Once spallings or cracks are visible in the coating of a piston ring it also
should be replaced.
Piston/Piston rings
034.05
MAN Diesel & Turbo
6682 034.05-03 EN
General
R
FO
2007-10-24 - de
TR
AI
NI
NG
PU
RP
OS
E
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.
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
050
TR
R
FO
6632 050-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
050
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 (2)
6632 050-05 EN
Top land ring

ON
LY
Summary
The top land ring must always be removed when the corresponding piston is
to be removed or if the seal ring needs to be changed.
RP
OS
E

Engine stopped
PU
1 Technician
Duration in h
1 Assistant
Tools/aids required
Number
Status
050.165
Standard
1 Carrier
050.165-1
Standard
3 Hexagon bolt
050.165-3
Standard
2 Spacer pipe
050.133
Standard
050.099
Standard
1 Carrier
050.099-1
Standard
2 Thrust screw
050.099-1
5
Standard
1 Pilot rod
034.006
Standard
1 Shackle A0.6
002.452
Standard
Inventory
Inventory
Inventory
R
FO
2007-09-24 - de
TR
AI
NI
NG
Quan- Designation
tity

Work card
Work card
055.02
6629 050.01-04 EN
Work card
32/40
Safety requirements
050.01
MAN Diesel & Turbo
1 (5)
050.01
MAN Diesel & Turbo
Technical data
Information
Top land ring
33,5 kg
Work sequence 1 - Disassembling the top land ring

Starting position
ON
LY
Designation
Cylinder cooling water has been fully drained. Cylinder head has been
removed, running gear approximately 60 before/after TDC.
RP
OS
E
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
NI
AI
2 (5)
1 Backing ring
6 Top land ring
2 Rope
7 Piston
3 Hexagon bolt BM16x140
8 O-ring seal
4 Sealing ring
5 Cylinder liner
10 Nut
Figure 1: Removing the top land ring (illustration shows in-line engine)
6629 050.01-04 EN
2007-09-24 - de
TR
R
32/40
FO
NG
PU
1. Remove any coke deposits on the top land ring (6) and around the cylinder liner (5) area. Cover the gap between the piston (7) and the cylinder liner to prevent foreign objects from falling into it.
1. Clean the three blind holes on the interior diameter of the top land ring
and remove loose debris on the piston upper surface.
ON
LY
2. Attach the carrier (050.165-1) to the top land ring. Make sure that the
pin in the carrier is located in the sleeve (12) of the backing ring (1) (see
figure 1).
050.01
MAN Diesel & Turbo
3. Screw three hexagon bolts (050.165-3) into the blind holes in the top
land ring, hand-tight.
4. Plug the spacer pipes (050.133) diagonally over the cylinder head bolts
(9) and fix them with the nuts (10).
5. Pull the top land ring out until it is loose by even, alternating turning of
the hexagon bolts (3).
RP
OS
E
6. Fasten the rope (2) with the shackle (002.452) onto the support and
hook the rope to the lifting tackle (depending on the engine type,
choose the correct suspension point).
7. Screw the pilot rod (034.006) into the carrier.
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.
Work sequence 2 - Fitting the top land ring
R
FO
2007-09-24 - de
Starting position
Work steps
The top land ring has been cleaned

1. Insert new O-ring seals (8), oiled with clean lubricating oil, in the ring
groove. Make sure that they are clamped over the entire circumference
and are not twisted.
2. Insert a new O-ring (4) in the groove.
3. Attach the support (050.165-1) to the top land ring (6) and turn back
hexagon bolts (3).
4. Screw three hexagon bolts (050.165-3) into the blind holes on the top
land ring hand-tight.
6629 050.01-04 EN
32/40
TR
AI
1 Backing ring
6 Top land ring
2 Rope
Figure 2: Removal and fitting of the top land ring in the backing ring (figure shows an
in-line engine)
NI
NG
PU
10. Release sealing ring (4) and remove.
3 (5)
050.01
MAN Diesel & Turbo
choose the correct suspension point).
ON
LY
7. Carefully insert the top land ring into the backing ring (1) and guide
using the pilot rod (see figure 2).
PU
RP
OS
E
When fitting the top land ring, ensure the correct placement of the
marking (M) on the top land ring - backing ring.
NG
1 Backing ring
M Mark
6 Top land ring
AGS Exhaust counter side
Figure 3: Mark on backing ring - top land ring
1. Detach the tool.

2. Screw the thrust screws (050.099-15) back in the carrier (050.099-1).
NI
3. Place the carrier on the backing ring and take care with the position of
the recess for the sleeve (12).
6. Using even, alternating turns of the thrust bolts, press the top land ring
down, until it abuts the cylinder liner.
2007-09-24 - de
TR
AI
5. Screw down the thrust bolts until they reach the top edge of the top
land ring.
32/40
FO
4. Fasten carrier onto backing ring using hexagon bolts (11).
4 (5)
6629 050.01-04 EN
1
4
5
6
8
Backing ring
Sealing ring
Cylinder liner
Top land ring
O-ring seal
RP
OS
E
ON
LY
050.01
MAN Diesel & Turbo

12 Sleeve
A Check hole for cooling water

leakages and gas leakages
Figure 4: Pushing down the top land ring (illustration shows in-line engine)
1. Detach the tool.
2. Fit the engine parts removed, fit the pipes and fittings, add cooling
water to the engine.
PU
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
check holes (A).
6629 050.01-04 EN
32/40
R
FO
2007-09-24 - de
TR
AI
NI
NG
4. With the engine running, check for gas coming out of the inspection
holes (A).
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Summary
ON
LY
Cylinder liner
measure
Check the components as to their state / extent of their wear, prevent operational problems / damage.
The cylinder liners are to be checked within the scope of maintenance and
repair work.
Tools/aids required
Quan- Designation
tity
RP
OS
E

Measuring components and
Assessing contact pattern /wear condition.
Number
Status
050.164
Option
050.162
Option
1 Micrometer (Internal) 48/60
050.062
Option
1 Micrometer (Internal) 32/40
050.038
Option
1 Gauge bar 32/40
PU
1 Gauge bar 48/60
050.02
MAN Diesel & Turbo
Preliminary remarks
NG
Cylinder liners are not evenly worn all the way around their surface or along
the running surface. The wear values are limited both with regard to ovality
as well as to the maximum wear. This way, any sealing problems and overloads on the piston rings may be avoided.
NI
Regular inspection will provide ideas for optimising the operating conditions
and will be decision-making factors for any necessary cylinder liner replacement.
AI
1. Insert gauge bar (050.162 or 050.164) in cylinder liner (8). See Fig. 2.
The measuring bar is held magnetically to the running surface and the
upper side of the collar. The quantity and location of the measuring
points (1 to 5) are defined by the bores in the gauge bar.
2. Bring internal micrometer (050.038 or 050.062) up to the temperature
of the cylinder liner (8)
3. Insert the internal micrometer into each of the bores in the gauge bar,
take measurements and make a note of the measured values. See Fig.
3.
6682 050.02-02 EN
32/40;48/60B;V48/60CR
R
FO
2008-10-22 - de
Work steps
Cylinder head is detached, top land ring is disassembled, piston and connecting rod (in engine 32/40) or small end (in engine 48/60 B) are disassembled. Cylinder liner thoroughly cleaned, particularly in the upper area and on
top (in the contact area of the gauge bar).
TR
Starting position
Work sequence 1 - measuring the cylinder liner
1 (5)
050.02
MAN Diesel & Turbo
ON
LY
Measure the dimensions in the transverse and longitudinal direction of

the engine.
4. Determine the temperature of the cylinder liner (8) during the measurement 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).
RP
OS
E
If the measured values exceed the maximum permitted values for wear
or out-of-roundness then the cylinder liner must be replaced!
NI
AI
TR
2008-10-22 - de
FO
32/40;48/60B;V48/60CR
NG
PU
The wear is calculated by subtracting the nominal dimension from the measured values. The out-of-roundness is the difference between the measured
values (in the transverse and longitudinal direction of the engine) in one
plane.
2 (5)
6682 050.02-02 EN
AI
TR
R
FO
2008-10-22 - de
ST Control side
NI

7 Backing ring
8 Cylinder liner
Figure 1: Cylinder liner
6682 050.02-02 EN
32/40;48/60B;V48/60CR
NG
PU
RP
OS
E
ON
LY
050.02
MAN Diesel & Turbo
3 (5)
4 (5)
2008-10-22 - de
32/40;48/60B;V48/60CR
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
050.02
MAN Diesel & Turbo
1-5 Measuring point

Figure 2: Cylinder liner - inserted gauge bar
6682 050.02-02 EN
8 Cylinder liner
050.02
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
Cyl. 1
NI
transverse longitudinal
480,36
480,52
480,24
480,18
480,07
AI
TR
1
2
3
4
5
Cylinder diameter (mm)

Cyl. 2
transverse
longitudinal
480,28
480,45
480,16
480,15
480,05
Temperature of cylinder liner during

measurement
30 C
Running surface condition
perfect
R
FO
2008-10-22 - de
Table 1: Measurement report - Example for engine 48/60 B
6682 050.02-02 EN
Cyl. 3
transverse
longitudinal
etc.
32/40;48/60B;V48/60CR
Measuring plane
NG
8 Cylinder liner
Figure 3: Measuring the cylinder liner
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Cylinder liner (with backing ring)

Tools/aids required
Quan- Designation
tity
RP
OS
E

Number
Status
050.157
Standard
050.157-1
Standard
050.157-3
Standard
050.099
Standard
1 Carrier
050.099-1
Standard
2 Thrust screw
050.099-1
5
Standard
1 Pilot rod
034.006
Standard
002.454
Standard
2 Shackle A0.6
002.452
Standard
000.155
Standard
Inventory
Inventory
Inventory
1 Suspension device
1 Carrier
PU
3 Retaining bow
AI
NI
NG
1 Shackle A1.6
TR
Work card
Work card
034.01
050.02
Work card
R
FO
2007-07-18 - de
Technical data
Designation
Information
Cylinder liner
172,5 kg
Cylinder liner (with backing ring)
407,5 kg
Backing ring
233,5 kg
6629 050.03-04 EN
32/40
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.
ON
LY
Summary
050.03
MAN Diesel & Turbo
1 (5)
050.03
MAN Diesel & Turbo
Preliminary remarks
ON
LY
State of wear and ovality are to be determined, the appearance of the running 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.
NI
O-ring seal
Sleeve
O-ring seal
O-ring seal
Sleeve
Inspection hole for cooling water
leakage
Figure 1: Removal and fitting of the cylinder liner (with backing ring) - illustration
shows in-line engine
TR
AI
1
2
3
4
5
6
Cylinder head bolt

Rope
Hexagon bolt M16x35
Backing ring
Cylinder crankcase
Cylinder liner
7
8
9
10
11
A
Starting position
32/40
Work steps
2 (5)
Big-end bearing fixed to balance weight with turning stirrup, piston with connecting rod shank removed and screwed fittings on backing ring removed.
1. Clean and measure the cylinder liner (6) (see Work Card 050.02).
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 the exhaust counter side. Figure 1.
6629 050.03-04 EN
2007-07-18 - de
Work sequence 1 - Removing the cylinder liner/Removal of the backing ring
FO
NG
PU
RP
OS
E
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.
4. Screw in the thrust screws until they reach the top edge of the cylinder
liner. This avoids the potentially loose backing ring from falling down
when removing the drawn cylinder liner.
ON
LY
choose the correct suspension point). Screw pilot rod into branch
socket on carrier.
050.03
MAN Diesel & Turbo
6. Cover the crankcase using suitable means, especially on the side, to

prevent dirt from penetrating into the cooling chambers in the big-end
and crankshaft bearings.
RP
OS
E
7. Pull the cylinder liner and backing ring parallel to the cylinder centre axis
upward from the cylinder crankcase, in doing so guide the cylinder liner
using the pilot rod.
6 Cylinder liner
NG
PU
When removing the cylinder liner, do not damage the cylinder head
bolts.
Figure 2: Suspending the cylinder liner
1. Place cylinder liner and backing ring on a wooden support.
NI
2. Screw two lifting eye bolts (000.155) into the backing ring.
5. Remove the support and lower the backing ring onto the wooden support.
6. Suspend the rope from the shackle (002.452) and the lifting tackle and
fix the shackle to the carrier (050.157-1).
7. Lower the carrier (050.157-1) onto cylinder liner and fix in position with
retaining bow (050.157-3) and hexagon bolts (16) on the cylinder liner
(6). (Figure 2)
8. Lift the cylinder liner out of the backing ring and place on a wooden
support.
9. Clean the cylinder liner and backing ring.
6629 050.03-04 EN
32/40
R
FO
2007-07-18 - de
TR
AI
4. Unscrew two thrust screws by a few rotations, slacken the lifting tackle
slightly and loosen the backing ring by gently knocking it (using a
wooden or copper packer).
3. Separate the shackle from the carrier. Unhook the rope and fix with
shackles to the lifting eye bolts. Tension rope.
3 (5)
050.03
MAN Diesel & Turbo
Work sequence 2 - Installing the cylinder liner

Starting position
ON
LY
The cylinder liner has been thoroughly cleaned inside and out. Measure the
inside of the cylinder liner (deep scoring in the piston running surface or too
much wear requires the cylinder liner to be replaced, especially if the maximum permitted wear has been reached around the upper compression ring
area in TDC or if the ovality is excessive (see operating Instructions, section
1)). The lube oil holes have been blown out with compressed air, the sealing
faces are clean and undamaged. The crankcase is adequately covered. Cylinder liner is located in the backing ring.
Work steps
RP
OS
E
1. Insert new O-ring seals (7), lubricated with acid-free grease, in the ring
grooves, ensuring that these are tightened equally around the entire circumference and not twisted.
2. Fasten rope with shackle (002.452) on two lifting eye bolts (000.155)
and suspend rope from lifting tackle.
3. From below, pull the backing ring (4) over the cylinder liner (6), in the
process pay attention to the O-ring seals.
PU
Make sure that the mark (M) backing ring-cylinder liner is correctly
located (see figure 3).
NG
5. Fix the carrier on the backing ring with hexagon bolts (3) and screw two
thrust screws in position up to the top edge of the cylinder liner.
NI
AI
6. Separate the rope from the lifting eye bolts.
32/40
4 (5)
8. Carefully insert the backing ring with the cylinder liner into the cylinder
crankcase (5), in doing so guide the cylinder liner with the pilot rod.
Ensure that the backing ring is positioned in line with the sleeves (8).
Avoid damaging the cylinder head bolts (1) during installation.
9. Remove the fixture, remove the cover in the crankcase.

10. Measure the cylinder liner.
11. Attach pipes and screwed connections.
6629 050.03-04 EN
2007-07-18 - de
TR
7. Suspend the rope from the shackle (002.454) and fix the shackle to the
carrier. Screw the pilot rod (034.006) into the carrier.
FO
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).
ON
LY
12. After completing the assembly tasks (cylinder head attached, cylinder
head bolts tightened, etc.), check, at the existing cooling water pressure rating, whether the O-ring seals are OK, and make sure no water is
leaking through the inspection holes (A).
050.03
MAN Diesel & Turbo
PU
RP
OS
E
If a new cylinder liner was installed, it must be run in according to

specifications (see Operating Instructions, section 3).
6629 050.03-04 EN
32/40
R
FO
2007-07-18 - de
TR
AI
NI
NG

14 Hexagon bolt
4 Backing ring
15 Sleeve
6 Cylinder liner
11 Sleeve
13 Washer
M Mark backing ring - cylinder liner
Figure 3: Suspending the backing ring/Mark backing ring-cylinder liner
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Cylinder liner (without backing ring)

Tools/aids required
Quan- Designation
tity
RP
OS
E

Number
Status
050.133
Standard
050.129
Standard
1 Cross tie
050.129-1
Standard
050.129-5
Standard
050.129-1
2
Standard
1 Spindle (short)
050.129-2
1
Standard
1 Spindle (long)
050.129-2
7
Standard
1 Spherical disc
050.129-3
3
Standard
1 Ball socket
050.129-3
4
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
1 Shackle A1.6
002.454
Standard
1 Ring nut M30 x 3
000.186
Standard
Inventory
Inventory
Inventory
Inventory
2 Spacer pipe
1 Carrier (upper)
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1 Carrier (lower)

Work card
Work card
Work card
012.03
034.01
050.02
6629 050.04-06 EN
32/40
measure components, assess surface/wear condition.
The cylinder liners must be removed and cleaned at regular intervals.
ON
LY
Summary
050.04
MAN Diesel & Turbo
1 (6)
050.04
MAN Diesel & Turbo
Technical data
Information
ON
LY
Designation
Cylinder liner
172,5 kg
Preliminary remarks
RP
OS
E
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.
NI
AI
7 O-ring seal
3 Collar nut M30
8 Hexagon nut M30
4 Backing ring
10 O-ring seal
11 Sleeve
6 Cylinder liner
12 Nut
Figure 1: Removal of the cylinder liner (illustration shows in-line engine)
Work sequence 1 - Removing the cylinder liner
32/40
Starting position
2 (6)
Work steps
Piston with connecting rod shank has been removed, the big-end bearing is
fastened to the balance weight using a turning stirrup and is turned so that
the cylinder liner is easily accessible from below.
1. Clean and measure the cylinder liner (6) (see Work Card 050.02).
6629 050.04-06 EN
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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.
2. Insert the lower carrier (050.129-12) through the drive casing and place
on the cylinder liner. Figure 1.
ON
LY
As from the installation of the lower carrier, the crankshaft should no

longer be turned.
050.04
MAN Diesel & Turbo
3. Insert the long spindle (050.129-27) into the carrier and fix in position
with the hexagon nut (8).
RP
OS
E
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).
PU
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).
NG
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
prevent dirt from penetrating into the cooling chambers in the big-end
and crankshaft bearings.
11. 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.
12. Pull the cylinder liner out upwards parallel to the central axis of the cylinder.
When removing the cylinder liner make sure that the cylinder head bolts
are not damaged.
13. Set the cylinder liner down on a wooden support.
6629 050.04-06 EN
32/40
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On V engines remove the cross tie (050.129-1) and fix the shackle on
the suspension point on the rib
NI
10. By tightening the collar nut, release the cylinder liner and pull it up.
3 (6)
050.04
MAN Diesel & Turbo
ON
LY
14. Detach tools.
6 Cylinder liner
Figure 2: Suspending the cylinder liner
RP
OS
E
1. For onward transport suspend the rope from the shackle (002.452) and
the lifting tackle and fix the shackle to the carrier (050.157-1). Figure 2.
2. Lower the carrier onto cylinder liner (6) and fix in position with retaining
bow (050.157-3) and hexagon bolts (16) on the cylinder liner. Figure 2.
3. Clean cylinder liner.
Work sequence 2 - Installing the cylinder liner

Starting position
PU
The cylinder liner has been thoroughly cleaned inside and out. Measure the
inside of the cylinder liner (deep scoring in the piston running surface or too
much wear requires the cylinder liner to be replaced, especially if the maximum permitted wear has been reached around the upper compression ring
area in TDC or if the ovality is excessive). The lube oil holes have been blown
out with compressed air, the sealing faces are clean and undamaged. Drive
chamber covered with suitable equipment, cylinder head bolts on exhaust
counter side have been removed. Cylinder liner is on wooden supports, bottom carrier (050.129-12) placed in cylinder liner.
NG
1. Insert new O-ring seals (7), lubricated with acid-free grease, in the ring
grooves, ensuring that these are tightened equally around the entire circumference and not twisted.
NI
AI
4 (6)
1
2
4
5
6
Cylinder head bolt

Rope
Backing ring
Cylinder crankcase
Cylinder liner
8 Hexagon nut M30

10 O-ring seal
11 Sleeve
A Inspection hole for cooling water

leakage
Figure 3: Fitting the cylinder liner (illustration shows in-line engine)
6629 050.04-06 EN
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32/40
FO
2. Insert the long spindle (050.129-27) into the carrier and fix in position
with the hexagon nut (8). Figure 3.
1. Place the upper carrier (050.129-5) over the spindle on the cylinder liner
(6) and fix in position with hexagon nut (8).
ON
LY
On V engines fix the shackle to the suspension point in the rib.
050.04
MAN Diesel & Turbo
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.
RP
OS
E
3. Insert the cylinder liner carefully in the backing ring (4) and cylinder
crankcase (5).
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
cylinder head bolts. (figure 4).
4. Detach the tool.
PU
5. Remove the cover from the drive chamber.

6. Measure the cylinder liner.
NG
7. After completing the assembly tasks (cylinder head attached, cylinder

head bolts tightened, etc.), check, at the existing cooling water pressure rating, whether the O-ring seals are OK, and make sure no water is
leaking through the inspection hole (A).
6629 050.04-06 EN
32/40
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If a new cylinder liner has been fitted, it must be run in according to

specifications (see Operating Instructions, section 3).
5 (6)
050.04
RP
OS
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ON
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MAN Diesel & Turbo
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32/40
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4 Backing ring
14 Hexagon bolt
6 Cylinder liner
15 Sleeve
11 Sleeve
13 Washer
M Mark backing ring - cylinder liner
Figure 4: Mark on the backing ring and the cylinder liner for correct installation
6 (6)
6629 050.04-06 EN
Tools/aids required
Quan- Designation
tity
RP
OS
E

Honing the reversing area of the piston rings,
Honing the entire running surface.
Number
Status
050.152
Option
1 Rope pull with remote control
050.152-1
Option
1 Cross bar
050.152-2
Option
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
050.152-1
0
Option
1 Honing head
050.152-1
1
Option
1 Container
050.152-1
2
Option
1 Funnel
050.152-1
3
Option
2 Spring strap
050.152-1
6
Option
1 Air supply station
050.152-1
7
Option
1 injection nozzles
050.152-2
0
Option
3 Cleaning brush
050.152-2
1
Option
1 Oil for air oiler
050.152-2
3
Option
1 Support
050.152-2
4
Option
2 Extension pipe
050.152-2
7
Option
1 Honing device
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2 Intermediate piece
6632 050.05-01 EN
V32/40;V32/40PGI
Execute work on time according to the maintenance schedule, ensure correct execution of work, check components for state/wear condition, re-create running surface.
Cylinder liners should be checked at regular intervals and the original running
surface geometry must be re-created.
Summary
ON
LY
Cylinder liner
honing
050.05
MAN Diesel & Turbo
1 (10)
050.05
MAN Diesel & Turbo
Quan- Designation
tity
Number
Status
050.152-2
8
Option
Inventory
1 Honing stone (set) for unhardened cylinder liners
Option
1 Honing stone (set) for laser-hardened cylinder liners
Option
1 Collecting tank
Inventory
Inventory
Inventory
1 Lifting tackle
1 Rope

Work card
034.01
Preliminary remarks
RP
OS
E
1 Cleaning agent (diesel oil / kerosene)
ON
LY
3 Ball-bearing
Work card
Work card
050.02
PU
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 lubricating film is thick enough and has sufficient adhesion. While the original microgeometry can be extensively restored through honing, it is not possible to
influence the wear profile, i.e. the macrogeometry of the cylinder liner.
NG
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.
NI
AI
Structure and mode of operation
2 (10)
the rope pull (1)
the drive unit (11)
the lubrication installation (18 and 20)
the guide elements (2 to 4, 6 and 7) and
the portable air supply station (23).
The honing device is driven and controlled using compressed air.

The fittings on the air supply station are used for filtering air and for drainage
as well as for adding oil.
The stroke speed and the honing head speed are preset, as is the contact
pressure of the honing sticks, using the control valves on the compressed air
outlet. The rope pull contol engine is activated for lifting and lowering movements using the buttons on the remote control (5).
6632 050.05-01 EN
2009-03-09 - de
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In essence, the honing device consists of:
V32/40;V32/40PGI
The cylinder liner honing operation is not particularly time consuming. However, 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.
Using the ball cock on the guide arm (7) the drive unit (11) is switched on and
off. The contact pressure of the honing elements is regulated with the sliding
valve located alongside.
ON
LY
Using the lubricating device, consisting of tank (20) and spray nozzles (18)
the grinding area can be lubricated and cleansed of abrasion particles. The
lubricant / cleaning agent is collected in a funnel (16), attached to the lower
edge of the cylinder liner, and from there it is guided outward. When switching from grinding strips to cleaning brushes (14), it is possible to mechanically
clean the cylinder liner (19).
050.05
MAN Diesel & Turbo
The device can be set for several different diameters and with the use of
extension pieces and adapters, it can be adjusted for varying strokes.
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 modelling 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.
PU
Starting position
RP
OS
E
Work sequence 1 - Honing the piston ring reversal point in the top dead centre (nip area)
NG
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
piston ring is honed during a subsequent work step (see work
sequence 2).
Work steps
2. Fit the ball-bearings (24) to the honing head (15).

3. Insert the honing head carefully into the cylinder liner (19).
4. Adjust the ball-bearings and thus centralise the honing head in the cylinder liner.
5. Set the stroke movement of the honing head in the cylinder liner (19)
with stops (4) in such a way that the upper edge of the honing stones
comes to rest approx. 10 mm above the top dead centre of the first
piston ring resulting in a stroke of 40-50 mm.
6. Align spray nozzles (18) so that lubricant coats the honing area on exiting.
7. Close the shut-off valve for the tank (20) and fill it with lubricant (diesel
oil, gas oil or petroleum).
6632 050.05-01 EN
V32/40;V32/40PGI
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The short honing stones can be produced by breaking long honing

elements: Notch using a steel hacksaw blade, clamp in vice and break
off.
NI
1. Clamp honing stones (20 mm lg.) in each grinding bar (13) at the same
height in the central section of the grinding bar.
3 (10)
050.05
MAN Diesel & Turbo
ON
LY
No smoking, do not use an open flame - fire hazard!
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
reaching the collecting tank (32) via the funnel (16) without leaking.
RP
OS
E
Honing a cylinder liner needs about 4-6 litres of lubricant. Always make
sure a sufficient quantity of lubricant is used when performing the
honing process. It is advantageous to wash away abraded material
immediately.
The lubricant may be used several times if it flows into the collecting
tank through a fleece mat.
Clean lubricant/cleaning agent must be used for subsequent cleaning
of the cylinder liner following the actual honing process.
NG
PU
9. Bring the honing device into operation using a tried-and-tested setting.

Bring the honing stones into contact.
Using slight upward and downward strokes (20 - 30 double strokes
each) hone the surface until the short honing stones have been completely used up. This takes between roughly 1 and 1.5 minutes. Speed
of the honing head should be about 35 1/min, pressure 2.5 bar. Due to
the short stroke, only a shallow honing angle is achieved. If honing
marks start to appear in the TDC area of the first piston ring, cancel the
honing operation. If a rounded ledge is still present at the reversal point
of the first piston ring, this is permissible. If required, the operation must
be repeated using a second set of short honing stones.
10. As soon as a satisfactory surface condition has been established, stop

the honing operation and cut off the supply of lubricant.
NI
4 (10)
Work steps
Reversal area of piston rings at TDC honed, or cylinder liner available with
low wear shoulders in the TDC area.
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
running surfaces to the underlying soft part of the cylinder liner.
1. Mount six long honing stones on honing head (15).
2. Guide honing head carefully into the cylinder liner (19) and readjust ball
bearing guides (24) if required.
6632 050.05-01 EN
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Starting position
AI
Work sequence 2 - Honing the entire running surface of the cylinder liner
V32/40;V32/40PGI
11. Move the honing head out of the cylinder liner and secure in the upper
position.
ON
LY
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 overshoot by roughly 100 mm.
050.05
MAN Diesel & Turbo
4. Align spray nozzles (18) so that lubricant coats the honing area on exiting. Fill the container (20) with lubricant (diesel oil, gas oil or petroleum).
RP
OS
E
No smoking, do not use an open flame - fire hazard!
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.
PU
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
performing the honing process. It is advantageous to wash away
abraded material immediately.
8. Measure the cylinder liner following the honing operation. If the maximum permissible wear at TDC of the first piston ring, or the maximum
permissible out-of-roundness, is exceeded (for limit values see Volume
010.005 Engine Operating Instructions, Chapter 2.5.5), replace the
cylinder liner.
9. Replace grinding elements (13) with hard cleaning brushes (14).
10. Retract the honing head and carefully remove (free and rinse away) all
grinding residues by applying a reduced contact pressure of 0.5 - 1.0
bar with the same rotational speed and stroke speed. Repeat the pro6632 050.05-01 EN
V32/40;V32/40PGI
7. Stop the honing device. Assess the roughness, honing angle and honing pattern (see Table 2).
If the result is satisfactory, finish by performing two double strokes over
the entire running surface of the piston rings. In doing so, adjust the
stops (4) so that the honing stones run partially out of the cylinder liner.
Making sure the honing head does not run into and strike the funnel
(16).
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6. Bring the honing device into operation using a tried-and-tested setting.

Move the honing stones up against the surface.
To hone a cylinder liner, 60-65 upward and downward movements (see
Table 1) are required with a hoisting speed of roughly 18 double strokes
per minute (see Table 1). The total honing time for a cylinder liner is normally 3.5 - 4 minutes; the higher values in the range apply for laserhardened cylinder liners.
Speed of honing head approx. 35 rpm; contact pressure 2.5 bar.
The stroke movement must be controlled so that a honing angle () of
45 60 (22.5 30) in relation to the horizontal plane is achieved (for
template see page 9). A surface roughness Rz of 10-15 m should ideally be achieved with laser-hardened cylinder liners and normal cylinder
liners.
5 (10)
050.05
MAN Diesel & Turbo
ON
LY
cedure using soft cleaning brushes if necessary. Use plenty of lubricant

when carrying out the cleaning. Perform roughly 50 double strokes in
total. Perform the last cycle using fresh lubricant. No grinding residues
should be left behind (check with fingertips).
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 residue in the oil ducts.
13. Remove the funnel, making sure that dirt does not enter the engine.
RP
OS
E
14. Then clean the cylinder liner manually.
Observe instructions for commissioning the engine!

Once you have installed the piston and mounted the cylinder head,
start up by following the instructions in Volume 010.005 Engine
Operating Instructions, Chapter 3.4.4.
Type
Lifting height (mm)
Rotational speed
(rpm)
Number of double
strokes per minute
Time for each
Double stroke *
Number of double
strokes required
32/40
450
PU
(s)
35
18
3.3
60 - 65
Table 1: Processing parameters for the honing of cylinder liners

*
Valid for a honing angle () of 45
NG
Test/measurement
As an alternative
1
Technovit impression (hard- Finger nail test and visual

ening plastic)
assessment
- allows subsequent evaluation of all three parameters
Honing angle
Protractor
Angle template
Assessment of fax film

impressions
Analysis assisted by magnifying glass, visual assessment

- experience required
NI
Roughness Rz,
Measuring device
measured at the TDC 1 and
mid-stroke ranges of piston
ring 1
TR
AI
Honing pattern, i.e. profile

and distribution of machining marks, so-called sheet
metal jacket formation
(smudging and tearing
along honing marks),
(cellulose acetate film)

under the microscope (50x
magnification)
Residual unhoned "holes"
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Table 2: Assessment of running surface of cylinder liners following honing
V32/40;V32/40PGI
Characteristic
6 (10)
6632 050.05-01 EN
6632 050.05-01 EN
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V32/40;V32/40PGI
12 Air connection with universal joint

13 Grinding element with honing
stones
3 Extension pipe
14 Cleaning brush
4 Stop for stroke limiter
15 Honing head
5 Remote control
16 Funnel
17 Spring strap
7 Guide arm with control valves
18 injection nozzle
8 Extension
19 Cylinder liner
9 Support
20 Container
11 Drive unit
24 Ball-bearing
Figure 1: Pneumatic honing device when mounted
TR
1 Rope pull
2 Cross bar
AI
NI
NG
PU
RP
OS
E
ON
LY
050.05
MAN Diesel & Turbo
7 (10)
050.05
RP
OS
E
ON
LY
MAN Diesel & Turbo

26 Filter/water separator
27 Oiler
PU
28 Pressure regulating valve
A Compressed air supply

B Compressed air to rope-pull
motor (lifting speed)
C Compressed air to drive unit
(rotational speed)
D Compressed air to guide arm/
honing head (contact pressure)
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V32/40;V32/40PGI
NG
29 Pressure gauge
Figure 2: Air supply station (side view and view from above)
8 (10)
6632 050.05-01 EN
NG
PU
RP
OS
E
ON
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050.05
MAN Diesel & Turbo
6632 050.05-01 EN
V32/40;V32/40PGI
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16 Funnel
31 Hose
19 Cylinder liner
32 Collecting tank
24 Ball-bearing
Honing angle
Figure 3: Honing of cylinder liner (starting position)
9 (10)
050.05
NI
AI
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X 135 45 honing angle

Y 120 60 honing angle
Figure 4: Auxiliary material required to manufacture a honing angle template
V32/40;V32/40PGI
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
10 (10)
6632 050.05-01 EN
055
TR
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6632 055-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
055
ON
LY
RP
OS
E
PU
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
NG
111
112
113/114
120
125
140
160-162
FO
MAN Diesel & Turbo
2 (2)
6632 055-05 EN
Cylinder head bolts

Safety requirements
RP
OS
E

Checking bolted connections,
loosening them,
tightening them.
Engine stopped
Tools/aids required
Quan- Designation
tity
Number
Status
055.157
Standard
2 Thrust piece
055.156
Standard
2 Thrust piece
030.243
Standard
4 Holder
012.042
Option
1 Socket wrench insert
012.043
Option
009.342
Standard
009.320
Standard
009.306
Standard
009.097
Standard
009.096
Standard
1 Ratchet 12.5
008.200
Standard
1 Torque wrench 5-60 Nm
008.181
Standard
1 Torque wrench
008.017
Standard
1 Adapter 25x20
001.924
Standard
1 Extension piece 20x200
001.913
Standard
1 Tommy bar, 10
000.263
Option
Inventory
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NG
PU
2 Tension screw

Work card
Work card
Work card
000.30
009.01
009.03
6632 055.01-01 EN
V32/40
ensure operational safety of the bolted connections.
Cylinder head bolts are to be checked at regular intervals using hydraulic tensioners.
ON
LY
Summary
055.01
MAN Diesel & Turbo
1 (7)
055.01
MAN Diesel & Turbo
Work sequence 1 - Checking the cylinder head bolts

Work steps
Fitting retaining bows
ON
LY
1. Remove protection caps (1).
To prevent damage to the cylinder head bolts (2), before fitting check
the retaining bows (012.042) for defects (sharp edges, etc.) and rectify,
if any are found.
RP
OS
E
2. Fit the clamp screw (012.042-1) between cylinder head (3) and backing
ring (4) around um cylinder head bolts (2).
3. Put stop pieces (012.042-2) on the bow.
4. Screw the nuts (5) on the clamp screw and tighten with a torque of 15
Nm.
5. Clean the threads of the cylinder head bolts (2).
6. Loosen the nuts (6) using appropriate tools and unscrew them.
7. Remove the retainer plate (7) from the cylinder head bolts (2).
8. Loosen the fastening screws (9) and remove the cylinder head cover
(8).
PU
9. Screw tension bolts (055.157) onto cylinder head bolt on the exhaust
side up to the contact. See Fig. 3.
10. Push the thrust pieces (055.156) over the tension screws.
NG
11. Screw on the tensioning cylinder (009.096) onto the tension screws; in
the process, make sure that the tensioning cylinder thrust piece is centred.
12. Push the thrust pieces (030.243) over the cylinder head bolts on the
exhaust counter side.
NI
AI
14. Rotate back the tensioning cylinder through 530.

V32/40
16. Start up the high-pressure pump or hydraulic hand pump (see Work
Card 009.03) and close the gap between the thrust pieces and the tensioning cylinder which has been created by rotating back the tensioning
cylinder.
2 (7)
6632 055.01-01 EN
2010-12-17 - de
TR
FO
13. Screw on the tensioning cylinder (009.097) onto the cylinder head bolts;
in the process, make sure that the tensioning cylinder thrust piece is
centred.
Danger area in axial direction!
ON
LY
Powerful forces can be released in the axial direction if the highpressure hydraulic tightening devices are damaged. This could inflict
personal injury and cause material damage. You should therefore make
sure when working with hydraulic tightening devices that all persons
stay clear of the extended axis of the tightening device.
Maximum tensioning pressure
055.01
MAN Diesel & Turbo
RP
OS
E
The pressure must lie max. 7% under and 5% over the tension
pressure (see Work Cards 000.30 and 000.33 or drawing "ZSB - Unit"
in Volume 000 System Information - Drawings).
18. Make a note of the release pressure and compare it to the specified
tensioning pressure.
19. Adjust the high-pressure pump to the specified locking pressure or
operate the hydraulic hand pump up to the required locking pressure
and retighten the nuts.
PU

21. Put the retainer plate (7) on the cylinder head bolts (2).
NG
22. Screw the nuts (6) on the the cylinder head bolts (2) and tighten with a
torque of 200 Nm.
Alignment of the retainer plate
TR
R
FO
2010-12-17 - de
23. Unscrew the nuts (5) from the clamp screw.

24. Remove the the stop piece and the clamp screw.
25. Place the cylinder head cover (8) on the cylinder head (3) and fix with
fastening screw (9).
26. Retract pistons of the tensioning cylinders. See Work Card 009.01.
Work sequence 2 - Releasing the cylinder head bolts
Work steps
1. Fit the hydraulic tensioners on the cylinder head bolts (2) and loosen the
nuts (10). See work sequence 1, points 1 to 17.
2. Turn back nuts. Turn-back angle see Work Card 000.30.
6632 055.01-01 EN
V32/40
AI
Removing the holder
To prevent damage to the surrounding components and tools, the

holder (012.042) should be removed while the engine is in operation.
NI
Pay attention to the alignment of the nut (6) and retainer plate (7). See
figure 2 / View Y.
3 (7)
055.01
MAN Diesel & Turbo
Work sequence 3 - Tightening the cylinder head bolts

Starting position
Work steps
ON
LY
Cylinder head (3) put on, nuts (10) screwed onto the cylinder head bolts (2).
1. Tighten the nuts (10) of the cylinder head bolts (2) with the Tommy bar
2. Screw tension bolts (055.157) onto cylinder head bolt on the exhaust
side up to the contact. See Fig. 3.
3. Push the thrust pieces (055.156) over the tension screws.
RP
OS
E
4. Screw on the tensioning cylinder (009.096) onto the tension screws; in

the process, make sure that the tensioning cylinder thrust piece is centred.
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
centred.
PU

NI
NG
8. Start up the high pressure pump or the hydraulic hand pump (see Work
Card 009.03) and tighten the cylinder head bolts using the specified
tension pressure (see Work Card 000.30). Tighten the nuts (10) using
the tommy bar hand-tight.
Powerful forces can be released in the axial direction if the highpressure hydraulic tightening devices are damaged. This could inflict
personal injury and cause material damage. You should therefore make
sure when working with hydraulic tightening devices that all persons
stay clear of the extended axis of the tightening device.
AI
4 (7)

10. Put the retainer plate (7) on the cylinder head bolts (2).
11. Screw the nuts (6) on the the cylinder head bolts (2) and tighten with a
torque of 200 Nm.
Alignment of the retainer plate

Pay attention to the alignment of the nut (6) and retainer plate (7). See
figure 2 / View Y.
6632 055.01-01 EN
2010-12-17 - de
TR
R
V32/40
FO
Danger area in axial direction!
055.01
MAN Diesel & Turbo
ON
LY
Removing the holder
To prevent damage to the surrounding components and tools, the

holder (012.042) should be removed while the engine is in operation.
13. Unscrew the nuts (5) from the clamp screw.
12. Mount the protection caps (1).
14. Remove the the stop piece and the clamp screw.
15. Place the cylinder head cover (8) on the cylinder head (3) and fix with
fastening screw (9).
6632 055.01-01 EN
V32/40
5 Nut
1 Protection cap
3 Cylinder head
4 Backing ring
Figure 1: Detaching / attaching the retainer plates
FO
2010-12-17 - de
TR
AI
NI
NG
PU
RP
OS
E
5 (7)
055.01
NI
AI
7 Retaining plate
2010-12-17 - de
TR

6 Nut
Figure 2: Detaching / attaching the retainer plates
V32/40
FO
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
6 (7)
6632 055.01-01 EN
AI
TR
R
FO
2010-12-17 - de
10 Nut
NI

8 Cylinder head cover
3 Cylinder head
9 Fastening screw
Figure 3: Attaching the hydraulic tensioners to the cylinder head bolts
6632 055.01-01 EN
V32/40
NG
PU
RP
OS
E
ON
LY
055.01
MAN Diesel & Turbo
7 (7)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Cylinder head
ON
LY
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.
RP
OS
E

Safety requirements
Fuel systems isolated / depressurized
Engine stopped
Tools/aids required
Number
Status
1 Suspension device
055.205
Standard
1 Carrier
055.205-1
Standard
034.006
Standard
002.454
Standard
Inventory
Inventory
Inventory
1 Pilot rod
PU
Quan- Designation
tity
NG
1 Shackle A1.6
NI
055.02
MAN Diesel & Turbo
055.01
434.01
TR
Work card
Designation
Information
Cylinder head, complete
750 kg
Cylinder head
525 kg
FO
2009-03-10 - de
Technical data
6629 055.02-03 EN
32/40
Work card
AI
Work card
1 (5)
055.02
MAN Diesel & Turbo
NG
PU
RP
OS
E
ON
LY
Work sequence 1 - Removing the cylinder head

16 Cylinder head
17 Charge air pipe section
Figure 1: Cylinder head with fitted suspension device
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
TR
AI
NI
Cooling water in the engine has been lowered to below the cylinder heads,
cooling water for the injection valves has been drained.
32/40
FO
Starting position
2 (5)
6629 055.02-03 EN
5
6
7
8
9
10
11
Cylinder head bolt

Nut
O-ring seal
Stud
Exhaust pipe
Sleeve
O-ring seal
12
13
14
15
16
17
18
Top land ring

Backing ring
Sealing ring
O-ring seal
Cylinder head
Charge air pipe section
sealing screw on distribution
block
PU
Figure 2: Cylinder head
RP
OS
E
ON
LY
055.02
MAN Diesel & Turbo
Cocks in the fuel pipes closed. Shut-off valve on compressed air tank closed,
starting air pipes not under pressure.
NG
Running gear switched so that the piston of the relevant cylinder is at ignition
TDC, cylinder head hood removed, cylinder head bolts released, push rods
removed.
Work steps
1. Remove all pipes and fasteners for the pipes from the respective cylinder head.
2. Detach casing of the exhaust pipe partially.
NI
3. Open the pipe clamp on the exhaust pipe connection.
R
FO
2009-03-10 - de
TR
6. Remove pressure pipe of injection line (see Work Card 434.01).

7. Remove the starting air pipe from the starting valve (see Work Card
161.01).
8. Unscrew and remove the nuts (6).
9. Set down the carrier (055.205-1) on the cylinder head (16) and secure it
with the hexagon bolts (1 and 2).
10. Fasten the rope with the shackle (002.454) to the carrier and attach to
lifting tackle.
Take care to select the correct suspension point (see figure 1).
6629 055.02-03 EN
32/40
AI
5. Release pipe clamps on charge air pipe section (17) and displace.
4. Unscrew screw plug (18) and drain condensed water from the charge
air pipe (17). Screw the sealing screw back in place (see figure 2).
3 (5)
055.02
MAN Diesel & Turbo
ON
LY
12. Lift cylinder head whilst guiding with the pilot rod and place on the
wooden support.
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.
RP
OS
E
14. Clean the cylinder head (see Work Card 055.03).
Work sequence 2 - Installing the cylinder head

Starting position
PU
The cylinder head has been cleaned; the sealing faces between the cylinder
head and the piston top land ring or cylinder liner, and between the cylinder
head and exhaust pipe, have been cleaned. All covers have been removed.
NI
1. Check sealing ring (14), replace if necessary.
3. Set down the carrier (055.205-1) on the cylinder head (16) and secure it
with the hexagon bolts (1 and 2).
4. Fasten the rope with the shackle (002.454) to the carrier and attach to
lifting tackle.
6. Insert new O-ring seals (7 and 20) that have been lubricated with acidfree grease in the ring grooves, making sure they are evenly tensioned
all around the circumference and are not twisted.
32/40
7. Move cylinder head until it is above the centre of the cylinder then lower
it, using the pilot rod to guide it.
4 (5)
6629 055.02-03 EN
2009-03-10 - de
TR
AI
2. Remove sleeves (10 and 22) and remove both O-ring seals (11); insert
new O-ring seals lubricated with acid-free grease in the ring grooves,
making sure they are evenly tensioned all around the circumference and
are not twisted. Install sleeves (see Figs. 2 and 3).
FO
Work steps
NG
11 O-ring seal
20 O-ring seal
13 Backing ring
21 Push rod
16 Cylinder head
22 Sleeve
19 Sleeve
Figure 3: Connecting sleeves between cylinder head and backing ring
ON
LY
Do not damage the stud bolts (8) and cylinder head bolts (5); observe
the position of the sleeves (10, 19 and 22).
055.02
MAN Diesel & Turbo
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).
RP
OS
E
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
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.
PU
16. Open all closed cocks.
6629 055.02-03 EN
32/40
R
FO
2009-03-10 - de
TR
AI
NI
NG
If the cylinder head is leaking in spite of tightened cylinder head bolts, it

must be removed again and the sealing ring should be checked.
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Cylinder head
cleaning

1 Assistant
Tools/aids required
Quan- Designation
tity
RP
OS
E
This includes:
Cleaning the components
Duration in h
Number
Status
Inventory
1 Cleaning trough
Inventory
1 Wire brush
Inventory
1 Safety goggles
Inventory
1 Protective gloves
Inventory
NG
PU
1 Degreasing and cold cleaning agent
NI
Work card
000.08
Work card
Work card
055.02
113.01
Cylinder head has been removed, rocker arm casing and charge air pipe
section has been removed, inlet and exhaust valves have been removed.
R
FO
2009-04-28 - de
TR
Starting position
AI
Work sequence - Cleaning the cylinder head
6629 055.03-02 EN
32/40;L32/44CR
ensure/restore operational safety.
Cylinder heads have to be cleaned from soot and coke deposits at regular
intervals.
ON
LY
Summary
055.03
MAN Diesel & Turbo
1 (2)
055.03
Figure 1: Sectional view of a dismounted cylinder head
Work steps
RP
OS
E
ON
LY
MAN Diesel & Turbo
PU
1. Check the inlet and outlet channels as well as the side positioned
toward the combustion chamber for deposits and, if necessary, clean
any sticking debris. Do not damage the surface in the process.
2. Check cooling chambers for deposits, if needed, remove coating (see
Work Card 000.08).
3. Clean any oily sludge off the upper surface of the cylinder head.
NI
AI
TR
2009-04-28 - de
R
32/40;L32/44CR
FO
NG
4. Install inlet and exhaust valves (see Work Card 113.01)
2 (2)
6629 055.03-02 EN
Tools/aids required
Quan- Designation
tity
RP
OS
E
The work includes:

Grinding the sealing face or the sealing groove.
Number
Status
050.119
Option
050.119-1
Option
050.119-2
Option
002.452
Standard
000.142
Standard
Inventory
1 Depth gauge
Inventory
1 Grinding paste, silicon-free
Inventory
1 Grinding-in fixture
1 Grinding wheel
2 Bow
1 Shackle A0.6
Work card
Work card
050.01
055.02
055.05
AI
Preliminary remarks
Work card
NI
NG
PU
R
FO
2007-10-31 - de
TR
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
cylinder head and top land ring must be at least 0.5 mm (see figure 2 in
the "work sequence" section).
6629 055.04-01 EN
32/40
Check components for condition/wear condition, prevent operating problems/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, reworked.
Summary
ON
LY
Sealing face on the cylinder head and the sealing groove in the top land ring
grinding
055.04
MAN Diesel & Turbo
1 (3)
055.04
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
NG

3 Top land ring
B Sealing face
2 Cylinder head
C Sealing groove
Figure 1: Grinding the sealing face on the cylinder head (illustration on the left) or the sealing groove in the top land ring
(illustration on the right)
Work sequence 1 - Grinding the sealing face on the cylinder head or sealing groove in
the top land ring
NI
The cylinder head has been removed and has been clamped into the turnover stand. The top land ring has been removed and the sealing ring has
been taken out.
AI
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.
32/40
3. Set the grinding tool onto the sealing face or insert it in the sealing
groove, see figure 1.
2 (3)
6629 055.04-01 EN
2007-10-31 - de
Do not apply too much grinding paste.
TR
Work steps
FO
Starting position
ON
LY
If necessary, hook the grinding tool with the shackle (002.452) to the
rope and using the lifting tackle, place it on the cylinder head or the top
land ring.
055.04
MAN Diesel & Turbo
4. Rotate the grinding tool back and forth, lift it up every now and then so
that the grinding paste can be redistributed.
RP
OS
E
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.
AI
R
FO
2007-10-31 - de
TR
Figure 2: Gap between the top land ring cylinder liner when the sealing ring is fitted
6629 055.04-01 EN
32/40
Cylinder head
Top land ring
Sealing ring
Cylinder liner
Backing ring
Gap
2
3
4
5
6
A
NI
NG
PU
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
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Cylinder head with reversing device

working/machining
ON
LY
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.
1 Turnover stand
RP
OS
E
Tools/aids required
Quan- Designation
tity
Technical data
Designation
Number
Status
055.153
Option
Inventory
Information
PU
Cylinder head 32/40
503 kg
515 kg
Cylinder head 32/44 CR
538 kg
NG
Cylinder head 32/40 PGI
General
055.05
MAN Diesel & Turbo
Grinding the valve seating surfaces in the cylinder head,
Checking the valve seats (see Work Card 113.03),
Measuring the inlet and exhaust valve seating surfaces,
Installing and removing the valve seat rings in the cylinder head (see
Work Card 113.04).
AI
TR
Work sequence - Mounting the cylinder head
R
FO
2008-09-19 - de
Starting position
Work steps
Cylinder head is hooked with the suspension device to the lifting tackle.
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
figure).
3. Open the support bracket and the locking latch (10).
4. Set the cylinder head down (see figure) and clamp it down with the support bracket. Close the locking latch.
5. Remove the suspension device. With a locking lever (7) flipped upward,
the cylinder head may now be brought into any desired position by
turning the handwheel (locking positions every 45).
6629 055.05-01 EN
32/40;32/44CR;V32/40PGI
thoroughly cleaning and checking the cylinder head (see Work Card
055.03),
NI
The turnover stand is suitable for:
1 (2)
055.05
MAN Diesel & Turbo
ON
LY
When working on the cylinder head, it is of utmost importance that the

locking lever locks into a groove in the adapter head (4).
11 Exhaust valve
7 Locking lever
8 Cylinder head
9 Adapter plate
12 Inlet valve
13 Collecting trough
14 Minimum circumscribed
circle (cylinder head with
valves)
PU
6 Reversing shaft axis
NG
1 Frame for the turnover

stand
2 Adapter plate
3 Shuttle gearbox
4 Adapter head
RP
OS
E
6. The adapter plates can be left attached to the frame (1) for storage.
NI
AI
TR
2008-09-19 - de
FO
32/40;32/44CR;V32/40PGI
5 Support bracket
10 Locking latch
Figure 1: The cylinder head is mounted in the turnover stand
2 (2)
6629 055.05-01 EN
071
TR
R
FO
6632 071-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
071
ON
LY
RP
OS
E
PU
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
NG
111
112
113/114
120
125
140
160-162
FO
MAN Diesel & Turbo
2 (2)
6632 071-05 EN
Summary
ON
LY
Speed sensor
inspection, removal and installation
Execute work on time according to the maintenance schedule, free components from dirt/residues, ensure / restore operational safety.
Check speed sensors at regular intervals and replace if necessary.
Safety requirements
RP
OS
E

checking parts/ components,
Engine stopped
Voltage supply / voltage generation interrupted

PU
1 Technician
Tools/aids required
Duration in h
0,2
Number
Status
000.451
Option
Inventory
1 Screwdriver (Set)
Inventory
NI
NG
Quan- Designation
tity
071.01
MAN Diesel & Turbo
R
FO
2007-10-31 - de
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.
6629 071.01-02 EN
32/40
1. Check the cable (8) to the speed sensors (3).
Engine shut off.
TR
Starting position
Work steps
AI
Work sequence 1 - Checking the speed sensor
1 (3)
071.01
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 Flywheel
8 Cable
9 Terminal box
F Gap between flywheel and
speed sensor
7 Dead centre indicator
A 1SE for engine-dependent
control (alarm)
Figure 1: Speed sensor with dead centre indicator
NG
PU
3 Speed sensor
4 Holder
5 Hexagon nut
B 2SE for engine-dependent

control (safety)
C 3SE for speed sensor
D 4SE for speed regulation
E 5SE for Slow Turn
Work sequence 2 - Removing and installing a speed sensor

Starting position
Work steps
Engine is switched off and has cooled down to room temperature.

1. Pull out plug (11) from relevant revolution recorder (3).
NI
AI
3. Unscrew the hexagon nuts (5) of the relevant revolution recorder and
pull the revolution recorder from the holder (4).
5. Fit the revolution recorder to the holder (4) with hexagon nuts (5) (see
figure 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
TR
4. Unscrew the hexagon nut on the new revolution recorder.
32/40
FO
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.
2 (3)
6629 071.01-02 EN
AI
1. Tighten hexagon nuts (5), whilst taking care with the revolution
recorder.
2. Carry out a function test.
FO
2007-10-31 - de
TR
After final tightening of the hexagon nuts (5) check the gap (F) once
again.
6629 071.01-02 EN
32/40
Cable
Terminal box
Cylinder crankcase
Plug
NI
1 Crankshaft
8
2 Flywheel
9
3 Speed sensor
10
7 Dead centre indicator
11
Figure 2: Speed sensor with dead centre indicator
NG
PU
RP
OS
E
ON
LY
071.01
MAN Diesel & Turbo
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
073
TR
R
FO
6632 073-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
073
ON
LY
RP
OS
E
PU
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
NG
111
112
113/114
120
125
140
160-162
FO
MAN Diesel & Turbo
2 (2)
6632 073-05 EN
Safety requirements
RP
OS
E
The work includes:

Engine stopped
Tools/aids required
Quan- Designation
tity
Number
Status
008.200
Standard
1 Torque wrench 5-60 Nm
008.181
Standard
001.790
Option
Inventory
1 Metal adhesive (Loctite Adhaesiv 307)
Inventory
NG
PU
1 Ratchet 12.5
Technical data
Information
Crankcase cover with safety valve
15 kg
Safety valve
9,5 kg
AI
NI
Designation
Preliminary remarks
R
FO
2010-12-14 - de
TR
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.
Do not open after an alarm or an engine stop until at least 10 minutes

have passed because of increased temperatures in the bearings or
concentrated oil mist in the crankcase. There is a risk of explosion
from inflowing oxygen, because components, which have run hot and
their surrounding operating media can reach ignition temperatures.
6632 073.01-01 EN
V32/40
ensure/restore operational safety.
Safety valves on crankcase covers must be checked for ease of motion at
regular intervals.
Summary
ON
LY
Safety valve on crankcase cover

inspecting
073.01
MAN Diesel & Turbo
1 (5)
073.01
MAN Diesel & Turbo
Work sequence 1 - Checking the safety valves

Work steps
2. Remove the crankcase cover (3).
ON
LY
1. Slacken the nuts (2) and turn the retaining bow (1).
3. Check that safety valve (7) is in good condition and check for ease of
movement, detach if necessary and replace with new safety valve (see
work sequence 2).
4. Check valve plate (11), compression spring (10) and O-ring seal (9) for
damage, detach safety valve (7) if necessary and replace with a new
safety valve (see work sequence 2).
RP
OS
E
5. Check sealing ring (5) for damage, replace if necessary.
Before installing a new sealing ring, clean the groove in the crankcase
cover to remove any adhesive residue that may still be attached. Glue
in the new sealing ring using metal adhesive (Loctite 307) (see Work
Card 000.19).
6. Fit crankcase cover (3) onto cylinder crankcase (4).
7. Rotate retaining bow (1) back and tighten nuts (2).
PU
8. Check the remaining safety valves in the same manner.
Work sequence 2 - Detaching and attaching the safety valve

Starting position
Work steps
Crankcase cover is detached with safety valve.
NG
1. Unscrew and remove hexagon bolts (8).

2. Remove safety valve (7) from crankcase cover (3).
3. Remove seal (6).
4. Clean the crankcase cover (3).
NI
5. Mount a new seal (6).
2010-12-14 - de
TR
AI
7. Position the new safety valve (7) on the crankcase cover (3), insert hexagon bolt (8) through the safety valve, screw into the crankcase cover
and tighten applying a maximum torque of 24.5 Nm..
V32/40
FO
6. Check the new safety valve (7) for ease of movement.
2 (5)
6632 073.01-01 EN
AI
TR
R
2010-12-14 - de
FO
6632 073.01-01 EN
V32/40
3 Crankcase cover
NI
NG
1 Retaining bow
2 Nut
Figure 1: Crankcase cover with safety valve
PU
RP
OS
E
ON
LY
073.01
MAN Diesel & Turbo
3 (5)
073.01
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
NI
8 Hexagon bolt
2010-12-14 - de
TR
AI
6 Seal
7 Safety valve
V32/40
FO
3 Crankcase cover
5 Seal
Figure 2: Crankcase cover with safety valve
4 (5)
6632 073.01-01 EN
6632 073.01-01 EN
11 Valve plate
V32/40
R
FO
2010-12-14 - de
TR
9 O-ring seal
Figure 3: Safety valve
AI
NI
NG
PU
RP
OS
E
ON
LY
073.01
MAN Diesel & Turbo
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
100
TR
R
FO
6632 100-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
100
ON
LY
RP
OS
E
PU
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
NG
111
112
113/114
120
125
140
160-162
FO
MAN Diesel & Turbo
2 (2)
6632 100-05 EN
Studs for intermediate wheel axles

inspecting
ON
LY
Summary
ensure operational safety of the bolted connections.
Studs for intermediate wheel axles are to be checked at regular intervals
using hydraulic tensioners.
Engine stopped
1 Technician
PU
1 Assistant
Duration in h
Tools/aids required
Number
Status
2 Thrust piece
030.243
Standard
2 Tensioning screw
021.251
Standard
2 Intermediate ring
021.250
Standard
009.342
Option
009.320
Standard
009.306
Standard
009.097
Standard
009.096
Standard
1 Tommy bar, 10
000.263
Standard
Inventory
TR
AI
NI
NG
Quan- Designation
tity
FO

Work card
Work card
Work card
000.30
000.32
009.01
009.03
6629 100.01-01 EN
32/40
Safety requirements
RP
OS
E

determining and evaluating the loosening pressure and
tightening the connection as per specified pressure.
2007-10-31 - de
100.01
MAN Diesel & Turbo
1 (4)
100.01
MAN Diesel & Turbo
NG
PU
RP
OS
E
ON
LY
Work sequence 1 - Checking the fastening screws
NI
6 Washer
7 Spur wheel (intermediate wheel)
8 Double spur wheel (intermediate
wheel)
9 Cover ring
32/40
2 (4)
Crankshaft external bearing is removed, covering on the coupling side is

removed, pushed in the engine longitudinal axis up to the flywheel and supported with a wooden support (see figure 2).
Work steps
1. Unscrew the hexagon bolts (4) and remove the washers (6) (see figure
1).
2. Remove the side disc (9) on axle (1) for double spur wheel (8).
4. Check the tensioning cylinder (009.096 and 009.097) to ensure that the
pistons are pressed in completely.
5. Screw the tension screws (021.251) until they abut the tensioning cylinder head (009.096) (see figure 2).
6. Push the thrust pieces (030.243) over the nuts (2) and screw the tensioning cylinder (009.096) until it abuts.
6629 100.01-01 EN
2007-10-31 - de
TR
Starting position
AI
4 Hexagon bolt
5 Lockwasher
Figure 1: Partial view of the camshaft drive (Side view)
FO
1 Axle
2 Nut
3 Stud
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 tension screws.
ON
LY
8. Rotate the entire tandem tensioner back by 2305.
100.01
MAN Diesel & Turbo

10. Put the high-pressure pump or the hydraulic hand pump into operation
(see Work Card 009.03) and close the gap that resulted from turning it
back between the thrust pieces and the axles (1).
RP
OS
E
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.
PU
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.
NG
17. Attach the covering (11) onto the coupling side and the crankshaft
external bearing.
6629 100.01-01 EN
32/40
R
FO
2007-10-31 - de
TR
AI
NI
3 (4)
100.01
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
7 Spur wheel (intermediate

11 Casing (on coupling side)
wheel)
2 Nut
8 Double spur wheel (intermediate wheel)
3 Stud
10 Flywheel
Figure 2: Attaching the hydraulic tandem tensioners (right) and sectional view of an attached tandem tensioner (left)
NI
AI
TR
2007-10-31 - de
R
32/40
FO
NG
1 Axle
4 (4)
6629 100.01-01 EN
Summary
ON
LY

inspecting
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.
RP
OS
E
The work includes:

Tools/aids required
Quan- Designation
tity
Number
Status
000.451
Option
Inventory
Preliminary remarks
100.02
MAN Diesel & Turbo
PU
We recommend having overhaul work to the camshaft drive performed at a

customer service support point or by a MAN Diesel & Turbo fitter.
Work sequence - Checking the camshaft drive
The covering cap on the control drive has been removed.
NG
Starting position
Work steps
1. Make a visual check of all gear wheels, assess the contact pattern.
NI
2. Measure the gear backlash with a feeler gauge (000.451), note it down
and compare with the prescribed values. See 010.005 Engine - Operating Instructions, Section 2.5.
6632 100.02-01 EN
V32/40
R
FO
2009-06-24 - de
TR
AI
4. Check the hexagon bolts (4) for secure seating.
3. Check spray nozzles (15) to ensure they function perfectly, if necessary,

blow them out with compressed air.
1 (2)
100.02
NI
AI
TR
Axle
Hexagon bolt
14 Crankshaft
Spurwheel (intermediate gear)
15 Spray nozzle
Double spurwheel (intermediate
16 Injection camshaft gearwheel
gear)
12 Camshaft gearwheel
Figure 1: Control drive - upper figure seen from the coupling side
2009-06-24 - de
1
4
7
8
V32/40
FO
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 (2)
6632 100.02-01 EN
TR
R
FO
6632 101/102-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
101/102
MAN Diesel & Turbo
1 (2)
101/102
ON
LY
RP
OS
E
PU
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
NG
111
112
113/114
120
125
140
160-162
FO
MAN Diesel & Turbo
2 (2)
6632 101/102-05 EN
Injection camshaft
Removing and installing camshaft section
ON
LY
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.
RP
OS
E

installing components,
Logging the measured values.
Engine stopped
Duration in h
PU
1 Assistant
1 Engineer
NG
1 Technician
Tools/aids required
Number
Status
1 Torque wrench
008.011
Standard
001.757
Standard
000.298
Standard
Inventory
Inventory
Inventory
Inventory
1 Marker pen
Inventory
FO
2007-10-31 - de
TR
AI
NI
Quan- Designation
tity
Work card
Work card
Work card
000.30
200.03
200.07
6629 101.10-01 EN
32/40
Safety requirements
101.10
MAN Diesel & Turbo
1 (4)
101.10
MAN Diesel & Turbo
Technical data
Information
ON
LY
Designation
Camshaft section
45 kg
Preliminary remarks
RP
OS
E
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 fitting 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 certificate will become void.
Work sequence 1 - Evaluation of the current condition or evaluation of the target

condition
As far as is permitted by the damage, evaluate the current condition on
the relevant cam (see Work Card 200.07).
Determine the current condition of the plunger lift (seen from the direction
of camshaft drive).
Compare the evaluated values with the values given in the acceptance
test record or the IMO certificate and note in the engine log.
PU
Work sequence 2 - Removing a camshaft section
NG
Starting position
Fuel injection pump of the relevant camshaft section removed. Turn the
engine, if possible, so that the adjacent pump drive rollers are in position on
the relevant cam base circle.
Work steps
NI
1. Unscrew the hexagon socket bolts (4) and remove the lubricating oil line
(1) to the thrust bearing.
AI
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
lifting 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.
32/40
8. Remove the camshaft section through the opening on the cylinder

crankcase (5).
2 (4)
6629 101.10-01 EN
2007-10-31 - de
TR
3. Mark the location of the camshaft section with a marker pen (e.g. at the
point of maximum cam lift)
FO
2. Unscrew hexagon bolts (2) and remove thrust bearing of the injection
camshaft (3).
PU
RP
OS
E
ON
LY
101.10
MAN Diesel & Turbo
9
10
11
12
Hexagon bolt
Bearing ring
Camshaft section
Rope
NG
1 Lube oil pipe

2 Hexagon bolt
6 Fuel injection pump
3 Thrust bearing
7 Hexagon bolt
8 Hexagon nut
Figure 1: Removing the camshaft section (illustration shows in-line engine)
Work sequence 3 - Fitting a camshaft section
AI
1. Insert the camshaft section in correct location and bolt to the injection
camshaft hand-tight.
R
FO
2007-10-31 - de
TR
2. Fitting the fuel injection pump (see Work Card 200.07)

3. Determine the plunger lift of the camshaft section (see Work Card
200.03).
4. Compare the value determined with the target value from the acceptance test record or the IMO certificate.
5. If the actual value is within the permitted range continue to work
sequence 3 point 8. Otherwise continue from point 6.
6. Release the camshaft bolted connections and adapt the relative position of the camshaft section in accordance with the value determined.
7. Determine the plunger lift again (see Work Card 200.07). Repeat the
process until the plunger lift is within the permitted range.
8. Tighten the camshaft bolted connections with MoS2 lubricant and prescribed tightening torque (see Work Card 000.30).
6629 101.10-01 EN
32/40
Work steps
Roller of the fuel injection pump drive on relevant camshaft section checked,
replaced if necessary. The fitting of a camshaft section best takes place in
reverse order to the removal. In doing so, observe the following points:
NI
Starting position
3 (4)
101.10
MAN Diesel & Turbo
9. Determine and adjust the plunger lift of the subsequent camshaft sections (seen in the direction of the camshaft drive) in the same way.
PU
RP
OS
E
ON
LY
Only release the screwed connections on the replaced camshaft

section in order to adjust the plunger lift.
AI
NI
9 Hexagon bolt
11 Camshaft section
13 Starting cam
TR
2007-10-31 - de
R
32/40
FO
NG
7 Hexagon bolt
8 Hexagon nut
Figure 2: Fitting the camshaft section
4 (4)
6629 101.10-01 EN
Injection/valve camshaft
Check thrust bearing
ON
LY
Summary
Check components for state/wear condition, ensure/ restore operational

safety.
Examine the thrust bearings of the valve and injection camshaft regular intervals for damage, determine the axial clearance. This helps detect changes /
problem sources in a timely manner and rectify them if necessary.
Quan- Designation
tity
RP
OS
E
The work includes:

Tools/aids required
Number
Status
002.452
Standard
000.142
Standard
Inventory
Inventory
1 Sliding calliper
Inventory
1 Depth gauge
Inventory
1 Sealing compound
Inventory
Inventory
1 Shackle A0.6
NG
PU
Work card
102.02
MAN Diesel & Turbo
Work card
Work card
Bearing body
47 kg
Work sequence 1 - Checking the thrust bearing
R
FO
2009-01-15 - de
Work steps
1. Remove the lube oil supply pipe (6) to the thrust bearing.
2. Remove the cap (9).
3. Remove butting disc (8).
4. 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.
6629 102.02-01 EN
32/40
Information
TR
Designation
AI
Technical data
NI
000.11
1 (3)
102.02
RP
OS
E
ON
LY
MAN Diesel & Turbo
8
9
10
11
12
13
Butting disc
Cover
Hexagon bolt
Hexagon bolt
O-ring seal
Oil bore
NG
PU
1 Valve camshaft
2 Shaft
3 Bearing bush
5 Hexagon bolt
6 Lube oil supply pipe
7 Bearing body
Figure 1: Thrust bearing for the valve camshaft
1. Push off the bearing body with two hexagon bolts M16, remove and
place on a support surface.
NI
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
TR
AI
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.
32/40
FO
2. Clean all the components and check for damage. Replace if necessary.
2 (3)
6629 102.02-01 EN
RP
OS
E
ON
LY
102.02
MAN Diesel & Turbo
7 Bearing body
A Projection
8 Butting disc
B Dimension
Figure 2: Measuring the projections to determine the axial clearance
Exchanging of the bearing bush should be carried out only by a service

support location or by MAN-Diesel staff, as the bearing bush is
pressed into the bearing body.
PU
2. Place new O-ring seal (12) coated with acid-free grease in ring groove,
ensuring that it is not twisted.
NG
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.
NI
6. Oil the contact face of the butting disc (8) and fit in position.
6629 102.02-01 EN
32/40
R
FO
2009-01-15 - de
TR
AI
8. Coat the contact face of the cap (9) with sealing compound Hylomar
SQ 32/M and fit the cap onto the bearing body.
7. Attach lube oil supply pipe (6).
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Injection/valve camshaft
Check thrust bearing
ON
LY
Summary

safety.
Examine the thrust bearings of the valve and injection camshaft regular intervals for damage, determine the axial clearance. This helps detect changes /
problem sources in a timely manner and rectify them if necessary.
Quan- Designation
tity
RP
OS
E
The work includes:

Tools/aids required
Number
Status
002.452
Standard
000.142
Standard
Inventory
Inventory
1 Sliding calliper
Inventory
1 Depth gauge
Inventory
1 Sealing compound
Inventory
Inventory
1 Shackle A0.6
Work card
Work card
000.11
000.30
NI
NG
PU
102.03
MAN Diesel & Turbo
Work card
1. Remove the lube oil supply pipe (6) to the thrust bearing.
3. Remove butting disc (8).
FO
2009-06-25 - de
TR
6629 102.03-01 EN
32/40
Work steps
AI
Work sequence - Checking the thrust bearing
1 (3)
102.03
RP
OS
E
ON
LY
MAN Diesel & Turbo
8
9
10
11
14
15
Thrust plate
Cover
Hexagon bolt
Hexagon bolt
Thrust plate
Circlip
NG
PU
1 Valve camshaft
2 Shaft
5 Hexagon bolt
6 Lubricating oil supply pipe
7 Bearing body
Figure 1: Thrust bearing for the valve camshaft

2. Push off the bearing body with two hexagon bolts M16, remove and
place on a support surface.
NI
2009-06-25 - de
TR
AI
4. 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.
32/40
FO
2 (3)
6629 102.03-01 EN
RP
OS
E
ON
LY
102.03
MAN Diesel & Turbo
7 Bearing body
A Projection
8 Thrust plate
B Dimension
Figure 2: Measuring the projections to determine the axial clearance
1. Screw lifting eye bolt (000.142) into bearing housing (7), fasten cable to
lifting eye bolt with shackle (002.452) and suspend cable from lifting
tackle.
2. Fit the bearing body carefully, taking account of the correct location.
3. Screw the hexagon bolts (5) in position.
PU
4. Oil the contact surface of the thrust washer (8) and fit in position.
5. Attach lubricating oil supply line (6).
6629 102.03-01 EN
32/40
R
FO
2009-06-25 - de
TR
AI
NI
NG
6. Coat the contact surface of the cap (9) with sealant Hylomar SQ 32/M
and fit the cap onto the bearing body.
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
ON
LY
RP
OS
E
TR
R
FO
6632 101-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
Camshaft
101
MAN Diesel & Turbo
1 (2)
MAN Diesel & Turbo
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
Camshaft
101
2 (2)
6632 101-05 EN
Carry out the work in good time in accordance with the maintenance schedule; 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.
Tools/aids required
Quan- Designation
tity
RP
OS
E
The work includes:

Number
Status
027.019
Standard
027.018
Standard
008.023
Standard
008.011
Standard
001.912
Option
001.755
Option
1 Eye bolt
000.028
Standard
1 Lifting tackle
Inventory
Inventory
Inventory
1 Rope
Inventory
1 Sealing compound (Silicone Rhodorsil)
Inventory
Inventory
1 Pipe clamp
1 Removing fixture
1 Ratchet tool
NI
NG
PU
1 Torque wrench
TR
AI
Work card
Work card
000.30
000.32
Work card
R
FO
2007-10-29 - de
Technical data
Designation
Information
Cover ring
15,5 kg
Cover with oil supply
8,5 kg
Cover with block distributor and oil pump
28 kg
Work sequence - Checking the sleeve spring packs

Work steps
1. Remove all pipes to the block distributor (1), to the cap (6) and to the oil
pump (7). Secure the openings created from the ingress of dirt.
6632 101.02-01 EN
Camshaft
ON
LY
Summary
V32/40;V32/40PGI
Torsional vibration damper of the valve camshaft

inspecting
101.02
MAN Diesel & Turbo
1 (4)
MAN Diesel & Turbo

2. Remove the cap (4), including block distributor (1), cap (6) with oil supply and oil pump (7).
Camshaft
ON
LY
4. Unscrew and remove the hexagon bolts (13). Dismantle the side disc
(14) and remove.
5. Pull out the bolts (8) with the eye bolt (000.028).
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.
RP
OS
E
101.02
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 necessary replace them.
PU
In the event of broken springs, replace entire sleeve spring pack only.
8. Clean all oil channels in the damper support (12) thoroughly.
NG
9. Brush the springs of the sleeve spring pack (9) one at a time with MoS2
lubricant.
NI
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.
2 (4)
14. Place the cap (11) on the damper carrier (12), align centrally and fix in
position with hexagon socket bolts (10).
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
crankcase with "Silicone Rhodorsil" sealing compound.
18. Fit the cap (4), including block distributor (1), cap (6) with oil supply and
oil pump (7).
6632 101.02-01 EN
2007-10-29 - de
FO
TR
AI
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).
V32/40;V32/40PGI
12. Attach the side disc (14) and locate on the torsional vibration damper.
19. Fasten cap (4) with hexagon nuts (3).
20. Align the cap (6) with oil supply centrally to the rotation vibration
damper, if necessary turn the engine over. Tighten the hexagon bolts
(5).
NG
PU
RP
OS
E
21. Connect the pipes to the block distributor (1), cap (6) with oil supply
and oil pump (7).
Camshaft
ON
LY
Make sure that the pipe on the cap (6) is inserted in the hole in the cap
(11) and that no adjacent parts are damaged!
101.02
MAN Diesel & Turbo
6632 101.02-01 EN
V32/40;V32/40PGI
R
FO
2007-10-29 - de
TR
AI
NI
1 Block distributor
5 Hexagon bolt
2 Stud
6 Cover with oil supply
3 Hexagon nut
7 Oil pump
4 Cover
Figure 1: Covering cap for valve camshaft on free engine end with fitted block
distributor and fitted oil pump
3 (4)
MAN Diesel & Turbo
NG
PU
RP
OS
E
ON
LY
Camshaft
101.02
NI
AI
TR
2007-10-29 - de
FO
V32/40;V32/40PGI
4 Cover
12 Damper support
6 Cover with oil supply
13 Hexagon bolt
8 Pin
14 Cover ring
9 Sleeve spring pack
15 Damper mass
16 Camshaft
11 Cover
Figure 2: Rotation vibration damper on the valve camshaft
4 (4)
6632 101.02-01 EN
111
TR
R
FO
6632 111-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
111
ON
LY
RP
OS
E
PU
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
NG
111
112
113/114
120
125
140
160-162
FO
MAN Diesel & Turbo
2 (2)
6632 111-05 EN
Summary
ON
LY
Valve clearance
inspection and adjustment
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.
RP
OS
E
Safety requirements
Drive shaft secured to prevent it from rotating
Engine stopped
1 Technician
0,2
0,2
PU
1 Assistant
Duration in h
Tools/aids required
Number
Status
1 Locating device
113.227
Standard
2 Fixing screw
113.227-1
Standard
1 Setting device
113.226
Standard
1 Box spanner
113.226-1
Standard
1 Box spanner
113.226-2
Standard
1 Setting gauge (exhaust valve) 0.9
113.139
Standard
1 Torque wrench
008.011
Standard
1 Feeler gauge (set) 0.2
000.455
Standard
Inventory
TR
AI
NI
NG
Quan- Designation
tity
R
FO
2010-07-16 - de

Work card
Work card
000.30
111.03
Work card
Preliminary remarks
Execute an inspection and adjustment, if necessary, for the valve clearance,
during commissioning, when new parts are installed or the rocker arms are
re-fitted after servicing activities.
6629 111.02-02 EN
32/40;32/40G;32/40PGI
111.02
MAN Diesel & Turbo
1 (5)
111.02
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
NG
1 Cylinder head cover

16 Cylinder head
2 Rocker arm (inlet valve)
19 Inlet valve
3 Rocker arm (exhaust valve)
39 Sealing cord
15 Exhaust valve
Figure 1: Cylinder head with rocker arm bearing
Engine is cold (same temperature of all engine parts), or
Engine is at operating temperature (similar temperature of all engine

parts).
AI
2 (5)
Incorrectly adjusted valve clearance
With engine at operating temperature, valve clearance may be

checked/adjusted 0.5 hours after engine shut-off at the earliest.
Checking/adjusting the valve clearance with a preheated engine is
possible, it is absolutely imperative, however, to check/adjust the valve
clearance again after the temperatures of all engine components have
adjusted. For this purpose, the engine must be operated for a minimum
of 0.5 hours. Incorrectly adjusted valve clearances may lead to short
component service lives within the valve gear and, in the case of a
valve stem rupture, to significant engine damage.
Running gear of relevant cylinder has been turned to the ignition TDC position (inlet and exhaust valves are closed). Cylinder head cover removed.
6629 111.02-02 EN
2010-07-16 - de
TR
R
FO
32/40;32/40G;32/40PGI
Starting position
NI
Work sequence 1 - Checking the valve clearance
Work steps
1. Lift the rocker arms (2 and 3) by hand, until they rest on the push rods
with no clearance.
ON
LY
2. Measure valve clearance (C) for inlet and exhaust valves (15 and 19)
between valve stem and calotte (26) with setting gauge (113.139 for
exhaust valve) or feeler gauge set (000.455 for inlet valve). For target
values, see Volume 010.005 Engine - Operating Instructions, section
2.5.6.
111.02
MAN Diesel & Turbo
3. If necessary, reset the valve clearance (C) (see work sequence 2).
19
25
26
AS
AGS
Inlet valve
Valve adjusting screw
Calotte
Exhaust side
Exhaust counter side
Starting position
FO
2010-07-16 - de
Work sequence 2 - Setting the valve clearance
Engine is cold (same temperature of all engine parts), or
Engine is at operating temperature (similar temperature of all engine

parts).
6629 111.02-02 EN
32/40;32/40G;32/40PGI
TR
2 Rocker arm (inlet valves)

3 Rocker arm (exhaust valves)
15 Exhaust valve
16 Cylinder head
17 Nut
Figure 2: Attachment of the setting device
AI
NI
NG
PU
RP
OS
E
4. Place the cylinder head hood (1) on the cylinder head (16) and fix in
position. Take care with sealing cord (39). See Fig. 1.
3 (5)
111.02
MAN Diesel & Turbo
Incorrectly adjusted valve clearance
ON
LY
With engine at operating temperature, valve clearance may be

checked/adjusted 0.5 hours after engine shut-off at the earliest.
Checking/adjusting the valve clearance with a preheated engine is
possible, it is absolutely imperative, however, to check/adjust the valve
clearance again after the temperatures of all engine components have
adjusted. For this purpose, the engine must be operated for a minimum
of 0.5 hours. Incorrectly adjusted valve clearances may lead to short
component service lives within the valve gear and, in the case of a
valve stem rupture, to significant engine damage.
RP
OS
E
Running gear of relevant cylinder has been turned to the ignition TDC position (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.
PU
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).
NG
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).
NI
8. Screw in valve adjuster screw (25), until feeler gauge fits without clearance.
AI
10. Remove feeler gauge.
12. Adjust valve clearance on the exhaust valves (15) with setting gauge
(113.139) in the same way (see points 6 to 11).
13. Place the cylinder head hood (1) on the cylinder head (16) and fix in
position. Take care with sealing cord (39). See Fig. 1.
FO
2010-07-16 - de
TR
11. Adjust the valve clearance for a second inlet valve (19) in a similar way
(see Point 6 to 10).
32/40;32/40G;32/40PGI
9. Tighten nut (17) with specified torque (see Work Card 000.30), whilst
holding the valve adjuster screw. See Fig. 3.
4 (5)
6629 111.02-02 EN
RP
OS
E
ON
LY
111.02
MAN Diesel & Turbo
6629 111.02-02 EN
32/40;32/40G;32/40PGI
R
FO
2010-07-16 - de
TR
AI
NI
NG
PU

26 Calotte
C Valve clearance
Figure 3: Adjusting the valve clearance or tightening the nuts on the setting screws
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Rocker arm bracket with control levers

ON
LY
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.
RP
OS
E

Dismantling components,
fitting components.
Engine stopped
1 Technician
0.5
0.5
PU
1 Assistant
Duration in h
Tools/aids required
Number
Status
1 Locating device
113.227
Standard
2 Fixing screw
113.227-1
Option
000.143
Standard
1 Shackle A1.0
002.453
Standard
1 Ratchet tool
008.023
Standard
1 Torque wrench
008.011
Standard
1 Socket spanner insert (set)
Inventory
Inventory
Inventory
TR
AI
NI
NG
Quan- Designation
tity
R
FO
2007-07-18 - de

Work card
Work card
000.30
111.02
Work card
Technical data
Designation
Information
Rocker arm bracket with control levers
95 kg
6629 111.03-03 EN
32/40
Safety requirements
111.03
MAN Diesel & Turbo
1 (4)
111.03
MAN Diesel & Turbo
Work sequence 1 - Removal of rocker arm support with control level

Starting position
ON
LY
Running gear of the relevant cylinder in ignition -TDC (all valves closed). Cylinder head cover removed.
Work steps
1. Lift the rocker arms (2, 3) by hand, until they rest on the push rods without clearance.
2. Screw in fixing screws (113.227-1) thus keeping the rocker arm in a
clearance-free position (see figure 2).
3. Screw in the lifting eye bolt (000.143) in rocker arm bracket (1).
4. Unscrew three hexagon bolts (4) and remove them with washers (5)
(see figure 3).
RP
OS
E
5. Fasten cable with shackle (002.453) on lifting eye bolt and suspend
from lifting tackle.
6. Lift up rocker arm bracket (1) with rocker arm (2, 3) carefully, paying
attention to distance sleeves (6) and push rods.
7. Lift up the rocker arm bracket completely and place it on the wooden
support.
NI
AI
2 (4)
6629 111.03-03 EN
2007-07-18 - de
TR
R
1 Rocker arm bracket

4 Hexagon bolt
5 Washer
6 Spacer sleeve
Figure 1: Cylinder head with rocker arm bearing
32/40
FO
NG
PU
8. Remove distance sleeves (6) (see figure 4).
RP
OS
E
ON
LY
111.03
MAN Diesel & Turbo
4 Hexagon bolt
5 Washer
6 Spacer sleeve
Work sequence 2 - Attachment of rocker arm bracket with control lever
Starting position
Contact surfaces on rocker arm bracket, distance sleeves, cylinder head,

valve cones, rocker arms and push rods have been cleaned.
6629 111.03-03 EN
32/40

Figure 3: Removing the rocker arm bearing
R
FO
2007-07-18 - de
TR
AI
NI
NG
PU

Figure 2: Attachment of the locating device
3 (4)
111.03
MAN Diesel & Turbo
Work steps
1. Insert rocker arm (2,3) in rocker arm bracket and fasten with fixing
screws (113.227-1).
2. Screw in lifting eye bolt (000.143) in rocker arm bracket.
ON
LY
3. Fasten cable with shackle (002.453) on lifting eye bolt and suspend
from lifting tackle.
4. Lift rocker arm bracket with rocker arm and move over cylinder centre.
5. Insert distance sleeves (6) in cylinder head (16) (see figure 4).
6. Lower the rocker arm bracket carefully, ensuring that distance sleeves
engage in rocker arm bracket. Moreover, ensure that thrust pieces of
the rocker arm (2, 3) fit properly on pressure cup of the push rods (see
figure 4).
RP
OS
E
7. Unscrew the fixing screws (113.227-1) and lifting eye screw (000.143).
8. Screw in three hexagon bolts (4) with washers (5) and tighten with
specified torque (see Work Card 000.30) (see figure 3).
9. Readjust valve clearance on exhaust and inlet valves (see Work Card
111.02).
NI
AI
2007-07-18 - de
TR
R

6 Spacer sleeve
16 Cylinder head
Figure 4: Cylinder head with rocker arm support removed
32/40
FO
NG
PU
10. Set the cylinder head cover on rocker arm casing and tighten.
4 (4)
6629 111.03-03 EN
112
TR
R
FO
6632 112-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
Push rods
MAN Diesel & Turbo
1 (2)
112
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
Push rods
MAN Diesel & Turbo
2 (2)
6632 112-05 EN
112.01
MAN Diesel & Turbo
Summary
ON
LY
Push rods
Cam follower with valve cams

checking and evaluation
Execute work on time according to the maintenance schedule, ensure correct 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.
Engine stopped

1 Technician
PU
1 Assistant
Tools/aids required
2,5
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
1 Case for ILH-2A and IF8C5-20
101.138
Option
1 Endoscope holder
101.137
Option
1 Tripod with universal joint
101.136
Option
1 Adapter AT100D/FF
101.135
Option
1 Industrial fibrescope IF8C5-20
101.134
Option
1 High-power light source ILH-2A
101.133
Option
1 Guide tubes (Bank A)
101.130
Option
2 Support
101.129
Option
1 Guide pipes (Bank B)
101.128
Option
Inventory
1 Torch
Inventory
1 Toolbox
Option
1 Compressed air, max. 15 bar
Inventory
NI
AI
TR
R
FO
2007-10-31 - de
2,5
Number
NG
Quan- Designation
tity
Duration in h
6632 112.01-03 EN
V32/40;V32/40PGI
Safety requirements
RP
OS
E
The work includes:

1 (7)
Push rods
112.01
MAN Diesel & Turbo
ON
LY
Preliminary remarks
The guide pipes (101.128 and 101.130) are ready fitted and should not
be dismantled.
In addition to the work prescribed in the maintenance schedule there is the

checking of the running surfaces of the valve cams and of the cam follower
rollers.
RP
OS
E
In order to keep the fitting work as little as possible this work is carried out
using a flexible endoscope which is directed to the relevant points via the
guide pipes.
Operation of the fibrescope and the evaluation of the valve cam and cam follower roller running surfaces requires care and a certain level of experience.
We thus recommend having this task performed at least once for instruction
purposes by MAN Diesel & Turbo personnel.
NI
AI
TR
2007-10-31 - de
FO
V32/40;V32/40PGI
NG
PU
Read the operating instructions provided by the manufacturer before

using the fibrescope and the high-power light source and the colour
camera.
2 (7)
6632 112.01-03 EN
112.01
RP
OS
E
ON
LY
Push rods
MAN Diesel & Turbo
6632 112.01-03 EN
V32/40;V32/40PGI
5 Tool box
Figure 2: Guide tubes with supports
R
FO
2007-10-31 - de
TR
AI
NI
NG
PU
12 Bush for light guide

18 Plug for light guide
13 Ocular
19 Angle piece
14 Locking lever for bending-direc20 Flexible part
tion selection (top/bottom)
15 Locking lever for bending-direc21 Objective (direct view)
tion selection (top/bottom)
16 Locking lever for bending-direc22 Optical adapter
tion selection (right/left)
17 Locking lever for bending-direc23 Objective (side view)
tion selection (right/left)
Figure 1: Fibrescope with objective lenses and high-power light source
3 (7)
Push rods
112.01
MAN Diesel & Turbo
Work sequence 1 - Fitting the guide pipes (on the example of Bank B)
Starting position
ON
LY
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.
RP
OS
E
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 fibrescope (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).
PU
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.
NG
Danger of dazzling. Set the lowest brightness level on the high-power

light source.
5. Set the locking lever for bending-direction selection (14 and 17) in position "F".
NI
AI
7. Release locking-lever for bending-direction selection (14 and 17) and

adjust the optimum viewing angle with the bending-direction selection
lever (15 and 16) if necessary. See Fig. 5.
4 (7)
9. If fitted:
Place the Video-Adapter (101.141) on the ocular,
Fit the colour camera (101.139),
Connect the colour camera to the colour monitor (101.140) via video
cable,
Connect the colour camera and colour monitor to the power supply,
Start the colour camera and colour monitor.
Any drops of oil adhering to the valve cam can be removed by

compressed air if required. See Fig. 6.
10. Turn the engine over and check the entire valve cam running surface.
6632 112.01-03 EN
2007-10-31 - de
FO
TR
8. Focus the image in the ocular (13).
V32/40;V32/40PGI
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).
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 Fig. 5.
ON
LY
12. Turn the engine over and check the entire roller running surface.
Push rods
112.01
MAN Diesel & Turbo
6632 112.01-03 EN
11 Push rod
24 Stud
25 Nut
V32/40;V32/40PGI
R
FO
2007-10-31 - de
TR
AI
2 Valve camshaft
3 Cam follower
4 Roller
Figure 3: Mounting the guide pipes
NI
NG
PU
RP
OS
E
13. Set the locking lever for bending-direction selection (14 and 17) in position "F" to pull back the flexible part (20).
5 (7)
112.01
PU
RP
OS
E
ON
LY
Push rods
MAN Diesel & Turbo
Exhaust cam (Bank B)

Inlet cam (Bank A)
Inlet cam (Bank B)
Exhaust cam (Bank A)
AI
NI
6
7
8
9
6 (7)
3 Cam follower
8 Inlet cam (Bank B)
4 Roller
Figure 5: Fibrescope images of an inlet valve cam and a cam follower roller
6632 112.01-03 EN
2007-10-31 - de
TR
R
FO
V32/40;V32/40PGI
NG
2 Valve camshaft
3 Cam follower
4 Roller
Figure 4: Valve camshaft
112.01
ON
LY
Push rods
MAN Diesel & Turbo
RP
OS
E
8 Inlet cam (Bank B)

10 Oil drops on the running
surface
6632 112.01-03 EN
V32/40;V32/40PGI
R
FO
2007-10-31 - de
TR
AI
NI
NG
PU
Figure 6: Valve cam with adhering oil drops
7 (7)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
112.02
MAN Diesel & Turbo
Push rods
Push rods
ON
LY
Summary
Check components for quality/ wear status, ensure /restore operating safety.
push rods are to be disassembled and assessed within the scope of maintenance and repair work.
RP
OS
E


Work card
Work card
111.03
Technical data
Designation
Work card
Information
6,5 kg
PU
Push rod
Work sequence 1 - Removing the push rods

Starting position
Rocker arm casing removed, cap of the camshaft covering has been
removed.
Work steps
NG
1. Rotate push rod (1), until it can be uncoupled from the thrust piece (2)
(push rod with transverse slot, thrust piece with milled shoulder - see
figure 1).
2. Remove the push-rod (1).
NI
3. Dismantle second push rod (1) in the same manner.
R
FO
2007-10-31 - de
1. Clean thrust piece (2), then oil it lightly.

2. Place push rod (1) in the engine and set it on the thrust piece (2), paying
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).
6629 112.02-01 EN
32/40;L32/44CR;V32/40PGI
Push rods have been cleaned and checked for damage.
TR
Starting position
Work steps
AI
Work sequence 2 - Installing of the push rods
4. Clean push rods (1) and check for damage.
1 (3)
112.02
ON
LY
Push rods
MAN Diesel & Turbo
RP
OS
E
1 Push rod
3 Cam follower (inlet /
exhaust valve)
4 Cylinder head
5 Valve camshaft
NI
Figure 2: Connection push rod - cam follower
6629 112.02-01 EN
2007-10-31 - de
TR
AI
2 (3)
1 Push rod
2 Thrust piece
3 Cam follower (inlet /
exhaust valve)
FO
32/40;L32/44CR;V32/40PGI
NG
PU
Figure 1: Installed push rod (illustration shows in-line engine)
ON
LY
Push rod
Cylinder head
Exhaust side
Marking on the push rod
RP
OS
E
1
4
AS
M
Push rods
112.02
MAN Diesel & Turbo
6629 112.02-01 EN
32/40;L32/44CR;V32/40PGI
R
FO
2007-10-31 - de
TR
AI
NI
NG
PU
Figure 3: Position of the marks on the push rods, if the push rods are connected to
the thrust pieces (plan view)
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
113/114
TR
R
FO
6632 113/114-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
113/114
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 (2)
6632 113/114-05 EN
Summary
ON
LY
Valve rotator
Checking rotating motion
Execute work on time according to the maintenance schedule, check components for state/wear condition.
Valve rotators are to be assessed at regular intervals.
The work includes:
Checking parts/ components.
1 Technician
Tools/aids required
0,1
Status
Inventory
Inventory
Principle of operation
Inlet valve
Duration in h
Number
PU
Quan- Designation
tity
RP
OS
E
113.01
MAN Diesel & Turbo
FO
2009-06-26 - de
Starting position
Work steps
Engine at a standstill.
1. Remove the cylinder head hood.
2. Make line markings on the valve rotators (15) and thrust bearings (17)
with a felt-tip pen (see Fig. 2).
3. Fit the cylinder head hood and fasten.
4. Start up the engine and run it for 1 minute at nominal speed and 25%
to 30% power output.
5. Shut down the engine.
6629 113.01-03 EN
32/40;32/44CR;V32/40PGI
Work sequence - Checking the valve rotators
AI
When the valve is opened, it is put into rotation by a valve propeller on the
valve stem as soon as the gas stream flows past the valve propeller. This
rotation is made possible by a deep groove thrust ball bearing friction mounted at the top end of the valve.
TR
Exhaust valve
NI
NG
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 process, 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
valve closes, the cup spring is relieved and also the balls, which are then
pushed back to their initial position without rolling by the compression spring.
1 (3)
113.01
MAN Diesel & Turbo
Danger of burning due to hot components!
ON
LY
Wear protective gloves during assembly work! Do not walk on hot

surfaces!
6. Remove the cylinder head hood.
7. Check the markings. If the valve rotators are working correctly, the
markings will now be in a different position. If the position of the markings has not changed, repeat work steps 3 and 4 again once.
RP
OS
E
Due to dirt, especially of the ball pockets due to residues in the oil (due
to abrasion, combustion products) there can be malfunctions. The
depositions stick to the individual parts and hinder the balls in their
movement. The valve rotator must be removed, dismantled, washed
carefully and lubricated before reassembling (see Work Card 113.02).
PU
If the balls have been pressed in through concentrated load with a

non-rotating inlet and exhaust valve in the running surface, the
complete valve rotator or the thrust bearing must be replaced.
Moreover, for non-rotating inlet or exhaust valves, check the condition
of the valve cone and valve seat ring (see Work Card 113.03).
NI
Base body
Ball
Cup spring
Cover
Circlip
Pressure spring
2009-06-26 - de
TR
AI
2 (3)
1
2
4
5
6
7
Figure 1: Inlet valve rotator
FO
32/40;32/44CR;V32/40PGI
NG
8. Fit the cylinder head hood and fasten.
6629 113.01-03 EN
113.01
6629 113.01-03 EN
M Mark
32/40;32/44CR;V32/40PGI
R
FO
2009-06-26 - de
TR
12 Pressure spring
Figure 2: Inlet and outlet valve
14 Pressure spring
15 Valve rotator
16 Valve cone piece (twopart)
17 Axial bearing
18 Outlet valve cone with

valve propeller
19 Exhaust valve seat ring
AI
9 Cylinder head
10 Inlet valve cone
11 Valve guide
13 O-ring
NI
8 Inlet valve seat ring
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Inlet/exhaust valve/valve rotator

removing and installing or disassembling and assembling
ON
LY
Summary
Inlet and exhaust valves as well as valve rotator are to be disassembled at
regular intervals and overhauled if necessary.
RP
OS
E

Separating parts/ components,
Engine stopped
PU
1 Technician
Duration in h
1 Assistant
Tools/aids required
Number
Status
1 Valve spring tensioner
113.211
Standard
1 Thrust piece
113.211-1
Standard
1 Bridge
113.211-7
Standard
000.451
Option
Inventory
1 Special anti-seize agent (Molykote G Rapid, Moly- kote G-n)
Inventory
TR
AI
NI
NG
Quan- Designation
tity
R
FO
2007-11-06 - de

Work card
Work card
Work card
000.34
055.02
055.05
113.03
113.04
113.05
Technical data
Designation
Information
Inlet valve cone
3,5 kg
Exhaust valve cone
3,5 kg
6629 113.02-03 EN
32/40;L32/44CR;V32/40PGI
Safety requirements
113.02
MAN Diesel & Turbo
1 (7)
113.02
MAN Diesel & Turbo
Work sequence 1 - Removing the inlet and exhaust valves

Starting position
ON
LY
Cylinder head is removed and clamped in the cylinder head turnover stand.
Cylinder head turned through 90 in the horizontal.
If only the valve rotators / thrust bearings or the compression springs
are to be disassembled, the cylinder head remains attached and the
piston is in ignition TDC.
Work steps
RP
OS
E
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 position it centrally over the valve rotator (15) or thrust bearing (17). See Fig.
2/I.
3. Screw the hexagon nut (20) onto the spindle.
PU
4. Press down the thrust piece by rotating the hexagon nut (20), compressing 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.
NG
Make sure that the valve cone does not rotate as well. If necessary,
push back the valve cone on the valve cone plate again to the valve
seat.
NI
2 (7)
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).
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).
Note the assignment valve cone / valve guide, since valve cones which
are not overhauled (ground) must be assembled in the same valve
guide.
6629 113.02-03 EN
2007-11-06 - de
FO
TR
AI
5. Unscrew hexagon nut (20) and relieve compression springs (12 and 14).
See Fig. 2/III.
32/40;L32/44CR;V32/40PGI
If the valve cone is not held, it falls out on removing the tapered piece
from the valve guide.
113.02
MAN Diesel & Turbo
ON
LY
11. Dismantle valve rotator (15) (see work sequence 2).
10. Remove O-ring seals (13) from valve guides (11).
If the balls have been pressed in through concentrated load with a

non-rotating inlet and exhaust valve in the running surface, the
complete valve rotator or the thrust bearing must be replaced.
12. Clean all individual parts and check for damage (for max. clearance see
Operating Instructions, section 2.5), renew if necessary.
RP
OS
E
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 regarding 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).
PU
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 compare with specified clearance. Refer to the Operating Instructions in
section 2.5.
17. Check valve seats (see Work Card 113.03).
Starting position
Work steps
NG
Work sequence 2 - Dismantling and assembling the valve rotator

Valve rotator removed and placed on the support (snap ring is on top).
1. Remove snap ring (6). See Fig. 3.
2. Remove cover (5) and cup spring (4).
NI
3. Remove all balls (2) and compression springs (7) from the basic body
(1).
R
FO
2007-11-06 - de
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.
6. Insert balls (2) and compression springs (7) in the ball pocket tracks in
the basic body (1).
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.
6629 113.02-03 EN
32/40;L32/44CR;V32/40PGI
TR
AI
5. Check, and if necessary, replace, individual parts for wear and ball
indentations.
4. Wash all individual parts in a suitable cleaning agent and then dry them.
3 (7)
113.02
MAN Diesel & Turbo
7. Insert cup spring (4), place cover (5) on top and install snap ring (6).
Never fill the valve rotator with grease.
Bearings
ON
LY
8. Place valve rotator (15) in clean lubricating oil and remove shortly before
installation.
RP
OS
E
Parts kept in stock must be well packed, protected against dust, water,
humidity and aggressive media. Dust sticks to the individual parts and prevents or hampers rotation during commissioning.
Work sequence 3 - Fitting the inlet and exhaust valves

Starting position
All individual parts cleaned, cylinder head clamped in the cylinder head turnover stand. Bridge mounted on the cylinder head.
PU
If only the valve rotators / thrust bearings or the compression springs

are to be disassembled, the cylinder head remains attached and the
piston is in ignition TDC.
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.
NG
3. Install compression springs (12 and 14) in the cylinder head (9) and set
valve rotator (15) or thrust bearing (17) on compression springs.
NI
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.
4 (7)
During the assembly of the tapered piece hold the valve cone by hand
on the valve cone plate.
7. Press down the thrust piece by rotating the hexagon nut (20), compressing the compression springs (12 and 14) until the two-part tapered
piece (16) can be fitted. Insert tapered pieces. See Fig. 2/II.
6629 113.02-03 EN
2007-11-06 - de
FO
TR
AI
6. Treat valve cone stem of the valve cone (10 or 18) with "Molykote G-n"
special anti-seize agent and push into the valve guide (11). For immediate commissioning of the engine, the valve stem can also be treated
with clean engine oil.
32/40;L32/44CR;V32/40PGI
5. Screw the hexagon nut (20) onto the spindle.
ON
LY
Before releasing the compression springs, check that the two-part

tapered piece is correctly inserted and that the gap between both
parts is evenly distributed.
113.02
MAN Diesel & Turbo
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).
Inlet valve seat ring

Cylinder head
Inlet valve cone
Valve guide
Compression spring
13 O-ring seal
Figure 1: Inlet and exhaust valve
6629 113.02-03 EN
14
15
16
17
18
Compression spring
Valve rotator
Valve tapered piece (two-part)
Thrust bearing
Exhaust valve cone with valve
propeller
32/40;L32/44CR;V32/40PGI
8
9
10
11
12
R
FO
2007-11-06 - de
TR
AI
NI
NG
PU
RP
OS
E
11. Remove valve spring tensioner.
5 (7)
113.02
NI
AI
16
17
18
20
21
Tapered piece (two-part)

Thrust bearing
Exhaust valve cone
Hexagon nut
Hexagon bolt
FO
6 (7)
22 Inlet valve
23 Exhaust valve
AS Exhaust side
2007-11-06 - de
TR
9 Cylinder head
10 Inlet valve cone
15 Valve rotator
32/40;L32/44CR;V32/40PGI
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
6629 113.02-03 EN
6629 113.02-03 EN
ON
LY
32/40;L32/44CR;V32/40PGI
R
FO
2007-11-06 - de
TR
AI
NI
NG
PU
Figure 3: Inlet valve rotator
Basic body
Ball
Cup spring
Cover
Snap ring
Compression spring
RP
OS
E
1
2
4
5
6
7
113.02
MAN Diesel & Turbo
7 (7)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Summary
ON
LY

Check and assess valve cone and valve seating surfaces
Execute work on time according to the maintenance schedule, check components 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.
RP
OS
E

executing touching tests ,
assessing contact pattern /wear status.
Tools/aids required
Number
Status
1 Touching bracket for engine L,V48/60B+CR:

51/60DF
114.033
Standard
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 32/40, 32/44CR
113.224
Standard
009.231
Option
Inventory
Inventory
1 Touching-test ink
Inventory
NG
PU
Quan- Designation
tity
113.03
MAN Diesel & Turbo
Preliminary remark
Continued use poses an inestimable risk to the engine!
FO
2009-10-12 - de
TR
The valve cone material is subject to fatigue as a result of frequent temperature fluctuations. The valve cones must be replaced once the operating periods specified in the maintenance schedule (see operating instructions) have
elapsed, even if the maximum permissible refinishing limits have not yet been
reached.
6682 113.03-05 EN
General
AI
The overhaul intervals specified in the maintenance schedule (see operating

instructions) represent guide values that depend on the mode of operation,
the condition of the engine and the quality of the fuel used. The most expedient overhaul intervals should be defined based on the prescribed inspection.
NI
Exhaust and inlet valves with a faulty wear surface appearance will not have
a long service life. And must be overhauled or replaced.
1 (9)
113.03
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 Cylinder head
2 Inlet valve cone
3 Valve seat ring
4 Exhaust valve cone

5 Valve seat ring
The valve seat angle () of the valve cone is 120 with a positive tolerance.
The valve seat angle () in the valve seat ring has been engineered with a
negative tolerance which produces a small differential angle (). This ensures
that a seal against the hot gases at the outer edge of the valve seat area is
maintained during operation. See Fig. 2.
NI
General
2 (9)
Check machining tools!

Clearance may develop in older valve seat grinders or valve seat lathes
as a result of wear that changes the valve seat angle and therefore
produces an incorrect wear surface appearance! We recommend that
a touching test is carried out using a new original MAN Diesel & Turbo
valve cone! If deviations are identified, check the valve seat grinder or
valve seat lathe!
Work sequence 1 - Touching test

Starting position
Cylinder head is clamped in the cylinder head turnover stand, inlet and
exhaust valves are dismantled.
6682 113.03-05 EN
2009-10-12 - de
TR
AI
2 Inlet valve cone

Angle at valve cone
Differential angle
3 Valve seat ring
Angle at valve seat ring
Figure 2: Relationship of geometric angle between valve seat ring and valve cone - illustration shows inlet valve
FO
NG
PU
The wear surface appearance is tested by performing a touching test.
113.03
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 Inlet valve cone

Figure 3: Touching bow or touching up device - figure shows inlet valve
Work steps
1. Clean valve seating surfaces carefully.
PU
Do not damage valve cones by using the wrong cleaning device (e.g.
chipping hammer)!
2. Attach touching bow or touching up device to the valve cone (2 or 4).

See Fig. 3.
NG
3. Apply the thinnest possible layer of touching-test ink to the valve seating surfaces of the valve cone (2 or 4) and spread very thinly.
NI
4. Introduce valve cone (2 or 4) in the relevant valve guide in the cylinder

head (1) and move by half a revolution with the touching bow or touching up device under pressure in a vertical position.
7. Remove touching bow or touching up device.
Work sequence 2 - Assessing the valve seating surfaces
Starting position
FO
2009-10-12 - de
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 figure 4.
6682 113.03-05 EN
General
TR
AI
6. Check valve seating surfaces in the valve seat ring (3 or 5). With the
correct differential angle and proper rework, a closed, load bearing face
must form a closed load bearing surface on the outer edge of the valve
seat.
5. Remove valve cone (2 or 4).
3 (9)
113.03
RP
OS
E
ON
LY
MAN Diesel & Turbo
Figure 4: Figure for Result 1
Action
PU
Apply silicon-free grinding paste on the valve seating surfaces of the valve
seat rings (follow the manufacturer's instructions!) and clean by hand using a
touching bow or touching up device, until the lacquer is removed. Conduct
touching test after the cleaning (see work sequence 1).
NG
Clean as little as possible with grinding paste and then wash valve cone
and valve seat ring carefully. Residues of grinding paste promote
further wear.
2009-10-12 - de
TR
AI
Valve seating surface of the valve seat ring shows heavy deposit, deeper corrosion cracks and/or distinct impact marks. Wear on valve seat ring - see figure 5.
General
FO
Result 2
NI
Existing small cracks after cleaning are still permitted, they do not affect the
durability too much.
4 (9)
6682 113.03-05 EN
113.03
Action
RP
OS
E
ON
LY
MAN Diesel & Turbo
PU
Machine valve seat ring by using valve seat grinder or valve seat lathe until
valve seating surfaces are clean and a new contact pattern appears (see
Work Card 113.04 and 113.05). Conduct touching test after the cleaning
(see work sequence 1).
NG
Grind or turn as little as possible and then wash valve cone and valve
seat ring carefully. Residues of grinding paste promote further wear.
NI
Existing small cracks after grinding/ turning are still permitted, they do not
affect the durability too much.
Result 3
R
FO
2009-10-12 - de
TR
Apply silicon-free grinding paste on valve seating surfaces of valve cones and
valve seat rings (follow the manufacturer's instructions!) and clean by hand
using a touching bow or touching up device, until lacquer is removed. Conduct touching test after the cleaning (see work sequence 1).
Result 4
Clean as little as possible with grinding paste and then wash valve cone
and valve seat ring carefully. Residues of grinding paste promote
further wear.
Existing small cracks after cleaning are still permitted, they do not affect the
durability too much.
Valve seating surface of the valve cone shows heavy deposit, deeper corrosion cracks and/or distinct impact marks. Wear on the valve cone - see figure 6.
6682 113.03-05 EN
General
AI
Action
Valve seating surfaces of valve cones are clean, lightly lacquered or only have
light crack formation. Uniform contact pattern all around.
5 (9)
113.03
RP
OS
E
ON
LY
MAN Diesel & Turbo
Action
PU
Machine valve cone with valve cone grinder until valve seating surfaces are
clean or a new contact pattern appears (see Work Card 113.xx). Conduct
touching test after the cleaning (see work sequence 1).
NG
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.
2009-10-12 - de
TR
AI
NI
Valve cone with the start of burning through or cracks in the valve seat
armouring. Wear on the valve cone - see figure 7.
General
FO
Result 5
6 (9)
6682 113.03-05 EN
113.03
Action
Replace the valve cone.
PU
Work sequence 3 - Assessing the valve cone
RP
OS
E
ON
LY
MAN Diesel & Turbo
Result 6
Valve cone with the start of stem corrosion. Wear on the valve cone - see
figure 8.
6682 113.03-05 EN
General
A Stem corrosion
R
FO
2009-10-12 - de
TR
AI
NI
NG
Starting position
7 (9)
113.03
MAN Diesel & Turbo
Action
Replace the valve cone.
Result 7
RP
OS
E
ON
LY
Valve cone with burn-up on the valve plate. Wear on the valve cone - see figure 9.
Action
PU
B Burn-up on the valve plate

Replace the valve cone if the limits indicated on the Work Card 113.09 are
exceeded.
8 (9)
C Tension cracks on the valve stem

Action
6682 113.03-05 EN
2009-10-12 - de
TR
AI
NI
NG
Valve cone with tension cracks on the valve stem. Wear on the valve cone see figure 10.
R
General
FO
Result 8
6682 113.03-05 EN
General
R
FO
2009-10-12 - de
TR
AI
NI
NG
PU
RP
OS
E
ON
LY
Replace the valve cone, if tension cracks are detected on the valve stem.
Conduct a crack test as given in Work Card 000.34.
113.03
MAN Diesel & Turbo
9 (9)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Impart necessary knowledge, ensure correct execution of work. Execute

work on time according to the maintenance schedule, make possible/ support economic operation, prevent operational problems/damage.
Removal and installation of valve seat rings are not part of the work specified
in the maintenance schedule.
1 Technician
1 Assistant
Tools/aids required
Status
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
1 Nut
002.512-1
Standard
1 Spindle head
002.512-4
Standard
1 Crown
002.512-5
Standard
1 Spindle
002.512-8
Standard
3 Shell
002.512-9
Standard
1 Expanding solid
002.512-1
0
Standard
1 Counter support
002.524
Standard
1 Cross tie
002.524-4
Standard
2 Adjusting nut
002.524-5
Standard
2 Pin
002.524-7
Standard
1 Spindle
002.524-8
Standard
2 Angle
002.524-9
Standard
000.451
Standard
Inventory
NG
NI
AI
TR
R
FO
2008-09-19 - de
Number
PU
Quan- Designation
tity
Duration in h
6629 113.04-04 EN
32/40;L32/44CR
RP
OS
E

Summary
ON
LY
Valve seat rings

113.04
MAN Diesel & Turbo
1 (7)
113.04
MAN Diesel & Turbo

Number
Status
Inventory
1 Autogenic welding unit
Inventory
Inventory
Inventory
Inventory
Inventory
1 Inside micrometer
1 Sliding calliper
Work card
113.02
Work card
Work card
113.03
113.06
NI

A Heating locations
AS Exhaust side
AI
1 Welding torch
2 Cylinder head
Figure 1: Heating valve seat rings
if there are corrosion or impact points, which cannot be removed by

machining,
if breakaway or burn-through or tension cracks are present and
if rework limits (see Work Card 113.06) are reached.
It is not possible to dismantle valve seat rings without prior heating and cooling.
2008-09-19 - de
TR
Valve seat rings must be dismantled and replaced,
32/40;L32/44CR
FO
NG
PU
Preliminary remarks
RP
OS
E
ON
LY
Quan- Designation
tity
2 (7)
6629 113.04-04 EN
113.04
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
AI
Work sequence 1 - Removing the valve seat rings
R
FO
2008-09-19 - de
Work steps
Cylinder head removed, cleaned carefully of oil and fuel and loaded in the
cylinder head turnover stand (combustion chamber side facing up). Corresponding inlet and exhaust valve removed.
TR
Starting position
1. Heat valve seat ring (3 or 7) with welding torch (1) on the valve seat at
four places offset by about 90 until the material starts to melt (see Figure 1).
2. Let cylinder head (2) and valve seat ring cool down.
The tangential stress is reduced in the heating zone as a result of

exceeding the yield point.
6629 113.04-04 EN
32/40;L32/44CR
D Gap between cylinder

head and valve seat ring
6 Hexagon nut M16
Figure 2: Dismantling the valve seat rings (figure shows dismantling of an inlet valve seat ring)
NI
2 Cylinder head
3 (7)
113.04
MAN Diesel & Turbo
3. Screw back expanding solid (002.512-10) until the extractor (002.512)

can be guided into the valve seat ring (see figure 2/I).
4. Set complete extractor (113.218) over valve seat ring.
ON
LY
5. Align bolts (002.524-7) by opening the hexagon nuts (6) such that they
fit on the cylinder head in a supporting position. Then retighten the hexagon nuts.
6. Set shells (002.512-9) before gap (D) between valve seat ring and cylinder head (2) by turning the spindle (002.524-8) (see figure 2/I or Detail
X).
RP
OS
E
7. Hold the crown (002.512-5) and spread the extractor (002.512) by turning the spindle (002.524-8) to the maximum extent. See that shells grip
in the gap (D) between valve seat ring and cylinder head (see figure 2/II
or Detail Y).
8. Extract valve seat ring by turning the adjusting nut (002.524-5) (see figure 2/III).
See that the valve seat ring is extracted uniformly i.e. it is not tilted.
PU
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).
NI
Cylinder head loaded in cylinder head turnover stand (combustion chamber

side facing up), locating hole in the cylinder head cleaned and measured.
TR
R
2 Cylinder head
B Max. permitted dimension of the locating hole
E Distance of the two surfaces
32/40;L32/44CR
4 (7)
Work steps
Figure 3: Locating hole for the valve seat ring in the cylinder head
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
min. 0.2 mm greater.
6629 113.04-04 EN
2008-09-19 - de
Starting position
AI
Work sequence 2 - Fitting of the valve seat ring
FO
NG
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.
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 twisted. The inlet valve seat ring has no O-ring seal (see figure 4).
RP
OS
E
ON
LY
3. Push the guide piece (113.221) into the valve guide (8), set the clamp
(113.222) on it and screw on hexagon nut (6) hand-tight (without openended or ring spanner) up to contact.
113.04
MAN Diesel & Turbo
6629 113.04-04 EN
32/40;L32/44CR
R
FO
2008-09-19 - de
TR
AI
NI
NG
PU
2 Cylinder head
5 O-ring seal
Figure 4: Cylinder head with inlet and exhaust valve seat ring
5 (7)
113.04
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 Cylinder head
6 Hexagon nut M20
8 Valve guide
C Contact face cylinder

head
D Gap between cylinder
head and valve seat ring
NG
Figure 5: Fitting the valve seat ring (figure shows the fitting of an inlet valve seat ring)
1. Apply Loctite 640 on the contact face (C) in the cylinder head (2) and, in
addition, apply clean mineral oil on the area of the O-ring seals (5) on
exhaust valve seat ring.
NI
AI
3. Screw on second hexagon nut (6) on guide piece up to contact.
32/40;L32/44CR
6 (7)
See that the valve seat ring is pressed in uniformly and is not tilted.
5. Detach the tool.

6. Check gap (D) for uniform width at several places by using feeler gauge
(000.451).
6629 113.04-04 EN
2008-09-19 - de
TR
4. Tighten valve seat ring by turning the hexagon nut until it touches.
FO
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).
ON
LY
The gap must not be smaller than 0.2 mm!
113.04
MAN Diesel & Turbo
7. Grind valve seat ring by using a valve seat grinder (see Work Card
113.06) and touch up with new valve cone (see Work Card 113.03).
6629 113.04-04 EN
32/40;L32/44CR
R
FO
2008-09-19 - de
TR
AI
NI
NG
PU
RP
OS
E
8. Install inlet or exhaust valve with new or reground valve cone (see Work
Card 113.02).
7 (7)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Valve guide in cylinder head

ON
LY
Summary

check valve guides are to be replaced within the scope of the service and
maintenance work.
1 Assistant
Tools/aids required
Number
Status
113.219
Standard
1 Thrust piece
113.220
Standard
1 Guide piece
113.221
Standard
1 Clamping piece
113.223
Standard
Inventory
NI
NG
PU
Quan- Designation
tity
Work card
Work card
055.05
113.02
113.04
AI
Work card
TR
Work sequence 1 - Check valve guide
R
FO
2008-09-19 - de
Replace the valve guide if the wear limit is reached. The wear limit is
reached,
If the valve cone (20) picks up on the combustion chamber side

cylindrical 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.
6629 113.05-03 EN
32/40;L32/44CR;V32/40PGI
1 Technician
Duration in h
RP
OS
E

Checking parts /components,
Assembling components.
113.05
MAN Diesel & Turbo
1 (4)
113.05
RP
OS
E
ON
LY
MAN Diesel & Turbo
PU
20 Valve cone
21 Valve guide
A Wearing edge in new condition
Figure 1: Wearing edge on the valve guide
B Wearing edge worn

C cylindrical hollowing out
NG
Work sequence 2 - Dismantling a valve guide

Starting position
1. Introduce the guide piece (113.221) into the valve guide (8) and hold.
NI
Work steps
Cylinder head is removed and clamped in the cylinder head turnover stand.
Corresponding inlet/exhaust valve has been detached.
4. Clean locating hole in cylinder head (2).

5. Clean the valve guide (8) and check for wear/damage, renew if necessary.
FO
2008-09-19 - de
TR
AI
3. Extract valve guide (8) from cylinder head (2) by turning the hexagon nut
(6).
32/40;L32/44CR;V32/40PGI
2. Insert clamp piece (113.223) over the guide piece and screw on the
hexagon nut (6). See Fig. 2.
2 (4)
6629 113.05-03 EN
ON
LY
113.05
MAN Diesel & Turbo
RP
OS
E
2 Cylinder head
6 Hexagon nut M20
8 Valve guide
PU
Figure 2: Removing the valve guide
Work sequence 3 - Assembling a valve guide
Cylinder head is loaded in cylinder head turnover stand (combustion chamber side facing upwards). Locating hole in cylinder head has been cleaned.
Valve guide is cleaned, checked and renewed where necessary.
NG
Starting position
Work steps
1. Insert valve guide (8) on guide piece (113.221) and fix with hexagon nut
(6). See Fig. 3.
TR
4. Screw on second hexagon nut (6).

5. Pull in valve guide (8) up to the contact in the locating hole by turning
the hexagon nut (6).
R
FO
2008-09-19 - de
Ensure that the valve seat guide is pulled in uniformly and is not tilted.
6. Dismantle complete tool.
6629 113.05-03 EN
32/40;L32/44CR;V32/40PGI
AI
3. Insert thrust piece (113.220) over guide piece and place on valve seat
ring (7).
NI
2. Introduce guide piece including valve guide (8) from below in cylinder
head (2) and hold.
3 (4)
113.05
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
NI
AI
TR
2008-09-19 - de
FO
32/40;L32/44CR;V32/40PGI
2 Cylinder head
7 Valve seat ring
6 Hexagon nut M20
8 Valve guide
Figure 3: Fitting the valve guide (figure shows valve guide on the exhaust valve)
4 (4)
6629 113.05-03 EN
Execute work on time according to the maintenance schedule, ensure correct execution of work, restore contact pattern.
Valve seating surfaces are to be checked at regular intervals and remachined
if necessary. This is carried out using the Hunger VDS2.3E valve seat lathe.
1 Technician
Tools/aids required
Quan- Designation
tity
Status
113.230
Option
1 Valve seat lathe of type VDS2.3E (120V)
113.229
Option
113.228
Option
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
1 TORX screwdriver
113.228-1
0
Option
1 Pilot nut
113.228-1
3
Option
1 Compensation cone
113.228-1
4
Option
1 Power supply unit 277V
113.343
Option
113.342
Option
113.332
Option
113.339
Option
113.338
Option
1 Milling cutter
113.337
Option
2 Clamping screw
113.334
Option
1 Tool holder
113.333
Option
1 Carry case
113.341
Option
Inventory
1 Cutting oil
Inventory
PU
NG
NI
AI
TR
R
FO
0,5
Number
2010-06-23 - de
Duration in h
6629 113.06-02 EN
32/40;V32/40PGI
RP
OS
E
The work includes:

Creating a correct contact pattern.
Summary
ON
LY
Valve seating surface

working/machining
113.06
MAN Diesel & Turbo
1 (6)
113.06
MAN Diesel & Turbo

Work card
055.05
113.03
NI
AI
TR
2010-06-23 - de
R
32/40;V32/40PGI
FO
NG
PU
RP
OS
E
Work sequence 1 - Fitting the pilot
Work card
ON
LY
Work card
2 (6)
Figure 1: Valve seat lathe, Type VDS2.3E
6629 113.06-02 EN
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
guide in the cylinder head and valve seating surface have been cleaned.
Work steps
ON
LY
1. Carefully read through the manufacturer's operating instructions before

commissioning the machine.
113.06
MAN Diesel & Turbo
2. Free conical surfaces (chamfers) of any adhering coke residues on the

valve guide (3) on both sides using a milling cutter (113.337) and restore
clean bearing surface for the guide pilot (see figure 2).
RP
OS
E
3. Push the guide pilot (113.228-6) on the combustion chamber side into
the cleaned valve guide (3) and screw nut (113.228-13) on to guide pilot
until the cone is firmly seated in the valve guide.
In case of engines with shortened valve guide see that pilot is mounted
with compensation cone (113.228-14).
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.
3 Valve guide
4 Clamping screw
6629 113.06-02 EN
5 Clamping screw
32/40;V32/40PGI
1 Valve seat ring

2 Cylinder head
Figure 2: Installation of guide pilot
R
FO
2010-06-23 - de
TR
AI
NI
NG
PU
5. Front stem and surface of the pilots (113.228-6) with a few drops of
machine oil.
3 (6)
113.06
MAN Diesel & Turbo
Work sequence 2 - Setting up the valve seat lathe
ON
LY
1. Install insert (113.228-5) and clamping screw (113.334) in tool holder

(113.333) using a screwdriver (113.228-10).
2. Install tool holder with mounted insert in the tool slider of the milling
head.
3. Set lathe (113.228-1) down on guide pilot (113.228-6) so the integrated

stop pin (7) in the guide tube rests on the front surface of the guide
pilot.
RP
OS
E
Do not let insert impact on the valve seat ring!
4. Position the insert with the feed adjusting ring (12) above the centre of
the valve seating surface to be processed.
PU
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).

Before connecting the valve seat lathe to the mains you must check
the following:
Does the mains voltage match the input voltage stated on the
identification plate of the power supply unit (113.332/113.342/113.343).
Is the speed switch (13) on the power supply unit set to 30V.
NI
NG
AI
TR
2010-06-23 - de
R
32/40;V32/40PGI
FO
6. Plug the circular plug of the output cable (14) into the socket on the
valve seat lathe and engage locking tag.
4 (6)
6629 113.06-02 EN
113.06
10
11
12
13
14
15
Push-button
Feed ring
Feed adjusting ring
Speed switch
Output cable
Swivel arm
TR
Work sequence 3 - Milling out the valve seating surface

Starting position
R
FO
2010-06-23 - de
Work steps
Valve seat lathe set up as described under work sequence 2. The point of
the insert is level with the valve seating surface.
1. Position the point of the insert with the feed adjusting ring (12) before
the inner edge of the valve seating surface (see Fig. 3).
2. Turn the feed adjusting ring (9) anticlockwise. One scale division line
corresponds to an adjustment of 0.025 mm. During the initial boring
operation, the chosen cutting depth should be such that the chip
removal from the entire valve seating surface can be ensured.
3. Make sure that the swivel arm (15) has engaged in the groove provided
in the feed ring (11).
4. Wet valve seating surface with cutting oil.
6629 113.06-02 EN
32/40;V32/40PGI
AI
NI
1 Valve seat ring

2 Cylinder head
3 Valve guide
7 Stop pin
8 Clamping screw
9 Feed adjustment ring
Figure 3: Mounting the valve seat lathe
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
5 (6)
113.06
MAN Diesel & Turbo
5. Hold lathe (113.228-1) fixed with both hands and start the boring operation by pressing the push button (10).
ON
LY
6. Hold the push-button pressed until machining of the valve seating surface 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.
RP
OS
E
Markings are for checking a uniform chip removal.
Work sequence 4 - Conduct touching test

Work steps
1. Take lathe (113.228-1) from pilot (113.228-6) and remove pilot.
PU
2. Conduct touching test (see Work Card 113.03)
NG
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.
NI
TR
AI
The maximum permitted rework is reached if the valve seat is machined up

to the surface (B). On reaching the rework limit the valve seat ring should be
replaced (see figure 4).
2010-06-23 - de
1 Valve seat ring

A Valve seating surface
B Rework limit
32/40;V32/40PGI
FO
Work sequence 5 - Maximum permitted rework of the valve seating surfaces
6 (6)
Figure 4: Rework limit of the valve seating surface
6629 113.06-02 EN
Valve cone
grinding
ON
LY
Summary
Execute work on time according to the maintenance schedule, ensure correct execution of work, restore contact pattern.
Valve seating surfaces are to be checked at regular intervals and remachined
if necessary. This is carried out using the valve seat turning machine Hunger
VKM 3.1.
Quan- Designation
tity
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
Inventory
AI
NI
PU
Number
NG
Tools/aids required
0,5
TR
Work card
Work card
Work card
113.03
113.06
113.09
R
FO
2008-10-24 - de
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 approximate values, which are dependent on the operating method and the condition of the engine as well as the quality of the fuels used. The most expedient
overhaul intervals should be defined based on the prescribed inspection.
6629 113.08-02 EN
32/40;L32/44CR;V32/40PGI
1 Technician
Duration in h
RP
OS
E
The work includes:

113.08
MAN Diesel & Turbo
1 (6)
113.08
MAN Diesel & Turbo
ON
LY
The valve cone material is subject to fatigue as a result of frequent temperature fluctuations. The inlet and exhaust valve cones are to be replaced after
the operating periods specified in the maintenance schedule, even if the
maximum permitted reworking limits have not yet been reached.
Continued use poses an inestimable risk for the engine.
NI
NG
PU
RP
OS
E
The valve seat angle of the valve cone is 120 with a plus tolerance. The
valve seat angle in the cylinder head is executed with a minus tolerance, so
the valve cone seating surface bears fully on the seating area of the valve
seat ring or there is a small differential angle. This ensures that there is sealing on the outer area of the valve seating area against the hot gases during
operation.
AI
Starting position
Work steps
Valve cone is cleaned.

To set and grind the valve cone see the User Manual and observe the following points:
1. Before beginning work, check the grinding wheel fastening for firm seating.
6629 113.08-02 EN
2008-10-24 - de
FO
2 (6)
Before commissioning the device, read the manufacturer's user manual

the manufacturer carefully, use existing guards.
TR
Work sequence - Grinding the valve cone seat face
32/40;L32/44CR;V32/40PGI
Figure 1: Valve cone grinder
ON
LY
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 - 20.
Due to the cutting speed the grinding wheel diameter must not be
smaller than 150 mm.
3. Insert collect chuck in the spindle head.
113.08
MAN Diesel & Turbo
RP
OS
E
4. Insert valve cone in the workpiece spindle head. Clamp valve cone to
the collar provided as short as possible (Clamping point: Collar before
vane area or collar on the stem) (see figure 2).
5. Tighten collet (hand-tight with hook spanner), knock with plastic hammer on the valve plate floor (2-3 light impacts), tighten collet again.
6. Check concentricity (see figure 3).
PU
If the maximum permissible value for concentricity has been exceeded,

consult the MAN Diesel & Turbo SE service department.
7. Grinding slot is fixed at set value by manufacturer with the pin.
NG
8. Before starting the cut, set grinding wheel and valve cone so that centre
of the valve cone seat surface = centre of the grinding wheel (see figure
4).
9. Advance until the valve cone seat surface starts to be ground.
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.
6629 113.08-02 EN
32/40;L32/44CR;V32/40PGI
R
FO
2008-10-24 - de
TR
AI
Always supply sufficient coolant to the taper between the grinding

wheel and valve cone seating surface. During the grinding process
ensure that the grinding wheel does not cut into the valve cone radius
(R). Dress the grinding wheel often when grinding, because it clogs
quickly and presses (high grinding sound).
NI
10. Grinding with coolant and oscillating (to and fro) movement of the grinding wheel by hand. Ensure that the grinding wheel is always on the
valve seat. Grinding motion as low as possible (0.025 mm = 1/2 greater
than the pitch mark on the scale), to avoid chatter marks.
3 (6)
113.08
MAN Diesel & Turbo
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.
Maximum rework on inlet and exhaust valve cone
The maximum permitted rework has been reached on the valve cone seating
surface, if the valve cone seat width (G, new condition) has enlarged to the
tangential point (X) of the radius (A) (see Table 1 and figure 5).
RP
OS
E
Maximum rework on inlet

and exhaust valve cone
ON
LY
On reaching the maximum value (H) the valve cone may no longer be
used (see table 1).
NI
FO
2008-10-24 - de
TR
AI
Figure 2: Clamped exhaust valve cone
32/40;L32/44CR;V32/40PGI
NG
PU
For permitted rework on the valve plate outer diameter and permitted burnup and corrosion depth on valve plate see Work Card 113.09.
4 (6)
6629 113.08-02 EN
113.08
RP
OS
E
ON
LY
MAN Diesel & Turbo
3 Collar plate
1 Valve cone
4 Grinding wheel
NG
PU
1 Valve cone
2 Collet
Figure 3: Concentricity check on the valve cone (figure shows inlet valve)
A Radius
Figure 5: Rework on the valve cone
G Valve cone seat width

(new condition)
H Max. rework
6629 113.08-02 EN
R Valve cone radius

X Tangential point
32/40;L32/44CR;V32/40PGI
1 Valve cone
R
FO
2008-10-24 - de
TR
AI
NI
Figure 4: Position grinding wheel/valve cone seating surface before grinding
5 (6)
113.08
Inletvalve cone
Exhaustvalve cone
Valve cone seat width (G)

in the new condition in (mm)
9,8
9,8
maximum rework (H)

in (mm)
13
ON
LY
MAN Diesel & Turbo
12,8
NI
AI
TR
2008-10-24 - de
FO
32/40;L32/44CR;V32/40PGI
NG
PU
RP
OS
E
Table 1: Valve cone seat width (new condition/max. rework)
6 (6)
6629 113.08-02 EN
Summary
ON
LY
Valve seating surface

inspecting
Combat corrosion attack, keep quality in the permitted range.
When regrinding the valve seating surface, the permissible valve plate thickness is to be determined.
Tools/aids required
Number
Status
000.451
Option
1 Sliding calliper
Inventory
Inventory
1 Steel ruler
Inventory
PU
Quan- Designation
tity
RP
OS
E

Measuring components and
Assessing contact pattern /wear condition.
113.09
MAN Diesel & Turbo
Work card
Work card
Work card
113.03
113.05
113.06
NG
Work sequence 1 - Checking the valve thickness

Work steps
1. Clean valve cone and remove any adhering carbon residue.
4. Measure and note the plate thickness using sliding calliper at point (C).
Dimension A = Difference between HN and the measured value must
not be greater than 10 % of HN (new condition) at any point
If regrinding is necessary on a used valve cone on the seating surface,

then the expected material reduction due to grinding should be taken
into account when assessing the determined grinding dimension A.
(The material reduction on the seating surface S further reduces the
plate thickness).
5. Measure and take note of the wear dimension (B) by placing a ruler on
the plate bottom with depth gauge or feeler gauge somewhere in the
centre of the plate. Dimension B may be maximum 3.0 mm at the
deepest point.
6682 113.09-01 EN
General
R
FO
2008-09-11 - de
TR
AI
3. Mark one or more measuring points (C), depending on the state of the
valve cone to be tested, distributed on the periphery, using a felt-tip
pen.
NI
2. Determine plate thickness in new condition (HN) at measuring point (C)

on a new, same valve and note.
1 (3)
113.09
MAN Diesel & Turbo
NG
PU
RP
OS
E
ON
LY
Regrinding the valve seating surface (S) and possibly occurring hot
corrosion on the plate bottom could reduce the valve plate thickness to
inadmissible values.
1 Valve plate in new condition
NI
HN Plate thickness in the new condition at measuring point C
AI
S Seating surface
Figure 1: Determine wear dimension A on the valve plate
General
Work steps
2 (3)
Circumferential corrosion grooves of low depth can be produced at the

transition from the base to the armouring material on the valve plate
outside diameter (D). The transition point must be checked for cracks. If
there are cracks the outside diameter it must be ground down until
there are no more cracks, whilst maintaining machining limits.
1. Clean valve cone, do not damage surface by using the wrong cleaning
device (e.g. chipping hammer).
2. Check armouring transition by using the dye-penetrant method (Met-LCheck) for cracks (see Work Card 000.34)
6682 113.09-01 EN
2008-09-11 - de
TR
Work sequence 2 - Checking for corrosion grooves on the valve plate outer diameter (D)
FO
A Wear dimension on the plate

edge at measuring point C
C Measuring point at 1/6 D from the
plate diameter
E Tracer arms of the sliding calliper
2 Valve plate with maximum permitted wear

B Wear dimension in the plate centre
D Valve plate outer diameter
3. If there are cracks, regrind on valve plate outer diameter without coolant
supply until free from cracks, maintaining machining limits (see table 1).
Permitted rework related to diameter against
new condition
ON
LY
Valve plate outer diameter
113.09
MAN Diesel & Turbo
up to 100 mm
0.2 mm
over 100 mm
0.5 mm
6682 113.09-01 EN
General
R
FO
2008-09-11 - de
TR
AI
NI
NG
PU
RP
OS
E
Table 1: Limit values for rework on valve plate outer diameter
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
120
TR
R
FO
6632 120-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
120
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 (2)
6632 120-05 EN
RP
OS
E

fitting components.
Tools/aids required
Quan- Designation
tity
Number
Status
120.003
Standard
1 Rail (Bank B)
120.003-4
Standard
120.003-2
3
Standard
120.003-4
2
Standard
1 Rope guide (Bank A)
120.003-5
5
Standard
2 Holder
120.003-6
6
Standard
2 Holder
120.003-7
2
Standard
2 Spindle
120.003-7
8
Standard
1 Plate (Bank B)
120.003-8
2
Standard
1 Plate (Bank A)
120.003-8
9
Standard
1 Wire rope clamp
120.003-1
00
Standard
1 Wire rope
200.067
Standard
1 Pilot rod
034.006
Standard
1 Ratchet hoist
002.552
Option
2 Shackle A0.6
002.452
Standard
1 Tool holder
008.180
Standard
1 Socket ring spanner SW24
008.024
Standard
1 Torque wrench
008.011
Standard
001.912
Standard
1 Cross handle
001.891
Standard
001.858
Standard
1 Rail (Bank A)
R
FO
2007-11-06 - de
TR
AI
NI
NG
PU
1 Rope guide (Bank B)
6632 120.01-02 EN
V32/40
Execute work on time according to the maintenance schedule, ensure correct execution of work, check components for quality/wear condition.
Control pistons should be checked at regular intervals and overhauled if necessary.
Summary
ON
LY
Control piston of the injection camshaft

120.01
MAN Diesel & Turbo
1 (6)
120.01
MAN Diesel & Turbo

Number
Status
Inventory
Inventory
Inventory
Inventory
Inventory
ON
LY
Quan- Designation
tity

000.30
Technical data
Designation
Work card
RP
OS
E
Work card
Work card
120.02
Information
Control piston with lifting cylinder
Preliminary remarks
127 kg
PU
Checking the function of the control piston also forms part of the specified
work in the maintenance schedule.
NG
If any defects are found, the external control elements, i.e. their activation
and setting as well as the oil circuit, must be checked in particular. Only
when defects can be safely excluded can the control piston be dismantled
and the O-ring seals and sealing rings and the bearing bush be checked.
Removal of the control piston is not part of the usual maintenance work.
NI
The covering cap on the camshaft drive has been removed.

1. Remove the cabling to the lifting cylinder (24).
AI
Starting position
Work steps
V32/40
2 (6)
3. Place container under the control piston, unscrew the screw plugs and
drain the oil from the control piston. Reseal oil drain holes.
4. Unscrew hexagon bolts (18), remove washers (19).
6. Attach rail (120.003-4) to cylinder crankcase (20) with hexagon bolts
(27) and lightly oil the sliding surfaces (figure 3).
7. Mount left-hand holder (120.003-66) and right-hand retainer
(120.003-72) on control piston (23) with hexagon bolts (26 and 29) (figure 2).
8. Attach wire rope (200.067) to front hole of the supports with shackles
(002.452) and suspend from a suitable lifting tackle.
9. Attach plate (120.003-82) to control piston (23) with hexagon bolts (28)
and screw in the pilot rod (034.006) (figure 2 and 3).
6632 120.01-02 EN
2007-11-06 - de
TR
2. Remove oil supply pipe and oil leakage drain pipe from the pilot piston
(23) and seal with suitable means (figure 1).
FO
Work sequence 1 - Removing the control piston (Description for Bank B)
10. Carefully pull control piston forwards with hoist and pilot rod on rail
(120.003-4).
ON
LY
11. Place the hoist at the end of the rail as vertically as possible over the
control piston (23) and lift it. In doing so, guide it with the pilot rod.
120.01
MAN Diesel & Turbo
AI
TR
R
FO
2007-11-06 - de
21
23
24
25
O-ring seal
Control piston
Lifting cylinder
Hexagon socket bolt
NI
17 Injection camshaft
18 Hexagon bolt
19 Washer
Figure 1: Control piston with lifting cylinder
6632 120.01-02 EN
V32/40
NG
PU
RP
OS
E
12. Set the control piston down on a wooden support, disassemble plate
with pilot rod.
3 (6)
120.01
RP
OS
E
ON
LY
MAN Diesel & Turbo
PU
22 Charge air cooler

Figure 2: Installation of the removal and fitting fixture
NG
Work sequence 2 - Installation of the control piston

Starting position
Control piston cleaned, O-ring seals and sealing rings and bearing bush
checked and replaced if required.
Work steps
NI
1. Clean locating boree in the cylinder crankcase (20) and contact face of
the injection camshaft (17).
4. Attach wire rope to front hole of the supports with shackles and suspend wire rope from the lifting tackle.
5. Lift the control piston (23) and place it on the rail (120.003-4) with the
pilot rod.
Hold control piston in position with the pilot rod until the wire rope is
loosened.
2007-11-06 - de
TR
AI
3. Attach plate (120.003-82) to control piston (23) and screw pilot rod
(034.006) into this.
V32/40
FO
4 (6)
6632 120.01-02 EN
120.01
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
23 Control piston
22 Charge air cooler
Figure 3: Removing and installing the control piston

NG
1. Loosen and remove the wire rope.

2. Fasten rope guide (120.003-42) to the cylinder crankcase (20) with hexagon bolts (26).
NI
3. Attach wire rope (200.067) to retainers with shackles (002.452) via rope
guide, suspend loop of the wire rope from the ratchet hoist (002.552)
and attach wire rope clamp (120.002-100) (figure 2 and 3).
6. Remove the wire rope with shackle and rope guide (120.003-42).
7. Slide the control piston (23) axially on the spindles and insert in the cylinder crankcase. In doing so, pay attention to the centring of the injection camshaft (17) - control piston.
8. Apply MoS2-lubricant to threads and resting surface of the hexagon
bolts (18), including washers (19), screw in hand-tight and tighten up
with the specified torque (see Work Card 000.30) - see figure 4 for
tightening sequence.
9. Use the tool holder (008.180) and insertion spanner (008.024) to turn
the hexagon bolts by the prescribed angle of torque (see Work Card
000.30) - see figure 4 for tightening sequence.
6632 120.01-02 EN
V32/40
R
FO
2007-11-06 - de
TR
AI
5. Carefully pull the control piston (23) backwards on the spindles

(120.003-78) with the ratchet hoist and pilot rod and continue until the
control piston (23) is located just in front of the cylinder block and
crankcase (20) (figure 3).
4. Screw spindles (120.003-78) into cylinder crankcase (20) and oil lightly.
5 (6)
120.01
MAN Diesel & Turbo
ON
LY
For turning the hexagon bolts on through the turn angle the torque
wrench must not be used.
10. Remove rail (120.003-4) and spindles (120.003-78). Retainers remain

on the control piston (23).
11. Screw in the hexagon socket bolts (25) and tighten them.
12. Connect the oil leakage drain pipe and oil supply pipe to the pilot piston
and the cabling to the lifting cylinder.
RP
OS
E
13. Remove the screw plugs, fill the control piston with clean lubricating oil.
Bleed the control piston and screw in the screw plugs, including seal.
14. Fit the covering cap.
15. Carry out a function check of the control piston.
NI
AI
2007-11-06 - de
TR
R

19 Washer
18 Hexagon bolt
23 Control piston
Figure 4: Tightening sequence for the fixing bolts
V32/40
FO
NG
PU
After dismantling/assembling the control piston, when loading the

engine for the first time with 50% of the nominal power, the ignition
pressures must be measured and compared with the documented
values. Full engine loading is only possible if the ignition pressure level
is OK.
6 (6)
6632 120.01-02 EN
Summary
ON
LY
Control piston of the injection camshaft

Ensure correct execution of the work, fit/adjust the components properly.
The control pistons need not be dismantled during normal maintenance
work. If faults are detected during the functional check or if sealing rings
need to be checked or replaced, this may necessary.
Tools/aids required
Quan- Designation
tity
RP
OS
E

disassembly of components,
replacement of sealing rings/sealing elements,
assembly of components.
Number
Status
008.023
Standard
008.011
Standard
001.912
Standard
1 Cross handle
001.891
Standard
001.856
Standard
001.854
Standard
000.451
Standard
Inventory
1 Sliding calliper
Inventory
Inventory
Inventory
1 Ratchet tool
NI
NG
PU
1 Torque wrench
120.02
MAN Diesel & Turbo
Work card
Work card
000.11
000.30
120.01
Work sequence 1 - Dismantling the control piston
R
FO
2007-10-31 - de
Starting position
Work steps
Control piston removed and set on a wooden support.

1. Disconnect universal rod (70) from the fork head (48).
Set length of the universal rod must not be altered.
2. Remove lifting cylinder (24) including buckling lever.

3. Remove protection pipe (69).
6629 120.02-02 EN
32/40
Work card
TR
AI
1 (5)
120.02
MAN Diesel & Turbo
4. Determine dimension A and note it down.

5. Remove fork head (48), hexagon nuts (51) and washer (53).
6. Remove pointer (46).
ON
LY
7. Unscrew the hexagon bolts (55) and pull off the casing (67), remove the
O-ring seal (58).
8. Unscrew the hexagon socket bolts (52) and pull the clamping sleeve
(45) off.
9. Remove the pilot slide valve (59) from the piston rod (63).
10. Remove the O-ring seal (44) and piston (66).
11. Unscrew the hexagon socket bolt (73) and remove the shaft (29).
RP
OS
E
12. Measure the axial clearance between the butting disc (32) and butting
discs (65) at several places with feeler gauge (000.451), note down and
compare with the permissible clearance.
13. Unscrew the hexagon socket bolts (33), take off bearing cover (64) and
remove butting discs.
14. Remove piston rod from casing (38).
15. Clean all individual components and check for damage.
PU
16. Check the bearing bush (31) for damage or grooves caused by dirt (see
Work Card 000.11).
NG
The bearing bush should only be replaced by a Service Centre, or MAN

Diesel & Turbo personnel, as the bearing bush is pressed into the
casing.
17. Check the sealing rings (34, 39 and 60) for perfect condition and fit new
sealing rings if necessary (see work sequence 2).
NI
AI
TR
2007-10-31 - de
R
32/40
FO
18. Check the rod guide rings (37) and oil control rings (54) for perfect condition and replace if necessary.
2 (5)
6629 120.02-02 EN
120.02
AI
Sealing ring
Piston rod
Bearing cover
Butting disc
Piston
Casing
Hexagon socket bolt
Protection tube
Universal rod
Hexagon bolt
Bracket

A Dimension
TR
60
63
64
65
66
67
68
69
70
71
72
FO
Work sequence 2 - Assembly of a sealing ring

Starting position
Work steps
Damaged sealing ring removed, ring groove cleaned out.

1. Place O-ring seal (35, 40 or 61) in the ring groove, making sure that it is
clamped uniformly on the entire periphery and is not twisted.
2. Heat the Turcon Glyd Ring (36, 41 or 62) in the oil bath to approx. 80 to
120 C.
6629 120.02-02 EN
32/40
Pointer
Cylinder screw
Fork head
Hexagon bolt
Hexagon nut
Hexagon nut
Hexagon socket bolt
Washer
Oil scraper
Hexagon bolt
sealing screw on distribution block
57 Seal
58 O-ring seal
59 Pilot valve
46
47
48
49
50
51
52
53
54
55
56
NI
Lifting cylinder
Shaft
Dowel pin
Bearing bush
Butting disc
Hexagon socket bolt
Sealing ring
Rod guide ring
Casing
Sealing ring
sealing screw on distribution block
43 Seal
44 O-ring seal
45 Clamping sleeve
Figure 1: Sectional view of the control piston
2007-10-31 - de
24
29
30
31
32
33
34
37
38
39
42
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
3 (5)
120.02
MAN Diesel & Turbo
3. Fit the Turcon Glyd Ring in the ring groove.
Sealing ring, consisting of:

O-ring seal
Turcon-Glyd-Ring
Rod guide
Casing
39
40
41
45
54
59
Figure 2: Special sealing rings in the control piston

O-ring seal
Turcon-Glyd-Ring
Clamping sleeve
Oil scraper
Pilot valve
PU
34
35
36
37
38
RP
OS
E
ON
LY
4. Reshape the extended Turcon Glyd Ring back by assembling with the
oiled counter-piece.
60
61
62
63
66
67

O-ring seal
Turcon-Glyd-Ring
Piston rod
Piston
Casing
NG
Work sequence 3 - Assembling the control piston

Starting position
NI
Individual parts cleaned and checked, sealing rings, rod guide rings and oil
control rings checked for perfect condition.
32/40
4 (5)
AI
1. Running surfaces of the butting discs (32 and 65) lightly oiled and fitted
in the shaft (29), taking care with the location of the hole / dowel pin
(30).
2. Place the bearing cap (64) on the shaft, taking care with the position of
the hole / dowel pin.
socket bolt (33), screw into shaft and tighten with the specified torque
(see Work Card 000.30). Tightening sequence see figure 3.
4. Lightly oil the running surface of the bearing bush (31) and fit the shaft
in the casing (38).
5. Lightly oil the running surface of the piston rod (63) and insert through
casing in the shaft.
6629 120.02-02 EN
2007-10-31 - de
TR
Work steps
FO
Keep the workplace absolutely clean when assembling the control

piston. Dirt particles can cause faults in the setting devices.
7. Place the piston (66) on the piston rod.
ON
LY

socket bolt (73), screw into piston rod and tighten across the diagonals
with the specified torque (see Work Card 000.30).
120.02
MAN Diesel & Turbo
8. Oil the running surface of the pilot slider valve (59) and fit into the piston
rod.
10. Place the clamping sleeve (45) on the piston rod.
RP
OS
E

socket bolts (52), screw into the piston rod and tighten with the specified torque (see Work Card 000.30). Tightening sequence see figure 3.
13. Lightly oil the inside of the casing and the outside of the clamping
sleeve.
14. Slide the casing (67) over the clamping sleeve and piston up to the casing (38) and fix to it with hexagon bolts (55).
15. Fix the pointer (46) onto clamping sleeve.
PU
16. Place washer (53) on pilot slide valve and fix with hexagon nut (51).
Screw two hexagon nuts in position, screw the fork head (48) onto the
thread, set the noted dimension A and secure the fork head in position
with hexagon nut.
17. Fit the protection tube (69) on the casing.
NG
18. Fit the lifting cylinder (24) onto the control piston and secure the universal rod (70) on the fork head.
Figure 3: Tightening sequence for fastening screws
6629 120.02-02 EN
32/40

sequence
Hexagon socket bolt
Hexagon socket bolt
16
33
52
FO
2007-10-31 - de
TR
AI
NI
Set length of the universal rod must not be altered.
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
125
TR
R
FO
6632 125-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
Operating device
MAN Diesel & Turbo
1 (2)
125
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
Operating device
MAN Diesel & Turbo
2 (2)
6632 125-05 EN
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.
1 Technician
Tools/aids required
Status
Inventory
1 Screwdriver (Set)
Inventory
Inventory
NG
Spare parts
0,5
Number
PU
Quan- Designation
tity
Duration in h
Quantity Designation
Number
125.98.306
1 Set of wear parts
125.99.306
AI
NI
1 Three-way valve
Work sequence 1 - Disassembling the three-way valve
R
FO
2007-08-01 - de
Work steps
Compressed air or control air system depressurised. Valve cleaned externally.
TR
Starting position
1. Detach pipe connections (mark if necessary), remove fastening screws

and take out valve.
2. Plug the open pipe ends using suitable equipment to prevent the
ingress of dirt.
3. Unscrew roller lever (11), thread off valve guide (12) with cam follower
(13) and spring.
4. Continue dismantling valve and thoroughly clean all individual parts.
5. Check wear parts (V) for abrasion or hardening (in the case of sealing
rings), replace if necessary.
6682 125.02-01 EN
General
RP
OS
E

Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Summary
ON
LY
Three-way valve M306

checking, overhauling
Operating device
125.02
MAN Diesel & Turbo
1 (2)
125.02
MAN Diesel & Turbo
ON
LY
Operating device
A wear parts kit is available from MAN Diesel & Turbo SE for you to use
to overhaul the M306 three-way valve.
6. Check all moving parts for ease of movement prior to assembly.
Work sequence 2 - Assembling the three-way valve
RP
OS
E
The assembly is done in reverse order of the dismantling. In doing so,

observe the following points:
When assembling, take utmost care in maintaining cleanliness at the

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.
NI
AI
TR
11 Roller lever
14 Valve seat
12 Valve guide
13 Valve slide
V Wear parts
Figure 1: Sectional view of the three-way valve M306
Connection
Position I
closed
General
Position II
2 (2)
6682 125.02-01 EN
4
connected
connected
closed
2007-08-01 - de
FO
NG
PU
2. Lightly oil all parts prior to assembly.

safety.
1 Technician
Tools/aids required
Status
Inventory
1 Screwdriver (Set)
Inventory
1 Hook wrench
Inventory
Inventory
NG
Spare parts
0,5
Number
PU
Quan- Designation
tity
Duration in h
NI
Number
125.98.317
1 Set of wear parts
125.99.317
AI
1 Three-way valve
TR
Work sequence 1 - Disassembling the three-way valve

Starting position
R
FO
2007-08-01 - de
Work steps

and take out valve.
ingress of dirt.
3. Unscrew hexagon socket bolts (11) and remove upper section of casing (12).
4. Unscrew valve guide (15) together with piston (13) and cam follower
(14) using hook spanner.
5. Take out valve seat (16) and remove valve (17).
6682 125.04-01 EN
General
RP
OS
E

Summary
ON
LY
Three-way valve M317

Operating device
125.04
MAN Diesel & Turbo
1 (3)
125.04
MAN Diesel & Turbo
Operating device
6. Continue dismantling valve, thoroughly clean all individual parts and

blow off with compressed air.
ON
LY
to overhaul the M317 three-way valve.
RP
OS
E
Work sequence 2 - Assembling the three-way valve

PU

NI
AI
2 (3)
6682 125.04-01 EN
2007-08-01 - de
TR
R

16 Valve seat
12 Casing top section
17 Valve
13 Piston
18 Casing bottom section
14 Valve slide
15 Valve guide
V Wear parts
Figure 1: Sectional view of the three-way valve M317
General
FO
NG
1
5 pressurised
2
connected
closed
closed
connected
6682 125.04-01 EN
General
R
FO
2007-08-01 - de
TR
AI
NI
NG
PU
RP
OS
E
5 without pressure
ON
LY
Connection
Operating device
125.04
MAN Diesel & Turbo
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Summary
ON
LY
3/2-way solenoid valve M329

safety.

1 Technician
Tools/aids required
Duration in h
0,5
Number
Status
Inventory
1 Screwdriver (Set)
Inventory
Inventory
NG
PU
Quan- Designation
tity
RP
OS
E

Work card
Operating device
125.05
MAN Diesel & Turbo
Work card
Work card
Number
1 3/2-way solenoid valve
125.98.329
1 Set of wear parts
125.99.329
Work sequence 1 - Disassembling the 3/2-way solenoid valve
Work steps
FO
2010-04-29 - de
Starting position

and take out valve.
ingress of dirt.
3. Unscrew hexagon bolts (11) and hexagon socket bolt (12).
4. Remove connection piece (13) with emergency override (14) and
unscrew hexagon socket bolt (12).
6682 125.05-01 EN
General
TR
AI
Spare parts
NI
125.30
1 (4)
125.05
MAN Diesel & Turbo
Operating device
ON
LY
to overhaul the M329 3/2-way solenoid valve.
RP
OS
E
Work sequence 2 - Assembling the 3/2-way solenoid valve

PU
NI
AI
TR
2010-04-29 - de
R
General
FO
NG
Ensure the pins in the valve casing are arranged correctly, taking the
application of the 3/2-way solenoid valve M329 into consideration. If
the pin arrangement is incorrect, severe damage to the machine and
serious physical injury may result.
2 (4)
6682 125.05-01 EN
125.05
RP
OS
E
ON
LY
Operating device
MAN Diesel & Turbo
PU
11 Hexagon bolt
14 Emergency operation
15 Valve casing
13 Connecting piece
V Wear parts
I-V Valve functions
Figure 1: Sectional view of 3/2-way solenoid valve M329
NG
6682 125.05-01 EN
General
R
FO
2010-04-29 - de
TR
AI
NI
The functions shown in Figs. 1 and 2 are available, depending on the pin
arrangement in the valve casing.
3 (4)
125.05
NI
AI
TR
2010-04-29 - de
I Starting valve, marine/stationary

IV Emergency stop valve, stationary
engine
engine
II Vent valve
V Slow-turn valve
III Emergency stop valve, marine
engine
Figure 2: Valve function depending on pin arrangement
General
FO
NG
PU
RP
OS
E
ON
LY
Operating device
MAN Diesel & Turbo
4 (4)
6682 125.05-01 EN
Summary
ON
LY
Emergency shutdown device

Functional testing at the engine
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.
1 Technician
1 Assistant
Tools/aids required
Quan- Designation
tity
RP
OS
E
Personnel and time requirements
Duration in h
0.5
0.5
Number
Status
Inventory
1 Protective gloves
Inventory
1 Ear defenders
Inventory
NG
PU
1 Screwdriver (Set)
Work card
Operating device
125.30
MAN Diesel & Turbo
Work card
Work card
Checking the emergency stop valve following removal/

installation
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.
6682 125.30-01 EN
General
R
FO
2010-09-03 - de
TR
AI
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.
Preliminary remarks
NI
125.05
1 (6)
Operating device
125.30
MAN Diesel & Turbo
Work sequence 1 - Checking the emergency stop valve

Starting position
Work steps
ON
LY
The engine is in idle, without dynamic load response.
NG
PU
RP
OS
E
Marine engines
NI
AI
General
2 (6)
When operating the emergency stop valve (1), this is charged abruptly
with compressed air at a maximum pressure of 30 bar. This is
accompanied by a loud bang. Please wear ear defenders.
Risk of injury due to crushing

When operating the emergency stop valve (1), the control rods of the
fuel-injection pumps are abruptly moved to the position "zero filling".
Danger of crushing due to moving machine parts. Before operating the
emergency stop valve, make sure that no maintenance work is carried
out in the area of the control linkage.
6682 125.30-01 EN
2010-09-03 - de
TR
Wear ear defenders
FO
1 Emergency stop valve M329/2

2 Emergency stop button
Figure 1: Emergency stop valve M329/2 (measuring range 1SZV1012) installed in
marine engines
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
the arresting device (3) (see Fig. 2).
RP
OS
E
ON
LY
2. Check the effects of the emergency stop operation:

The triggering of the emergency stop valve (1) is, among others,
accompanied by a loud bang.
Engines with conventional fuel injection
The control rods of the fuel-injection pumps are at the "zero filling" position, the engine stops. With fuel-injection pumps, manually check that
the control rod can no longer be pushed in.
Engines with Common-Rail injection
The pressure in the Common-Rail accumulator is released immediately,
the engine stops. The engine control display indicates insufficient pressure in the Common-Rail accumulator.
Operating device
125.30
MAN Diesel & Turbo
Malfunction of emergency stop device
NG
PU
If the engine continues running although the emergency stop has been
triggered, the fuel supply to the engine must be interrupted
immediately.
6682 125.30-01 EN
General
R
FO
2010-09-03 - de
TR
AI
NI

3 Arresting device
Figure 2: Emergency stop button with arresting device image on left: normal
position, image on right: locked in emergency stop position
3 (6)
125.30
MAN Diesel & Turbo
General
4 (6)
Wear ear defenders
When operating the emergency stop valve (1), this is charged abruptly
with compressed air at a maximum pressure of 30 bar. This is
accompanied by a loud bang. Please wear ear defenders.
Risk of injury due to crushing

When operating the emergency stop valve (1), the control rods of the
fuel-injection pumps are abruptly moved to the position "zero filling".
Danger of crushing due to moving machine parts. Before operating the
emergency stop valve, make sure that no maintenance work is carried
out in the area of the control linkage.
6682 125.30-01 EN
2010-09-03 - de
TR
AI
NI
1 Emergency stop valve M329/2

4 Connecting plug
5 Lock screw
Figure 3: Emergency stop valve M329/2 (measuring range 1SZV1012) installed in
stationary engines
FO
NG
PU
RP
OS
E
ON
LY
Operating device
Stationary engines
ON
LY
1. Unscrew lock screw (5) and pull off connecting plug (4). please refer to
figure 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.
Operating device
125.30
MAN Diesel & Turbo
RP
OS
E

Malfunction of emergency stop device
If the engine continues running although the emergency stop has been
triggered, the fuel supply to the engine must be interrupted
immediately.
Engine stopped.
NI
NG
Starting position
PU
Work sequence 2 - Operating an emergency stop button
FO
2010-09-03 - de
Work steps
1. Press the emergency stop button (6).
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.
6682 125.30-01 EN
General
Figure 4: Emergency stop button
TR
AI
5 (6)
Operating device
125.30
MAN Diesel & Turbo
Work sequence 3 - Resetting the emergency stop valve

Starting position
Work steps
ON
LY
Engine stopped.
Marine engines
1. Release the arresting device (3) for the emergency stop button (2). The
emergency stop button (2) then jumps back out and air is evacuated
from the emergency stop valve (1) (see Fig. 2).
Stationary engines
RP
OS
E
1. Plug in the connecting plug (4) for the emergency stop valve (1) and
screw in the lock screw (5) (see Fig. 3).
Work sequence 4 - Checking the emergency stop button

Starting position
The emergency stop valve has been successfully checked. The engine is in
idle, without dynamic load response.
Work steps
When an emergency stop button (6) is pressed, the emergency stop valve (1)
is triggered via the engine control.
1. Press all emergency stop buttons that belong to the engine (6).
NI
AI
TR
2010-09-03 - de
R
General
FO
NG
PU

6 (6)
6682 125.30-01 EN

safety.
1 Technician
Tools/aids required
Status
Inventory
Inventory
1 Screwdriver (Set)
Inventory
Inventory
NG
Spare parts
0,5
Number
PU
Quan- Designation
tity
Duration in h
NI
125.98.367
AI
1 5/2-way solenoid valve
Number
Work sequence 1 - Disassembling the 5/2-way valve

Compressed air or control air system depressurised. Valve exterior cleaned.
R
FO
2007-08-01 - de
TR
Starting position
Work steps
1. Undo pipe connections (mark if necessary), remove fastening screws

and take out valve.
2. Seal open pipe ends to prevent the ingress of dirt using suitable equipment.
3. Disassemble the valve and thoroughly clean all individual parts.
4. Check wear parts for wear or hardening (in sealing rings), replace with
new ones if necessary.

6682 125.08-02 EN
General
RP
OS
E

Summary
ON
LY
5/2-way solenoid valve M367

Operating device
125.08
MAN Diesel & Turbo
1 (2)
125.08
MAN Diesel & Turbo
ON
LY
Operating device

NG
PU
RP
OS
E
NI
Figure 1: 5/2-way solenoid valve M367
AI
Connection
Magnet deenergised
connected
closed
2
connected
connected
3
closed
connected
2007-08-01 - de
TR
Magnet energised
General
FO
2 (2)
6682 125.08-02 EN

safety.
1 Technician
Tools/aids required
Status
Inventory
Inventory
1 Screwdriver (Set)
Inventory
Inventory
NG
Spare parts
0,5
Number
PU
Quan- Designation
tity
Duration in h
NI
Number
125.98.409
1 Set of wear parts
125.99.409
AI
1 Pressure-reducing valve with pressure gauge
TR
Work sequence 1 - Disassembling the pressure-reducing valve

Starting position
R
FO
2007-03-28 - de
Work steps

and take out valve.
ingress of dirt.
3. Unscrew cylinder screws (11) and knurled screw (14).
4. Detach upper section of casing (12) from lower section of casing (13)
and remove wear parts (V).
6682 125.09-01 EN
General
RP
OS
E

Summary
ON
LY
Pressure-reducing valve M409

Operating device
125.09
MAN Diesel & Turbo
1 (2)
125.09
MAN Diesel & Turbo
ON
LY
Operating device
to overhaul the M409 pressure reducing valve.
Work sequence 2 - Assembling the pressure-reducing valve
RP
OS
E


NI
AI
2 (2)
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
6682 125.09-01 EN
2007-03-28 - de
TR
R
General
FO
NG
PU

safety.
1 Technician
Tools/aids required
0,5
Number
Status
Inventory
1 Screwdriver (Set)
Inventory
Inventory
NG
PU
Quan- Designation
tity
Duration in h
Spare parts
Number
125.98.462
1 Filter insert
125.99.462
AI
NI
1 Compressed air filter
Work sequence 1 - Disassembling the compressed air filter

Compressed air or control air system depressurised. Filter cleaned externally.
R
FO
2007-03-28 - de
TR
Starting position
Work steps

and take out filter.
ingress of dirt.
3. Drain the compressed-air filter initially via the hexagon bolt (13).
4. Unscrew the hexagon nut (11) and remove the pipe clamp.
5. Dismantle filter and thoroughly clean all individual parts.
6. Clean filter insert (12) according to the manufacturer's specifications, or
replace with new one as necessary.
6682 125.10-01 EN
General
RP
OS
E

Summary
ON
LY
Compressed air filter M462

Operating device
125.10
MAN Diesel & Turbo
1 (2)
125.10
MAN Diesel & Turbo
Work sequence 2 - Assembling the compressed air filter
ON
LY
Operating device
You can obtain the filter insert for the M462 compressed-air filter from
MAN Diesel & Turbo SE.
RP
OS
E

2007-03-28 - de
TR
AI
NI
11 Hexagon nut
12 Filter insert
13 Hexagon bolt
Figure 1: Sectional view of the compressed air filter M462
General
FO
NG
PU

2 (2)
6682 125.10-01 EN

safety.
Electric/ electronic control and/or switch elements are to be checked and, if
necessary, overhauled at regular intervals.
1 Technician
Tools/aids required
Status
Inventory
Inventory
1 Screwdriver (Set)
Inventory
NG
Spare parts
0,5
Number
PU
Quan- Designation
tity
Duration in h
Number
125.98.745
1 Set of wear parts
125.99.745
AI
NI
1 Limit switch
Work sequence 1 - Disassembling the limit switch

No voltage is present at the limit switch.
R
FO
2007-03-28 - de
TR
Starting position
Work steps
1. Release cable connections (mark if necessary), remove fastening

screws and disassemble switch.
2. Remove roller lever (1), unscrew cylinder screws (2) and remove pushbutton.
3. Unscrew cylinder screw (3) and cover (4).
4. Disassemble the limit switch further and thoroughly clean all individual
parts.
Work sequence 2 - Assembling the limit switch

6682 125.12-01 EN
General
RP
OS
E

Summary
ON
LY
Limit switch M745

Operating device
125.12
MAN Diesel & Turbo
1 (2)
125.12
MAN Diesel & Turbo
ON
LY
Operating device
Keep the workplace absolutely clean when assembling.
Roller lever
Cylinder screw
Cylinder screw
Cover
RP
OS
E
1
2
3
4
NI
AI
TR
2007-03-28 - de
R
General
FO
NG
PU
Figure 1: Illustration of the limit switch M745
2 (2)
6682 125.12-01 EN
Summary
ON
LY
2/2-way solenoid valve M314/M315/M316

safety.

1 Technician
Tools/aids required
Duration in h
0,5
Number
Status
Inventory
Inventory
1 Screwdriver (Set)
Inventory
Inventory
NG
PU
Quan- Designation
tity
RP
OS
E

Operating device
125.14
MAN Diesel & Turbo
Work sequence 1 - Disassembling the 2/2-way solenoid valve

Compressed air or control air system depressurised. Valve exterior cleaned.
NI
TR
AI
2. Seal open pipe ends to prevent the ingress of dirt using suitable equipment.
3. Disassemble the valve and thoroughly clean all individual parts.
4. Check wear parts for wear or hardening (in sealing rings), replace with
new ones if necessary.
FO
2007-07-31 - de

6682 125.14-01 EN
General
1. Undo pipe connections (mark if necessary), remove fastening screws

and take out valve.
Starting position
Work steps
1 (2)
125.14
MAN Diesel & Turbo
Operating device
RP
OS
E
ON
LY
PU
Figure 1: 2/2-way solenoid valve M314/M315/M316
Magnet deenergised
closed
closed
NG
Connection
AI
NI
connected
TR
2007-07-31 - de
R
General
FO
Magnet energised
2 (2)
6682 125.14-01 EN
140
TR
R
FO
6632 140-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
Speed regulation
MAN Diesel & Turbo
1 (2)
140
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
Speed regulation
MAN Diesel & Turbo
2 (2)
6632 140-05 EN
Electronic speed governor

Check in the case of an error
ON
LY
Summary
Ensure correct execution of work, allow emergency mode.

Electronic speed governors are largely maintenance-free. However, if operating problems do occur, the cause of the error must be remedied as quickly
as possible.
The work includes:
Repair of the speed governor.
RP
OS
E
Tools/aids required
Quan- Designation
tity

Work card
Work card
Number
Status
Inventory
Work card
PU
203.02
Speed regulation
140.01
MAN Diesel & Turbo
Work sequence 1 - Repairing the speed governor
Speed governor, alarm in engine control room.

1. Open speed governor cubicle (10).
NG
Starting position
Work steps
2. Remove cover from digital controller (11).

3. Connect hand-held parameterising unit (17) to socket (4) of digital controller.
NI
4. If "NO PARAMETER IN MASK" appears in the display (18), press

"MASK ON / OFF" button.
6. Search for and note down corresponding code number in Table 1.

7. Look for the code number in the "Fault handling" section of the governor brochure entitled "Programming the digital controller" and eliminate
the cause by carrying out the measure described.
8. If parameters have been modified, save these changes (by pressing
"2nd" button followed by "SAVE DATA" button).
6632 140.01-01 EN
V32/40
R
FO
2007-11-06 - de
TR
Display shows the last fault that has arisen.
AI
5. Read off error flag (text in 4th line) on display.
1 (5)
140.01
MAN Diesel & Turbo
ON
LY
Speed regulation
9. Press "RESET" button (14) on digital controller.

If other faults are present, the next error flag appears in the display once
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
display.
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.
NI
AI
V32/40
2 (5)
8 Pull rod
9 Position pick-up
KGS Free engine end
If the cause of the fault which led to the failure of the speed governor electronics cannot be eliminated and the speed governor therefore cannot be
brought into operation, proceed as follows:
With the hand-held parameterising unit plugged in, press the "MASK
ON / OFF", "2nd" and "ERRORS" buttons in this order, make a note of all
error flags that are set to "1" and consult MAN Diesel & Turbo SE.
6632 140.01-01 EN
2007-11-06 - de
TR
6 Actuator
7 Control rod
Figure 1: Fitting the actuator for the governor
FO
NG
PU
RP
OS
E
11. Disconnect the hand-held parameterising unit, mount the cover on the
digital controller. Close the speed governor cubicle.
Example:
ERR FEEDBACK O
= no error indicated by error flag
ERR EED OVER 1
= error indicated by error flag
Disconnect the hand-held parameterising unit.
Deactivate the automatic circuit breakers (12 and 13).
ON
LY
When the power supply is switched off, an alarm is signalled in the

engine control room.
RP
OS
E
Mount hand crank on governor control linkage (see Work Card 203.02)
and operate engine by hand.
TR
R
FO
2007-11-06 - de
1-5 Connecting socket

11 Digital controller
14 7-segment display
Figure 3: Digital controller
6632 140.01-01 EN
15 "RESET" button
16 LED row
V32/40
12 Automatic circuit breaker

13 Automatic circuit breaker
AI
NI
10 Speed governor cubicle

11 Digital controller
Figure 2: Speed governor cubicle
NG
PU
Speed regulation
140.01
MAN Diesel & Turbo
3 (5)
140.01
RP
OS
E
ON
LY
Speed regulation
MAN Diesel & Turbo
17 Hand-held parameterising unit

18 Display
Figure 4: Hand-held parameterising unit
Code number
SERR_ACTUATOR_DIFF
3104
ERR_ADC1
3041
ERR_ADC2
3042
ERR_ADC3
3043
3068
SERR_ALINE
3168
3005
SERR_AMPLIFIER
3105
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
ERR_FEEDBACK_ADJUST
3000
SERR_FEEDBACK_ADJUST
3100
ERR_GAS_PRESS_MIX
3030
SERR_GAS_PRESS_MIX
3130
ERR_GAS_PRESS_RED
3031
SERR_GAS_PRESS_RED
3131
NG
3004
3044
ERR_ADC5
3045
3046
3047
ERR_ALINE
V32/40
FO
TR
ERR_BOOST
AI
ERR_AMPLIFIER
6632 140.01-01 EN
2007-11-06 - de
ERR_ADC7
NI
ERR_ADC6
Code number
ERR_ACTUATOR_DIFF
ERR_ADC4
4 (5)
Error flag
(SERR)
PU
Error flag
(ERR)
19 Keyboard
Code number
Error flag
(SERR)
3072
SERR_INTER
3172
ERR_LMG_INPUT
3029
SERR_LMG_INPUT
3129
ERR_LOGICAL
3064
SERR_LOGICAL
ERR_MAP
3061
SERR_MAP
ERR_MEMORY
3063
SERR_MEMORY
ERR_OIL_ECY
3010
SERR_OIL_ECY
ERR_OIL_PRESSURE
3024
SERR_OIL_PRESSURE
ERR_OIL_WARN
3009
SERR_OIL_WARN
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
ERR_TEMP_CHARGE_AIR
3027
ERR_TEMP_COOL_WATER
3025
ERR_TEMP_OIL
ERR_VOLTAGE3
ERR_WATCHDOG
RP
OS
E
PU
3163
3110
3124
3109
SERR_TEMP_CHARGE_AIR
3127
SERR_TEMP_COOL_WATER
3125
3026
SERR_TEMP_OIL
3126
3067
SERR_USER
3167
3011
SERR_VOLTAGE
3111
3012
SERR_VOLTAGE2
3112
3013
SERR_VOLTAGE3
3113
3071
SERR_WATCHDOG
3171
AI
Table 1: Assignment of error flag to code number

also see Work Card 400.01
FO
TR
3161
3128
NI
ERR_VOLTAGE2
3164
SERR_SYNCHRON_INPUT
NG
ERR_VOLTAGE
ON
LY
ERR_INTER
ERR_USER
2007-11-06 - de
Code number
6632 140.01-01 EN
V32/40
Error flag
(ERR)
Speed regulation
140.01
MAN Diesel & Turbo
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
TR
R
FO
6632 160-162-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
160-162
MAN Diesel & Turbo
1 (2)
160-162
ON
LY
RP
OS
E
PU
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
NG
111
112
113/114
120
125
140
160-162
FO
MAN Diesel & Turbo
2 (2)
6632 160-162-05 EN
Summary
ON
LY

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.
Tools/aids required
Number
Status
000.451
Standard
Inventory
1 Depth gauge
Inventory
Technical data
Designation
PU
Quan- Designation
tity
RP
OS
E

Removing/disassembling components,
Replacing sealing rings/elements,
Assembling/fitting components.
Information
8,5 kg
NG
160.01
MAN Diesel & Turbo
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.
6629 160.01-02 EN
32/40
R
FO
2007-11-05 - de
Work steps
TR
AI
NI
On opening the starter air systems, ensure that no dirt of any kind can
enter the valves and pipes. Block open pipe ends with plastic caps or
adhesive tape. Dismantle starter pilot valve only at a clean workplace,
and use degreasing agents and compressed air for cleaning.
Absolute cleanliness at the workplace is essential when re-assembling.
Dirt particles of any kind can cause malfunctioning in the starter
system.
Work sequence 1 - Removal and dismantling of the starter pilot valve
1 (2)
MAN Diesel & Turbo
RP
OS
E
ON
LY
160.01
1 Spacing washer
6 Set of seals
12 Pitot tube
2 Air supply pipe
7 O-ring seal
13 Starting cams
3 Hexagon bolt
8 PTFE ring
A Clearance
4 Control air line
9 casing
B New dimension 20.6 mm
5 Control piston
Figure 1: Starter pilot valve - Arrangement left/Control piston right. Figure shows a clockwise rotating engine
PU
Work sequence 2 - Assembly of the seal set

Work steps
1. Insert O-ring seal (7) in groove.

2. Heat PTFE-Ring (8) in oil to 80 -100 C.
3. Pull PTFE ring over control piston (5) into the groove.
NG
4. Reshape the expanded PTFE-Ring by placing the control piston (5) into
the oiled casing (9).
Work sequence 3 - Assembly and installation of the starter pilot valve

Starting position
NI
1. Check the control piston (5) mobility.
3. Upon completion, check the air pipes (2 and 4) for leakage and functionality.
2007-11-05 - de
TR
AI
2. Check the gap (A) after screwing both the hexagon bolts (3) in (see
Operating 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).
32/40
FO
Work steps
Check all parts for cleanliness and assemble and fit in the reverse order. The
following must be particularly observed:
2 (2)
6629 160.01-02 EN
Starting valve
Tools/aids required
Quan- Designation
tity
RP
OS
E

checking for leakages,
Number
Status
161.018
Standard
1 Thrust piece
161.018-1
Standard
161.018-5
Standard
055.149
Standard
1 Ratchet tool
008.023
Standard
1 Torque wrench
008.011
Standard
1 Shackle A0.6
002.452
Standard
001.912
Standard
001.757
Standard
1 Ring nut M12
000.182
Standard
Inventory
Inventory
Inventory
Inventory
1 Spindle
AI
NI
NG
PU
1 Cleaning tool
TR
Work card
Work card
000.30
161.03
Work card
FO
2007-07-18 - de
Technical data
Designation
Information
Starting valve
6,5 kg
Thrust flange
5,5 kg
6629 161.01-01 EN
32/40

Starting valves are to be checked at regular intervals and overhauled, if necessary.
ON
LY
Summary
161.01
MAN Diesel & Turbo
1 (4)
161.01
MAN Diesel & Turbo
ON
LY
Work sequence 1 - Checking for leakage
1
2
3
4
5
6
7
8
Cylinder head
Thrust flange
O-ring seal
O-ring seal
Starting valve
Stud
Hexagon nut
Control air line
NG
PU
RP
OS
E
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.
2. Open the indicator valves on the cylinder head.

3. Switch piston to ignition TDC (inlet and exhaust valve closed).
4. Vent starting pipe. Leaking starting valves can be detected by the air
outlet on the indicator valves.
Overhaul leaking starting valves as soon as possible, otherwise the

valve seat will continue to deteriorate.
2 (4)
6629 161.01-01 EN
2007-07-18 - de
TR
AI
1. Remove the pipe section between the main starting valve and the distributing pipe to the starting air pilot valves and seal the open ends with
a union nut and sealing plug. This ensures that no starter valve can be
charged with pontrol air.
32/40
FO
Work steps
NI
Figure 1: Starting valve in the cylinder head
Work sequence 2 - removing the Starting valve

Work steps
ON
LY
1. Unscrew the pontrol air line (8) from the thrust flange (2).
161.01
MAN Diesel & Turbo
2. Unscrew two hexagon nuts (7) and remove the thrust flange.
3. Screw the spindle (161.018-5) until it fits onto the starting valve (5).
4. Set thrust piece (161.018-1) over the spindle on cylinder head (1),
screw on collar nut (10).
5. Release the starting valve by turning the collar nut and carefully
unscrew.
RP
OS
E
6. Screw the ring nut (000.182) onto the spindle, hook onto lifting tackle
with shackle (002.452) and rope, and remove from the cylinder head
7. Clean the starting valve bore in the cylinder head using a cleaning tool
(055.149). Make sure that no foreign bodies fall into the combustion
chamber.
8. Non-return valve seating surface in the cylinder head, grind if necessary
9. Cover the opening in the cylinder head.
10. Place starting valve on the workbench and remove tool.
AI
TR
Figure 2: Removing and installing the starting valve
Work sequence 3 - installing the Starting valve
FO
2007-07-18 - de
Starting position
Starting valve cleaned and checked, damaged parts replaced.

The installation is carried out in reverse order from the disassembling. The
following must be observed when doing so:
1. Insert new O-ring seals (3 and 4), lubricated with acid-free grease, in
the ring groove, ensuring that it is tightened equally around the entire
circumference and not twisted.
2. Fit starting valve (5) with the spindle (161.018-5) and ring nut (000.182).
6629 161.01-01 EN
32/40
Cylinder head
Starting valve
Adjacent cylinder head
Collar nut M20
1
5
9
10
NI
NG
PU
11. Dismantle starting valve and clean it (see Work Card 161.02).
3 (4)
161.01
MAN Diesel & Turbo
ON
LY
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
Card 000.30).
If the starting valve is installed in a cylinder head at operating
temperature, tighten the two hexagon nuts (7) initially only hand-tight
and, only after temperature equalisation, with specified torque.
NI
AI
TR
2007-07-18 - de
R
32/40
FO
NG
PU
RP
OS
E
4. After installing the starting valve, check for leakage (see work sequence
1).
4 (4)
6629 161.01-01 EN
Summary
ON
LY
Starting valve
Tools/aids required
Quan- Designation
tity
Number
Status
008.023
Standard
008.011
Standard
1 Socket spanner insert 19x12.5L
001.767
Standard
Inventory
Inventory
1 Touching-test ink
Inventory
1 Ratchet tool
NG
PU
1 Torque wrench
RP
OS
E

disassembly of components,
replacement of sealing rings/sealing elements,
assembly of components.
Work card
161.02
MAN Diesel & Turbo
Work card
Work card
000.30
R
FO
2007-07-18 - de
TR
2. Unscrew hexagon nut (11), this releases the compression spring (19).
3. Remove piston (15) from the valve cone. Then remove casing (20) with
compression spring.
4. Dismantle set of seals (12 and 16) from piston.
5. Clean all individual parts, check for attrition and damage.
6. Non-return valve seats with touching test.
7. If grinding is necessary, clamp house carefully in vice, without damaging
any sealing faces. Assemble valve cone with piston without compression spring and sets of seals in casing. Coat valve seat with fine grinding paste and rotate valve cone to and fro. Raise valve cone in the
meanwhile, so that grinding paste can be redistributed. After grinding,
clean valve cone, casing and piston.
6629 161.02-01 EN
32/40
1. Load starting valve on two surfaces of the valve cone (21) in the vice.
Starting valve removed and placed on the workbench.
AI
Starting position
Work steps
NI
Work sequence 1 - Dismantling the starting valve
1 (3)
161.02
MAN Diesel & Turbo
NI
TR
AI
11 Hexagon nut
17 O-ring seal
12 Set of seals
18 PTFE ring
13 O-ring seal
14 PTFE ring
20 casing
15 Piston
21 Valve cone
16 Set of seals
Figure 1: Sectional view of the starting valve (left)/removed piston with sealing sets
(right)
Work steps
32/40
2 (3)
1. Insert O-ring seal (13 or 17) in groove.

2. Heat PTFE-Ring (14 or 18) in oil to 80 C - 100C.
3. Pull PTFE ring over piston (15) into the groove.
4. Reshape the expanded PTFE ring by placing the piston into the oiled
casing (20).
6629 161.02-01 EN
2007-07-18 - de
Work sequence 2 - Mounting of the sets of seals (12 and 16)
FO
NG
PU
RP
OS
E
ON
LY
Remove as little material as possible and grind only until a uniform

matt-grey annular surface is obtained (check with touching-test ink).
Work sequence 3 - Assembling the starting valves

All individual parts cleaned, checked and possibly renewed.
ON
LY
Starting position
Work steps
161.02
MAN Diesel & Turbo
The assembly of the starting valve is done in reverse order of the dismantling.
The following must be observed when doing so:
6629 161.02-01 EN
32/40
R
FO
2007-07-18 - de
TR
AI
NI
NG
PU
RP
OS
E
Coat screw thread and contact face of the hexagon nut (11) with MoS2 lubricant, screw them on and tighten to the specified torque (see Work Card
000.30).
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY

1 Technician
Tools/aids required
Quan- Designation
tity
RP
OS
E
The work includes:

Duration in h
0,5
Number
Status
055.197
Standard
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)
055.197-1
3
Standard
1 Pliers for locking rings
055.197-1
9
Standard
1 Quick-acting cleanser Loctite 7061
055.197-2
1
Standard
1 Tap wrench
055.197-2
3
Standard
1 Cleaning tool
055.149
Standard
Inventory
1 Depth gauge
Inventory
1 Torch
Inventory
TR
AI
NI
NG
1 Spindle
PU
FO
2007-07-18 - de

Work card
Work card
161.01
6629 161.03-02 EN
Work card
32/40

Summary
ON
LY
Starting valve
Grind seating surface in the cylinder head
161.03
MAN Diesel & Turbo
1 (4)
161.03
MAN Diesel & Turbo
ON
LY
Work sequence 1 - Grinding the starting valve seating surface
RP
OS
E
1 Cylinder head
A maximum allowable
dimension
Figure 1: Summarised display of the max. permitted dimension for grinding the
starting valve seating surface
Starting position
Work steps
Starting valve disassembled.
1. Insert grinding wheel (055.197-9) onto the spindle (055.197-1) and fix
with hexagon nut (22) (see figure 3).
PU
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).
NG
5. Insert guide bush (055.197-3) with outer 70 mm and guide grinding

tool into the starting valve bore.
NI
7. Remove grinding tool (055.197) after the grinding process is complete

and clean valve seating surface carefully with cleaning tool (055.149)
(see Figure 3).
2007-07-18 - de
TR
AI
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
dimension, the cylinder head must be changed.
32/40
FO
6. Rotate grinding tool to and fro, raise in-between and blow off grinding
dust with compressed air.
2 (4)
6629 161.03-02 EN
NI
AI
TR
NG
6629 161.03-02 EN
ON
LY
RP
OS
E
PU
Figure 2: Gluing the grinding plates in position
32/40
FO
2007-07-18 - de
MAN Diesel & Turbo

161.03
3 (4)
161.03
NI
AI
TR
2007-07-18 - de
1 Cylinder head
22 Hexagon nut
Figure 3: Grinding (left) and cleaning (right) of the starting valve seating surface in the
cylinder head
32/40
FO
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
4 (4)
6629 161.03-02 EN
Summary
ON
LY
Main starting valve

The main starting valve is to be checked, cleaned and overhauled, if necessary, at regular intervals.
Tools/aids required
Quan- Designation
tity
RP
OS
E

Separating parts/ components,
Number
Status
009.229
Option
Inventory
1 Threaded rod
Standard
Technical data
Designation
PU
Information
26,2 kg
NG
Main starting valve
162.01
MAN Diesel & Turbo
Work sequence 1 - Removal and dismantling
Keep the workplace absolutely clean when assembling and act with extreme
care. Even the smallest dirt particles can cause malfunctions.
FO
2007-07-18 - de
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 compressed air all individual parts (5-7) and check the condition, replace if
necessary.
6629 162.01-01 EN
32/40;L32/40CR;L40/54
TR
AI
When opening the starting air and pontrol air systems, see that no dirt
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
cleaning.
Engine stopped, no starting process necessary. Compressed air tank, relief

valves opened in compressed air pipes.
NI
Starting position
1 (3)
162.01
MAN Diesel & Turbo
5. Release and remove closing cap (8), take out vent valve, separate into
all individual parts (9-13).
ON
LY
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.
NI
2 (3)
1
2
3
4
5
Hexagon bolt
Sealing ring
Hexagon bolt
casing
Valve piston
6 Seal ring, consisting of: O-ring

and PTFE ring
8 Closing cap
Figure 1: Main starting valve
9
10
11
12
13
Bleeding cone
Valve seat
Nut
Piston
Seal ring, consisting of: O-ring
and PTFE ring
14 Valve seat
15 Safety valve
Work sequence 2 - Assembly

Carry out assembly in the reverse sequence. Pay particular attention to the
ease of movement of the moving parts and the tightness of the separation
joints. Carry out functional check after the installation. If the casing is to be
checked for leakage then the moving inner components are not fitted at first.
The test takes place with a test pressure of max. 45 bar.
6629 162.01-01 EN
2007-07-18 - de
AI
TR
R
FO
32/40;L32/40CR;L40/54
NG
PU
RP
OS
E
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.
162.01
MAN Diesel & Turbo
1. Insert the O-ring in the groove.

2. Heat PTFE-Ring in oil to 80 -100C.
ON
LY
3. Pull PTFE-Ring over groove edge into the groove.
When installing new seal rings (6 or 13) proceed as follows:
6629 162.01-01 EN
32/40;L32/40CR;L40/54
R
FO
2007-07-18 - de
TR
AI
NI
NG
PU
RP
OS
E
4. Shape back the expanded PTFE Ring by placing the valve piston (5) or
venting taper (9) in the oiled casing (4) or the valve seat (10).
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
200
TR
R
FO
6632 200-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
200
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 (2)
6632 200-05 EN
Summary
ON
LY
Fuel injection pump

inspecting
Check Fuel injection pumps at regular intervals.
The work includes:
Checking parts/ components.
RP
OS
E
Tools/aids required
Quan- Designation
tity
Number
Status
Inventory
Inventory
Preliminary remarks
200.01
MAN Diesel & Turbo
PU
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 contribute towards extending the life in the face of adverse initial conditions.
Work sequence 1 - Checking a fuel injection pump
Cap of the injection camshaft covering and covering on the exhaust counter
side removed.
NG
Starting position
Work steps
1. Check condition (lubrication) of the injection cams (33), drive rollers (32)
and tappet guide.
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 injection pump (16) hand-tight.
7. Open the fuel pipes.
8. Check the leakage fuel drain at extended intervals. If there are major
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.
6629 200.01-01 EN
32/40
R
FO
2007-06-15 - de
TR
AI
Heavy to move or stuck regulating sleeve can be made free moving

again by using diesel fuel.
NI
2. Remove hexagon bolt (22) between control rod (25) and jointed head
(24) check easy movability of control rod and regulating sleeve (26).
1 (2)
200.01
Rack
Regulating sleeve
Pump element
Monobloc cylinder
Pump plunger
Cylinder crankcase
Tappet
Drive roller
Injection cams
A pump element comprises monobloc cylinder (28) and pump plunger

(29).. Pump plunger and monobloc cylinder can only be changed
together because both parts are matched to each other. In addition we
recommend fitting new sealing rings (19) and O-ring seals (20 and 21)
when fitting new pump elements.
32/40
2 (2)
25
26
27
28
29
30
31
32
33
2007-06-15 - de
TR
AI
NI

17 Baffle screw
18 Sealing ring
19 Sealing ring
20 O-ring seal
21 O-ring seal
22 Hexagon bolt
23 Hexagon nut
24 Jointed head
Figure 1: Fuel injection pump
FO
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
6629 200.01-01 EN
Summary
ON
LY
Fuel injection pump

shut off
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
Quan- Designation
tity
1 Spring washer
RP
OS
E
Tools/aids required
Preliminary remarks
200.02
MAN Diesel & Turbo
Number
Status
200.078
Standard
Inventory
PU
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).
NG
When switching off the control rod of the corresponding injection pump is
blocked in the ZERO position.
Work sequence 1 - Switching off a fuel injection pump
R
FO
2007-06-15 - de
Work steps
Covering on the exhaust counter side over the relevant cylinder is removed,
damaged parts are removed or the required measures for realisation of
emergency operation are in place (see Operating Instructions, section 3.6).
TR
Starting position
1. With the engine at standstill, check that control rod (25) is in ZERO
position, or, with the engine running, pull control rod against the force of
the buckling lever spring in ZERO position and keep it held there.
2. Fit two-part pipe clamp (200.078) on control rod, screw in hexagon
socket bolt (35) loosely.
3. Push the pipe clamp until it rests on the casing (34) and tighten the hexagon socket bolts hand-tight.
6629 200.02-01 EN
32/40
AI
The filling of the remaining fuel injection pumps is enabled by unbuckling the
buckling lever on the switched-off injection pump.
NI
The fuel supply to the injection pump must not be blocked off (pump
plunger lubrication).
1 (2)
200.02
RP
OS
E
ON
LY
MAN Diesel & Turbo
NI
AI
TR
2007-06-15 - de
R
32/40
FO
NG
PU
25 Rack
34 Casing
Figure 1: Fuel injection pump with blocked control rod
2 (2)
6629 200.02-01 EN
Fuel injection pump

RP
OS
E

Tools/aids required
Quan- Designation
tity
Number
Status
200.079
Standard
1 Lever
200.079-1
Standard
200.079-6
Standard
200.079-7
Standard
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
001.755
Standard
1 Offset screwdriver
000.445
Standard
Inventory
Inventory
Inventory
Inventory
Inventory
1 Bracket
1 Pin
TR
AI
NI
NG
PU
1 Spring clip
R
FO
2007-11-05 - de

Work card
Work card
000.30
434.01
Work card
Technical data
Designation
Information
Fuel injection pump
36,5 kg
6629 200.03-01 EN
32/40
Fuel injection pumps are to be dismantled within the scope of maintenance
and repair work.
ON
LY
Summary
200.03
MAN Diesel & Turbo
1 (6)
200.03
MAN Diesel & Turbo
Work sequence 1 - Removing a fuel injection pump

Starting position
Work steps
ON
LY
Covering on the exhaust counter side removed, fuel injection pipe removed.
1. Turn the engine so that the roller of the injection pump (16) is on the
cam base circle of the camshaft (spring relieved as much as possible).
2. Close all requisite shut-off valves (e.g. for fuel pipes, air lines etc.).
3. Remove the air pipe, fuel leakage pipe, lube oil pipe and sealing oil line
(if fitted) from the injection pump.
4. Unscrew the hexagon socket bolts (41) with hexagon screwdriver
(000.445) and remove the flanges (40) of the fuel admission pipe (38)
and drain line (42).
32/40
2 (6)
37
38
39
40
41
42

Fuel admission pipe
O-ring seal
Flange
Hexagon socket bolt
Fuel drain pipe
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.
1. Push it in completely to protect the control rod (full load position).
2. Unscrew the hexagon nuts (45) from the ring extension (200.073).
3. Screw the retainer (200.079-6) on the injection pump.
6629 200.03-01 EN
2007-11-05 - de
TR
AI
NI

22 Hexagon bolt
23 Hexagon nut
24 Jointed head
25 Rack
36 Buckling lever
Figure 1: Attached fuel injection pump
FO
NG
PU
RP
OS
E
5. Remove the hexagon bolt (22) between the linkage rod (25) and jointed
head (24).
ON
LY
On engines with a gallery fitted, removal and fitting by lever (200.079-1)

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.
200.03
MAN Diesel & Turbo
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
suspend from the lifting tackle.
6. Lift the rope until the lever is roughly in the position shown in figure 2/I.
RP
OS
E
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
injection pump does not collide with anything or does not stick,
thereby damaging components.
PU
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).
NG
12. Place aside injection pump on clean support.

13. Completely detach the tool.
6629 200.03-01 EN
32/40
R
FO
2007-11-05 - de
TR
AI
NI
14. Clean injection pump externally.
3 (6)
200.03
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
45 Hexagon nut
46 Stud
47 O-ring seal
NG

33 Injection cam
24 Jointed head
36 Buckling lever
25 Rack
43 Charge air pipe
44 Rope
Figure 2: Removing a fuel injection pump (illustration shows in-line engine)
Work sequence 2 - Fitting a fuel injection pump

Starting position
NI
AI
1. Clean contact face on the injection pump (16) and cylinder crankcase
(30).
4 (6)
2. Place the new O-ring seals (39), coated with acid-free grease, in the
ring grooves on the fuel admission pipe (38) or drain line (42), taking
care that they are not twisted.
3. Screw the retainer (200.079-6) on the injection pump.
Depending upon the type of removal, the work steps 4 to 9 or 10 to 13

must be carried out when fitting.
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
suspend from the lifting tackle. Lift the injection pump.
6629 200.03-01 EN
2007-11-05 - de
TR
R
32/40
FO
Work steps
Injection pump is cleaned and checked, control rod is pushed in completely

for protection (full load position).
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 circumference and is not twisted.
ON
LY
7. Lift the injection pump by pushing the lever down.
200.03
MAN Diesel & Turbo
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.
RP
OS
E
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 circumference and is not twisted.
PU
13. Place the injection pump (16) over the hole and carefully lower into the
hole with lifting tackle.
NG
When installing, see that studs are not damaged.
17. Apply MoS2 lubricant to threads and resting surface of the hexagon nut
(45) and screw them onto studs (46) hand-tight.
18. Turn the engine over (the roller of the injection pump aligns with the
cam).
19. Tighten the hexagon nuts (45) onto the ring extension (200.073). Ensure
specified torque (see Work Card 000.30) (tightening sequence see figure 3).
6629 200.03-01 EN
32/40
R
FO
2007-11-05 - de
TR
AI
16. Slide the flange between the injection pump and the fuel admission pipe
or drain line and loosely screw the hexagon socket bolts (41) in position
up to contact with a hexagon screwdriver (000.445) so that the injection
pump can align itself.
NI
15. Place new O-ring seals (39) coated with acid-free grease in ring
grooves on the flange (40), ensuring that it is not twisted.
5 (6)
200.03
14
16
45
46
A
G
S
Figure 3: Tightening sequence of the fixing nuts
1. Tighten hexagon socket bolts (41).
Tightening sequence
Fuel injection pump
Hexagon nut
Stud
Exhaust counter side
ON
LY
MAN Diesel & Turbo
RP
OS
E
2. Fit the air line, fuel leakage pipe, lube oil pipe and sealing oil pipe (if fitted) to the injection pump.
3. Attach fuel injection pipe (see Work Card 434.01).
4. Fix the jointed head (24) onto control rod (25).
PU
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
correct the zero setting between the injection pump and the speed
governor.
5. Open all shut-off valves closed in work sequence 1.
NG
6. Check that the control rod is in the end ZERO position when the entire
governor control linkage is set to ZERO (compare control rod position
with the position on the other injection pumps).
NI
AI
TR
2007-11-05 - de
R
32/40
FO
7. After commissioning determine the ignition pressure by indexing.
6 (6)
6629 200.03-01 EN
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.
1 Technician
1 Assistant
Tools/aids required
Status
1 Removing fixture
200.109
Standard
1 Thrust plate
200.109-1
Standard
1 Support ring
200.109-2
Standard
200.074
Standard
1 Bridge
200.074-1
Standard
1 Thrust piece with spindle
200.074-6
Standard
1 Hexagon screwdriver 6L
200.095
Standard
1 Hexagon screwdriver 6K
200.096
Standard
1 Ratchet tool
008.023
Standard
1 Torque wrench
008.011
Standard
1 Torque wrench
008.017
Standard
1 Adapter 12.5x20
001.927
Standard
1 Cross handle
001.891
Standard
001.857
Standard
001.856
Standard
001.758
Standard
1 Eye bolt
001.404
Standard
000.451
Standard
Inventory
Inventory
Inventory
NG
NI
AI
TR
R
FO
2009-06-08 - de
Number
PU
Quan- Designation
tity
Duration in h
6629 200.04-05 EN
32/40
RP
OS
E

Replace packing rings /sealing elements,
Summary
ON
LY
Fuel-injection pump
disassembly and assembly
200.04
MAN Diesel & Turbo
1 (8)
200.04
MAN Diesel & Turbo

Number
Status
Inventory
Inventory

Work card
Work card
000.30
200.03
Work card
RP
OS
E
Work sequence 1 - Dismantling a fuel injection pump
ON
LY
Quan- Designation
tity
The assembly of injection pumps is to be executed with great care, as

smooth working and good sealing is possible only with undamaged and
clean individual parts. This is valid especially for the monobloc cylinder
and the pump plunger.
Starting position
Work steps
Injection pump removed and cleaned on the outside.
PU
1. Unscrew hexagon socket bolts (48), remove valve support (52) and
place it on a clean support (see figure 1).
2. Screw back spindle (74), set bridge (200.074-1) diagonally on the casing (34) and fasten with hexagon nuts (75) (see figure 2/I).
3. Rotate spindle, until thrust pad (200.074-6) rests on tappet (31) (see figure 2/II).
NG
4. By turning the spindle, press the tappet so far down that the sealing
screw (57) is relieved and can be removed with eye bolts (001.404) (see
figure 2/III).
NI
5. Screw back the spindle and release the compression springs (see figure
2/IV).
32/40
2 (8)
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
piston.
11. Remove the compression spring from the housing, remove the spring
plate (55) and control sleeve (26).
12. Remove securing wire (76) and unscrew both the baffle screws (17).
6629 200.04-05 EN
2009-06-08 - de
TR
AI
7. Remove tappet including pump plunger (29) and place it on a clean

support.
FO
200.04
MAN Diesel & Turbo
14. Place the support ring (200.109-2) on the housing (34).
ON
LY
15. Place the thrust plate (200.109-1) on monobloc cylinder (28) and fix in
position with hexagon bolts (84) (see figure 3).
13. Unscrew hexagonal socket screws (49) and remove thrust ring (50).
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.
RP
OS
E
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.
PU
Replacement of the roller should only be carried out by a service

support location or by MAN-Diesel staff, as the roller pin is fitted into
the tappet by supercooling.
20. Check the entire valve support for leakage and ease of movement of
individual parts, disassemble the valve support if necessary.
NG
21. Clean all individual parts with clean diesel fuel and check for wear or
damage.
6629 200.04-05 EN
32/40
R
FO
2009-06-08 - de
TR
AI
NI
A pump element comprises monobloc cylinder and pump plunger.

Pump plunger and monobloc cylinder can only be changed together
because both parts are matched to each other.
3 (8)
200.04
NG
AI
NI
Impact bolt
Sealing ring
Variseal sealing ring
O-ring
Variseal sealing ring
Rack
Control sleeve
Pump element
Monobloc cylinder
Pump piston
Plunger
Roller
Housing
Hexagonal socket screw
TR
17
18
19
20
22
25
26
27
28
29
31
32
34
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62

Thrust ring
Cylinder pin
Valve carrier
Pressure spring
Pressure valve
Spring cup
Pressure spring
Screw plug
Sealing ring
Thrust plate
Set screw
Roller pin
63
65
66
67
68
69
70
71
72
73
76
Piston base plate

Cylinder pin
Spacer sleeve
Pressure spring
Spring cup
Ball
Piston seal
Cylinder
Sealing ring
Cylinder pin
Wire lock
A Clearance
M Mark control rod-regulation sleeve
2009-06-08 - de
Figure 1: Fuel-injection pump
32/40
FO
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
4 (8)
6629 200.04-05 EN
200.04
6629 200.04-05 EN
75 Hexagon nut M16
32/40
57 sealing screw on distribution block

34 Casing
58 Sealing ring
74 Spindle
Figure 2: Releasing/Tensioning the compression spring in the fuel injection pump
FO
2009-06-08 - de
31 Tappet
TR
AI
NI
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
5 (8)
200.04
RP
OS
E
ON
LY
MAN Diesel & Turbo
20 O-ring
28 Monobloc cylinder
34 Housing
83 Hexagon head bolt
M12x170
Figure 3: Removing the monobloc cylinder
Work sequence 2 - Assembling a fuel injection pump

Starting position
PU
All individual parts cleaned and checked for damage or replaced. Tappet and
valve carrier assembled.
Work steps
1. Lightly oil all individual parts with thin mineral oil before assembly.
NG
Metallic sealing and contact faces must be absolutely dry at the time of
assembly.
NI
2. Install new piston seal (70) in ring groove.
32/40
6 (8)
5. Insert new O-rings (20) which have been oiled with clean lubricating oil
in the ring groove, making sure that they are evenly tensioned all around
the circumference and are not twisted.
6. Place new Variseal sealing rings (19 and 22) in the housing (34) or monobloc cylinder (28).
7. Insert monobloc cylinder (28) in housing (34), paying attention to the
position of the parallel pins (65).
8. Press the monobloc cylinder in the housing whilst making sure that the
parallel pin (65) is located between the parallel pins (73) (see figure 1).
When pushing the monobloc cylinder in the casing ensure that it does
not tilt.
6629 200.04-05 EN
2009-06-08 - de
TR
AI
4. Coat the thread of the cylinder (71) over a length of 6 mm with Loctite
243 sealant and screw into the housing together with a new seal (72).
FO
3. Install control rod (25) in the housing (34).
200.04
MAN Diesel & Turbo
ON
LY
10. Apply MoS2-lubricant on threads and contact surface of the hexagonal

socket screws (49), screw in housing fingertight and tighten with the
specified torque (see Work Card 000.30) (figure 4 for tightening
sequence).
9. Place thrust ring (50) on monobloc cylinder.
11. Place valve support (52) on monobloc cylinder, paying attention to the
position of the hole/parallel pin (51).
12. Apply MoS2-lubricant on threads and contact surface of the hexagonal

socket screws (48), screw in fingertight and tighten in 3 stages with the
specified torque (see Work Card 000.30) (figure 4 for tightening
sequence).
RP
OS
E
13. Install control sleeve (26) such that markings (M) on control rod and
control sleeve match each other.
14. Fit the spring plate over the control sleeve in the housing.
Before fitting the plate spring check once again that the marks on the
regulating sleeve and control rod line up.
15. Install compression spring (56) in the casing.
PU
16. Place the piston spring plate (63) on the pump plunger (29), place the
thrust plate (59) in the piston spring plate.
NG
Do not touch pump plunger with bare hands. Protect control edges on
pump plunger from damage.
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 housing and fasten with hexagon nuts (75) (see figure 2/I).
21. Rotate spindle until pressure piece (200.074-6) rests on tappet (see figure 2/II).
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).
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
(76).
6629 200.04-05 EN
32/40
R
FO
2009-06-08 - de
TR
AI
18. Measure the clearance (A) between the thrust plate and piston foot
plate, note it down and compare with the prescribed clearance.
NI
17. Place the tappet (31) over the piston foot plate and fix in position with
four hexagonal socket screws (62).
7 (8)
200.04
RP
OS
E
ON
LY
MAN Diesel & Turbo
NI
AI
TR
2009-06-08 - de
R
32/40
FO
NG
PU
1-8 Tightening sequence

9-19 Tightening sequence
50 Thrust ring
52 Valve support
Figure 4: Tightening sequence of the fastening screws for monobloc cylinder (left) and
valve support (right)
8 (8)
6629 200.04-05 EN
200.07
MAN Diesel & Turbo
ON
LY
Summary
Fuel injection pump

Measure plunger lift
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 stopped
1 Technician
1 Assistant
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
2 Locking ring
200.098-7
Standard
1 Bolt
200.098-9
Standard
1 Prism
200.098-1
0
Standard
1 Dial gauge
200.098-1
5
Standard
1 Tool box
200.098-1
8
Standard
Inventory
Inventory
1 Pad
Inventory
AI
TR
R
FO
2007-07-17 - de
0,2
Number
NG
Quan- Designation
tity
0,2
NI
PU
Tools/aids required
Duration in h
6632 200.07-01 EN
V32/40
RP
OS
E
1 (3)
200.07
MAN Diesel & Turbo
PU
RP
OS
E
ON
LY
Work sequence - Measure plunger lift
NG
2 Injection pump drive

5 Hexagon nut
8 Hexagon socket bolt M6x18
4 Stud
Figure 1: Measuring device mounted on cylinder crankcase
Starting position
Work steps
Camshaft covering cap removed.

1. Check the movability of the rail (200.098-5) and the prism (200.098-10).
NI
AI
V32/40
2 (3)
3. Check mounting position and position of the prism (200.098-10) compared with the injection pump drive (2) (see figure 2).
4. Insert measuring gauge (200.098-15) in holder and fasten with hexagon
socket bolt (8).
5. Turn running gear until it reaches the cam base circle.
6. Reset measuring gauge to "zero".
7. Turn running gear until piston is at ignition TDC. Read off measuring
gauge and note the value.
8. Remove complete tool.
6632 200.07-01 EN
2007-07-17 - de
TR
When fitting take care with the fitting position of the prism.
FO
2. Place support (200.098-1) on stud bolts (4) of the camshaft covering,

attach spacer sleeves (200.098-3) and secure to the cylinder crankcase
(3) with hexagon nuts (5) (see figure 1 and 2).
9. Determine and note the values for the remaining cylinders in the same
manner.
6632 200.07-01 EN
6 Pressure spring
7 Dowel pin
A= 120 mm
V32/40
R
FO
2007-07-17 - de
TR
AI

2 Injection pump drive
4 Stud
5 Hexagon nut
Figure 2: Mounted measuring device
NI
NG
PU
RP
OS
E
ON
LY
10. Determine the mean value and compare with the mean value of ParentEngines in the Technical File, section 3 of the IMO Certification.
200.07
MAN Diesel & Turbo
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
203
TR
R
FO
6632 203-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
203
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 (2)
6632 203-05 EN
Summary
ON
LY

servicing and checking
ensure correct execution of the work, ensure /restore operational safety.
Regularly check the regulating linkage and lubricate.
The work includes:
Quan- Designation
tity
RP
OS
E
Tools/aids required
Number
Status
003.005
Standard
Inventory
Inventory
1 Lubricating grease, acid-free
Inventory
1 Grease gun
PU
Work sequence - Checking and maintenance
203.01
MAN Diesel & Turbo
2. Check governor control linkage for correct setting.
4. Check hexagon bolts and nuts and hexagon socket bolts for secure
location.
5. Check buckling lever (6) for free mobility.
6. Lubricate all jointed heads on the regulating rod (8) and tension rod (10)
and the connecting rods (16) with multi-purpose grease.
FO
2007-11-05 - de
TR
3. Check joints of the governor control linkage for easy movement.
6629 203.01-01 EN
32/40
1. Check the entire governor control linkage for attrition.
Covering removed.
AI
Starting position
Work steps
NI
NG
The control rod was set precisely at the time of commissioning of the
engine and needs only changing individual parts and possibly
correction 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.
1 (3)
203.01
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
11
12
13
14
Position pick-up
Lever
Actuator
Lever
NI
AI
TR
2007-11-05 - de
R
32/40
FO
NG
1 Bearing block
6 Buckling lever
2 Shaft
7 Lever
8 Control rod
9 Lever
5 Bearing block
10 Tie rod
Figure 1: Regulating linkage (figure shows in-line engine)
2 (3)
6629 203.01-01 EN
203.01
Bearing block
Shaft
Bearing block
Buckling lever
Lever
PU
1
2
5
6
7
RP
OS
E
ON
LY
MAN Diesel & Turbo
10
12
13
14
15
Tie rod
Lever
Actuator
Lever
Regulating rod on the fuel injection pump
16 Connecting rod
6629 203.01-01 EN
32/40
R
FO
2007-11-05 - de
TR
AI
NI
NG
8 Control rod
9 Lever
Figure 2: Regulating linkage (views and sections)
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Summary
ON
LY

actuate manually
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.
RP
OS
E
Tools/aids required
Quan- Designation
tity
1 Hand lever

203.01
Preliminary remark
Work card
Number
Status
203.008
Standard
Inventory
Work card
PU
Work card
203.02
MAN Diesel & Turbo
R
FO
2007-11-05 - de
Starting position
Work steps
Electronic speed generator failed.

Fasten hand lever (203.008) on lever (1) by means of hexagon bolts (2).
Separation of the regulation linkage from the speed governor is not

necessary if the electronic section of the speed governor fails.
In the event of seizing (pick-up) of bearings in the speed governor, the connection between the speed governor and the regulation linkage must be broken. 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).
6629 203.02-01 EN
32/40
TR
Work sequence - Fitting the hand lever
AI
NI
NG
Operation with non-functional speed generator is at the responsibility

of the operator. The operators must be informed of the existing
dangers: A sudden release of the engine due to the release of the
driving coupling or de-excitation of the generator causes
impermissible overspeed, resulting in the fracture of running gear parts
or the total destruction of the driven machine as a result of excessive
centrifugal forces.
1 (3)
203.02
MAN Diesel & Turbo
ON
LY
Under no circumstances must the fitting between the connecting rod

and the lever be released since otherwise the efficiency of the
governor stroke will be changed.
NG
PU
RP
OS
E
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.
NI
AI
TR
2007-11-05 - de
R
32/40
FO
1 Lever
2 Hexagon bolt
3 Shaft
Figure 1: Regulating linkage with fitted hand lever
2 (3)
6629 203.02-01 EN
203.02
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
6629 203.02-01 EN
32/40
R
FO
2007-11-05 - de
TR
AI
NI
NG
6 Connecting rod
9 Lever
12 Hexagon bolt
7 Position pick-up
10 Hexagon nut
8 Speed controller
11 Governor output shaft
Figure 2: Regulating linkage, speed governor and distance transmitter (illustration shows in-line engine)
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
221
TR
R
FO
6632 221-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
221
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
MAN Diesel & Turbo
2 (2)
6632 221-05 EN
Summary
ON
LY

Execute work on time according to the maintenance schedule, enable/ support 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 operating data, overhauled if necessary or replaced.
Engine stopped

PU
1 Technician
Tools/aids required
Status
221.182
Standard
1 Extractor sleeve
221.182-1
Standard
1 Threaded spindle
221.182-2
Standard
1 Spindle nut
221.182-3
Standard
1 Extractor
221.181
Standard
000.142
Standard
1 Cleaning tool
055.149
Standard
1 Ratchet tool
008.023
Standard
1 Torque wrench
008.011
Standard
1 Shackle A1.0
002.453
Standard
Inventory
Inventory
1 Wooden spatula
Inventory
1 Wire brush
Inventory
Inventory
Inventory
NI
AI
TR
R
FO
2007-10-24 - de
Number
NG
Quan- Designation
tity
Duration in h
6629 221.01-02 EN
32/40
Safety requirements
RP
OS
E

221.01
MAN Diesel & Turbo
1 (7)
221.01
MAN Diesel & Turbo

Work card
000.30
221.05
Work sequence 1 - Removing a fuel injection valve
Work card
ON
LY
Work card
434.01
RP
OS
E
If the engine normally operates with heavy fuel, it must be operated

briefly with diesel oil before the fuel injection valves are removed.
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.
PU
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.
NG
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.
NI
5. Take off the thrust piece (11).
32/40
2 (7)
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
extractor sleeve (221.182-1).
6629 221.01-02 EN
2007-10-24 - de
TR
AI
7. Screw on the threaded spindle (221.182-2) until it makes contact on

the injection valve (8) (see Fig. 3).
FO
6. Screw the extractor (221.181) into the thrust ring (12) and remove the
latter (see Fig. 2).
221.01
12 Thrust ring
13 Stud
16 O-ring seal
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.
6629 221.01-02 EN
32/40
6 Cylinder head
9 Rocker arm with bearing
7 Threaded piece
10 Hexagon nut
8 Injection valve
11 Thrust piece
Figure 1: Cylinder head with injection valve and parts of the fuel injection pipe
R
FO
2007-10-24 - de
TR
AI
NI
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
3 (7)
221.01
MAN Diesel & Turbo
2. Carefully pull out the injection valve from the cylinder head; in the process, make sure that the O-ring seal (18) is also removed (see Fig. 4).
3. Cover the opening in the cylinder head.
5. Remove the sealing ring (18).
ON
LY
4. Place the injection valve on the workbench and detach the device.
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.
NI
AI
TR
4 (7)
2007-10-24 - de
R
32/40
FO
NG
PU
RP
OS
E
Carry out the cleaning away from workbench.
6 Cylinder head
9 Rocker arm with bearing
Figure 2: Removal of the thrust ring
6629 221.01-02 EN
12 Thrust ring
13 Stud
221.01
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
7 Threaded piece
NG
6 Cylinder head
Figure 3: Removal of the injection valve
Work sequence 2 - Installation of a fuel injection valve
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 tensioned 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.
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
onto the lifting tackle.
6629 221.01-02 EN
32/40
AI
R
FO
2007-10-24 - de
Work steps
TR
Clean and check exterior of injection valve from obtained via reserve
stock or replacement delivery.
The injection valve, in particular the cylindrical shoulder of the nozzle body,
has been carefully cleaned. Spraying pressure, leak-tightness and nozzle
bores checked.
NI
Starting position
5 (7)
221.01
MAN Diesel & Turbo
ON
LY
6. Remove the cover from the bore in the cylinder head (6), and thoroughly clean the bore and the seat in the cylinder head with the cleaning device (055.149).
During cleaning, make sure that no foreign bodies are allowed to drop
into the combustion chamber!
RP
OS
E
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).
PU
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
several stages to the specified torque (see Work Card 000.30).
NG
If the injection valve is installed in a cylinder head which is at operating

temperature, initially only tighten the hexagon nut (10) finger-tight. Once
the temperature of the components has been equalized the nut should
then be tightened to the specified torque.
NI
14. Close the indicator valve.
AI
16. Open the shut-off valves on the fuel pipes.
2007-10-24 - de
TR
17. Attach the cylinder head cover.
32/40
FO
15. Fill up the injection valve cooling system with cooling water.
6 (7)
6629 221.01-02 EN
221.01
6629 221.01-02 EN
18 Sealing ring
32/40
R
FO
2007-10-24 - de
TR
AI
6 Cylinder head
8 Injection valve
Figure 4: Removal of the injection valve
NI
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
7 (7)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Summary
ON
LY
Fuel injector
inspecting
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
Number
Status
1 Nozzle test rig 32/40
221.221
Standard
1 Connecting piece
221.270
Standard
1 Receptacle for slushing oil
Inventory
Inventory
Inventory
1 Compressed air, max. 15 bar
Inventory
1 Slushing oil
Inventory
NI
NG
PU
Quan- Designation
tity
Work card
221.03
221.04
Work card
AI
Observation
Work card
Example: Tool number of high-pressure hose with

engine type 32/40: 221.221-10
Preliminary Remarks
FO
2009-11-13 - de
TR
The tool numbers of the individual parts of the nozzle test rig are composed
of the tool number of the nozzle test rig and the item number of the individual
part. See Figs. 1 and 2.
The functionality and setting of the injector affect the combustion process,
the operating data and loading of the injection system. If there are changes in
the operational values (ignition pressure, exhaust gas temperature), check
the opening pressure and leak-tightness of the relevant injectors. The basis
of the nozzle test bench is a hydropneumatic high-pressure pump that
ensures operating comfort under reproducible conditions.
6629 221.02-06 EN
32/40
1 Technician
Duration in h
RP
OS
E
221.02
MAN Diesel & Turbo
1 (6)
221.02
MAN Diesel & Turbo
Note
ON
LY
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 functioning of the injection nozzle in the engine. It is fully functional if it fulfils the
criteria for opening pressure, tightness and free nozzle apertures.
NG
PU
RP
OS
E
Layout and schematic design of nozzle tester
AI
NI
High-pressure pipe
High-pressure pump
Air coupling
Pressure relief valve
TR
2009-11-13 - de
R
32/40
FO
4a Filter pressure controller

10
4b Air tap
12
4c Pressure limiting valve
14
5 Nozzle jet collection receptacle
19
8 Pressure gauge
Figure 1: Diagram of nozzle test rig arrangement
2 (6)
6629 221.02-06 EN
221.02
6629 221.02-06 EN
8
10
14
18
19
20
Pressure gauge
High-pressure pipe
Air coupling
Oil filler neck
Pressure relief valve
Oil level indicator
32/40
R
FO
2009-11-13 - de
TR
2 Nozzle holder
4a Filter pressure controller
4b Air tap
6 Upper bar
7 Bottom bar
Figure 2: Nozzle tester
AI
NI
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
3 (6)
221.02
MAN Diesel & Turbo
HFO residues in injectors
ON
LY
Work sequence 1 - Preparation for the inspection
RP
OS
E
HFO residues in injectors can adversely affect test results and make
cleaning more difficult. You should therefore run the engine on diesel
fuel for around an hour before removing the injectors. If this is not
possible, and if the engine is shut down in HFO operation, the injector
must be dismantled and cleaned before carrying out the tests
described here.
Starting position
Injector removed and cleaned externally.
Inspection of the injectors
PU
Use anti-corrosion oil when carrying out the inspection of the injectors,
as this also acts as a preservation treatment. Only absolutely clean
anti-corrosion oil may be used in the nozzle test rig, otherwise
problems could occur at the pump or the injector to be tested. The oil
tank (20) fill level must be monitored via the oil level indicator (20).
Work steps
1. Insert injector into the nozzle holder (2) and clamp uniformly tight with
the bar (6, 7).
NG
2. Screw connecting piece (221.270) onto the pressure hose connection

of the injector and screw the high-pressure hose (10) onto the connecting piece.
3. Place the nozzle jet receptacle (5) under the injector and push it up into
a position where the jets are expected to strike its outer walls.
NI
AI
The inspection and adjustment of the injectors comprises the following steps:
Check opening pressure,
Check nozzle bores,
Set target pressure,
Check tightness.
32/40
Work sequence 2 - Checking the opening pressure
4 (6)
Work steps
1. Turn knob on filter pressure controller (4a) completely to the left (minus
- ) and set air tap (19) to "On".
2. Close pressure relief valve (4b).
6629 221.02-06 EN
2009-11-13 - de
TR
R
FO
Injector
The injector must always spray into the nozzle jet receptacle, and
never into the open air! 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! Oil mist should be extracted
wherever possible!
ON
LY
3. Turn the knob on filter pressure controller (4a) to the right (plus +) to
start the high-pressure pump (12) and raise the pressure slowly until the
injector opens. Note opening pressure and compare with the reference
value (for reference value see 010.005 Engine - Operating Instructions,
Chapter 2.5.2). Let the nozzle test rig run for at least 20 seconds,
thereby flushing the injector.
Opening pressure
RP
OS
E
The hydraulic pressure must be brought slowly up to the opening

pressure, as otherwise errors will occur when reading the opening
pressure. The test pressure must not exceed 400 bar! In new injectors,
the nozzle needle may stick during the initial spray test due to the
preservation treatment and must be released by intensive flushing. If
the injectors are already in service, collect the anti-corrosion oil which
is contaminated with fuel and do not reuse it in the nozzle test rig.
In case of new nozzles, there can be a drop in the opening pressure of
between 50 and 90 bar after just a few operating hours. This pressure
drop is not due to a malfunction and is a normal characteristic of all
injectors.
Decision
221.02
MAN Diesel & Turbo
Opening pressure drop less/greater than 90 bar?

continue to the next step
Opening pressure drop greater than 90 bar -
Dismantle injector (in accordance with Work Card 221.03)

Carry out visual inspection (spring breakage)
If components are in working order, continue to the next
step
NG
PU
Opening pressure drop less than 90 bar -
Work sequence 3 - Inspecting nozzle apertures

Work steps
All nozzle orifices open? See Fig. 3.

Yes continue to the next step
No - Dismantle injection valve (in accordance with Work Card 221.03)
6629 221.02-06 EN
32/40
3. Close pressure relief valve (4b). Run the high-pressure pump (12) via
the knob on the filter pressure controller (4a) and set the opening pressure to 30 bar using the adjusting screw (45).
FO
2009-11-13 - de
Decision
TR
AI
2. Release hexagon nut (44) and turn back adjusting screw (45) to release
the compression spring (49).
NI
1. Rotate filter pressure controller (4a) completely to the left (minus - ),

open pressure relief valve (4b) and proceed as follows (for position
details see Work Card 221.03).
5 (6)
221.02
ON
LY
MAN Diesel & Turbo
Figure 3: Assessment of the nozzle orifices. Left - open, right - partly blocked
Work sequence 4 - Adjusting the opening pressure to the reference value

Work steps
RP
OS
E
1. Raise hydraulic pressure by using the knob on the filter pressure controller (3), at the same time slightly tension the compression spring (49)
via the adjusting screw (45). Repeat the process until the reference
value (tolerance 20 bar) is reached (for reference value see 010.005
Engine - Operating Instructions, Chapter 2.5.2).
Compression spring
PU
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.
NG
2. If the set value is adjusted as repeatable, lock the adjusting screw (45)
with a hexagon nut (44) and check the opening pressure again.
Work sequence 5 - Checking for leaks

Work steps
NI
The injection valve can be made available for use!
No -
The injection valve must be sent to MAN Diesel & Turbo SE in Augsburg
for reconditioning.
Figure 4: Assessment of the tightness. Left - tight, right - drips
6 (6)
6629 221.02-06 EN
2009-11-13 - de
TR
AI
Yes -
32/40
FO
Decision
To check for leaks, set the pressure to 250 bar by using the knob on the filter
pressure controller (4a) and let it stand. The injection nozzle is considered
tight if no drops fall within 5 seconds.
Fuel injector
dismantling
ON
LY
Summary
Check components for state/wear condition, prevent operational problems/

damage.
Tools/aids required
Number
Status
221.221
Standard
1 Socket spanner 55
221.143
Standard
1 Torque wrench
008.017
Standard
1 Chuck
002.701
Standard
1 Eye bolt
001.412
Standard
1 Wire brush
Inventory
1 Wooden spatula
Inventory
Inventory
1 Paper towels
Inventory
1 Cleaning medium (wool)
Inventory
1 Cleaning wires
Inventory
Inventory
1 Depth gauge
Inventory
1 Tank with fuel
Inventory
Inventory
Inventory
R
FO
2009-10-15 - de
TR
AI
NI
NG
PU
Quan- Designation
tity

Work card
Work card
Work card
000.30
221.02
221.04
6629 221.03-06 EN
32/40
1 Technician
Duration in h
RP
OS
E

221.03
MAN Diesel & Turbo
1 (6)
221.03
MAN Diesel & Turbo
Dismantling the injector
ON
LY
Preliminary Remark
NI
AI
2 (6)
2 Nozzle holder
6 Upper bar
6629 221.03-06 EN
7 Bottom bar
60 Hexagon bolt
2009-10-15 - de
TR
R
32/40
FO
NG
PU
RP
OS
E
Dismantle injectors if, during the tests specified in Work Card 221.02,
errors are detected and if the nozzle element has to be changed due to
the operation time.
Dismantling takes place in the nozzle test rig.
221.03
Work sequence 1 - Dismantling a fuel injector
FO
2009-10-15 - de
Work steps
1. Wash injector in fuel and remove adhering carbon residue with a wire
brush.
2. Swing receptacle (5) to the side and insert injector with injection nozzle
downwards into nozzle holder (2).
3. Fix the injector in the nozzle holder (2) with the lower bar (7) and upper
bar (6).
4. Release hexagon nut (44) and turn back adjusting screw (45) to release
the compression spring (49).
6629 221.03-06 EN
32/40
TR
42 Nozzle body
48 Thrust piece
43 Nozzle needle
44 Hexagon nut
50 Spring plate
45 Adjusting screw
51 Parallel pin
46 Holder
52 Nozzle clamping nut
47 Set screw
Figure 2: Injection valve (figure shows injection valve of the engine type L,V 32/40)
AI
NI
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
3 (6)
221.03
MAN Diesel & Turbo
5. Unscrew hexagon head screws (60) on the nozzle holder (2). Turn nozzle holder (2) with injector through 180 and screw the hexagon head
screws (60) back in.
Releasing the nozzle clamping nut
ON
LY
6. Release nozzle tensioning nut (52) carefully.
RP
OS
E
If there is heavy resistance when releasing, try releasing the threads

again by soaking them in fuel and rotating them to and fro. Do not
release nozzle clamping nut by force, since threads can otherwise seize
and parts can become unusable.
7. Unscrew the nozzle tensioning nut and remove nozzle body. Ensure
that the nozzle needle (43) does not fall out.
8. Extract nozzle needle (43) from nozzle body and place it in fuel for
cleaning.
Nozzle needle
PU
Never interchange nozzle needles from one nozzle body to another.

They are manufactured in pairs.
9. Unscrew hexagon head screws (60) on the nozzle holder (2). Turn nozzle holder (2) with injector back through 180 and screw the hexagon
head screws (60) back in.
NG
10. Remove injector from nozzle holder (2) in the nozzle test rig and place
on the workbench.
11. Unscrew adjusting screw.
NI
12. If internal parts are not loose, screw eye bolt (001.412) into the thrust
piece (48) and extract thrust piece. If installed, remove set screw (47),
then remove pressure spring and spring cup (50).
AI
32/40
4 (6)
The inspection of the components includes:
the nozzle orifices,
the quality of fitting surfaces,
the mobility of the needle,
Traces of corrosion on the nozzle clamping nut and on nozzle body,
the nozzle specification.
Fault sources
Pay particular attention to those fault sources which have led to
unsatisfactory results in the inspection of the injection valve.
6629 221.03-06 EN
2009-10-15 - de
TR
Work sequence 2 - Checking components
FO
13. Place all parts for cleaning in diesel oil and wash them. Then blow with
compressed air.
Work steps
1. Differentiation feature nitrated nozzle elements and seat insert nozzle

elements (see figure 3).
ON
LY
2. Clamp a suitable cleaning wire in the chuck (002.701) for cleaning the
nozzle bores and insert through nozzle bores (see figure 4).
221.03
MAN Diesel & Turbo
3. Examine all components, especially sealing faces for damage/traces of

wear.
No rework on the seating and fitting surfaces
RP
OS
E
Seating and fitting surfaces should not be machined manually nor

mechanically, as the required accuracies cannot be achieved.
4. Check if the nozzle needle can be moved in the nozzle body easily and
without perceivable resistance (see figure 5).
5. Examine nozzle body for traces of corrosion. These may be maximum
2.5 mm deep. Check nozzle cooling water outlet temperature, increase
to maximum 90C if necessary.
6. Read off nozzle specifications on the collar of the nozzle body and
compare with reference specifications (see figure 6).
Original specification - see engine acceptance test record.
PU
1. Replace damaged parts. Always replace the nozzle needle and valve
body at the same time, and have these reconditioned by MAN Diesel &
Turbo SE in Augsburg or Hamburg. Other workshops are not authorised to do this.
NG
Identification of reconditioned nozzle elements
6629 221.03-06 EN
32/40
Figure 3: Differentiation feature: Left - Nitrided nozzle element, right - Seat insert
nozzle element
FO
2009-10-15 - de
TR
AI
NI
Reconditioned nozzle elements are identified with the code RA or RH

and the reconditioning date. Only valve seat insert nozzle elements can
be reconditioned more than once.
5 (6)
221.03
ON
LY
MAN Diesel & Turbo
RP
OS
E
41 Cleaning wire
42 Valve body
Figure 4: Cleaning of nozzle orifices.
NG
PU
42 Nozzle body
43 Nozzle needle
NI
AI
TR
2009-10-15 - de
Figure 6: Nozzle element. Left - Nozzle specification, right - Identification of the

regeneration
32/40
FO
Figure 5: Checking the mobility of the nozzle needle
6 (6)
6629 221.03-06 EN
Fuel injector
assembling
ON
LY
Summary

1 Technician
Tools/aids required
Quan- Designation
tity
RP
OS
E
The work includes:

221.04
MAN Diesel & Turbo
Duration in h
Number
Status
221.221
Standard
1 Socket spanner 55
221.143
Standard
1 Torque wrench
008.017
Standard
1 Eye bolt
001.412
Standard
Inventory
Inventory
1 Lubricant (Optimol "Paste White T")
Inventory
Inventory
NI
NG
PU
Work card
000.30
221.02
221.03
R
FO
2009-10-16 - de
Work sequence 1 - Assembly of a fuel injector
Starting position
Specification of the injection nozzle
Check before the assembly whether the specification of the injection

nozzle matches the reference specification. The original specification
can be consulted in the acceptance test record (no., number of nozzle
orifices, orifice diameter, spraying angle).
Injection valve disassembled, all individual parts carefully cleaned, damaged
parts replaced.
6629 221.04-05 EN
32/40
Work card
TR
Work card
AI
1 (4)
221.04
MAN Diesel & Turbo
Work steps
1. Clean set screw (47) and hole, if installed, carefully according to Loctite
specifications.
ON
LY
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 cup (50). If installed, pay attention
to the position of the groove for the set screw (47) (see fig. 1).
Check that the spring cup is positioned correctly.
3. If installed, 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.
RP
OS
E
5. Screw in adjusting screw (45), do not tighten compression spring yet.

6. Insert holder (46) into the nozzle holder (2) and lock it in place with the
lower bar (7) and upper bar (6).
7. Unscrew hexagon head screws (60) on the nozzle holder (2). Turn nozzle holder (2) with holder (46) through 180 and screw the hexagon
head screws (60) back in. The sealing face for the nozzle body (42)
faces upwards.
8. Dip nozzle needle (43) in clean fuel and guide into the nozzle body (42),
check for easy movement.
PU
9. Check nozzle needle lift between the upper edge of the nozzle body
(42) and ledge of the nozzle needle (43).
For reference value see Volume 010.005 Engine - Operating Instructions, "Technical data" section.
NG
10. Dry sealing face with paper towel. Insert nozzle body (42) with nozzle
needle (43) into holder (46), 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).
NI
14. Screw hexagon nut (44) loosely on adjusting screw and tighten only
after adjusting the spray pressure (see Work Card 221.02).
2009-10-16 - de
TR
AI
13. Screw nozzle tensioning nut (52) onto the holder (46) fingertight and in a
second step tighten with specified torque (see Work Card 000.30). Turn
nozzle holder (2) on nozzle test rig through 180 and fix.
32/40
FO
12. Coat screw threads of holder (46) and nozzle tensioning nut (52) as well
as pressure shoulder (D) on nozzle tensioning nut (52) with "Optimol
Paste White T" lubricant (see fig. 1).
2 (4)
6629 221.04-05 EN
221.04
6629 221.04-05 EN
32/40
R
FO
2009-10-16 - de
TR
42 Nozzle body
48 Thrust piece
43 Nozzle needle
44 Hexagon nut
50 Spring plate
45 Adjusting screw
51 Parallel pin
46 Holder
52 Nozzle clamping nut
47 Set screw
D Pressure shoulder
Figure 1: Injection valve (figure shows injection valve for the engine type 32/40)
AI
NI
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
3 (4)
221.04
NI
AI
TR
32/40
4 (4)
7 Bottom bar
60 Hexagon bolt
2009-10-16 - de
2 Nozzle holder
6 Upper bar
FO
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
6629 221.04-05 EN
Summary
ON
LY

Grind seating surface in the cylinder head
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.
1 Technician
Tools/aids required
Quan- Designation
tity
Duration in h
0,5
Number
Status
055.197
Standard
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)
055.197-1
3
Standard
1 Pliers for locking rings
055.197-1
9
Standard
055.197-2
1
Standard
1 Tap wrench
055.197-2
3
Standard
1 Cleaning tool
055.149
Standard
Inventory
1 Depth gauge
Inventory
1 Torch
Inventory
NI
NG
1 Spindle
PU
FO
2008-09-19 - de
TR
AI
1 Quick-acting cleanser Loctite 7061
Work card
Work card
221.01
Work sequence 1 - Grinding the seating surface

Starting position
Fuel injection valve removed.
6629 221.05-02 EN
Work card
32/40;L32/44CR
RP
OS
E
The work includes:

221.05
MAN Diesel & Turbo
1 (4)
221.05
MAN Diesel & Turbo
Cylinder head
Sleeve
Washer
Hexagon bolt
RP
OS
E
6
15
62
63
ON
LY
Work steps
NI
NG
PU
Figure 1: Securing the sleeves in the cylinder head
Figure 2: Bonding the small grinding plates in position
32/40;L32/44CR
2 (4)
3. Pull out consumed small grinding plates (055.197-13) from the grinding
wheel and remove any adhering adhesive residues by using quick-acting cleanser (055.197-21).
4. Stick new small grinding plates onto the grinding wheel (see figure 2).
5. Place grinding device in the cylinder head (6), paying attention to the
guide bush (055.197-5).
6. Insert guide bush (055.197-3) with outer 71 mm and guide grinding
tool into the sleeve (15).
7. Rotate grinding tool to and fro, raise in-between and blow off grinding
dust with compressed air.
6629 221.05-02 EN
2008-09-19 - de
TR
AI
2. Insert Grinding wheel (055.197-7) onto the spindle (055.197-1) and fix
with hexagon nut (61) (see figure 4).
FO
1. Unscrew the hexagon bolt (63) and remove washer (62) (see figure 1).
ON
LY
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:
32/40: 400 mm.
32/44 CR: 406.7 mm.
If this dimension is exceeded, the sleeve (17) must be changed (see
figure 3).
221.05
MAN Diesel & Turbo
RP
OS
E
8. Remove grinding tool (055.197) after the grinding process is complete

and clean valve seating surface carefully with cleaning tool (055.149)
(see Figure 4).
9. Mount washer (62) with hexagon bolt (63) on the cylinder head (6).
Cylinder head
Sleeve
Sleeve
max. permitted dimension
PU
6
15
17
A
6629 221.05-02 EN
32/40;L32/44CR
R
FO
2008-09-19 - de
TR
AI
NI
NG
Figure 3: Abbreviated representation of the max. permitted dimension for grinding the
fuel injection valve seating surface
3 (4)
221.05
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
NI
AI
TR
2008-09-19 - de
R
32/40;L32/44CR
FO
NG
6 Cylinder head
17 Sleeve
61 Hexagon nut M12
9 Rocker arm casing
Figure 4: Grinding (left) and cleaning (right) of the fuel injection valve seating surface in the cylinder head
4 (4)
6629 221.05-02 EN
Tools/aids required
Quan- Designation
tity
RP
OS
E
The work includes:

Number
Status
1 Pressure pipe grinding device
434.042
Option
1 Adapter plate
434.042-1
Option
434.042-2
Option
434.042-3
Option
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
434.042-1
0
Option
1 Swivel arm
434.042-1
1
Option
1 Bracket
434.042-1
2
Option
1 Stop
434.042-1
3
Option
1 Grinding wheel
434.042-1
6
Option
1 Baseplate
434.042-1
7
Option
1 Carriage
434.042-1
8
Option
1 Shaft
434.042-1
9
Option
1 Stop
434.042-2
0
Option
1 Counter flange (threaded piece)
434.042-2
1
Option
1 Adapter flange (threaded piece)
434.042-2
2
Option
1 Threaded ring
1 Bearing ring
R
FO
2007-11-05 - de
TR
AI
NI
NG
PU
1 Bearing flange
6629 221.06-02 EN
32/40
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.
Summary
ON
LY

Grind sealing faces on threaded piece
221.06
MAN Diesel & Turbo
1 (6)
221.06
MAN Diesel & Turbo
Quan- Designation
tity
1 Ball bearing
1 Hook wrench
1 Face spanner
434.042-2
4
Option
434.042-2
5
Option
434.042-3
7
Option
434.042-3
8
Option
434.042-4
1
Option
RP
OS
E
2 Clamping lever
1 Clamping piece
434.042-4
2
Option
5 Emery paper
434.042-4
4
Option
000.294
Standard
000.293
Standard
1 Tommy bar, 8
000.262
Standard
1 Cleaning medium
Inventory
1 Safety goggles
Inventory
PU
Status
ON
LY
1 Ball bearing
Number
Work card
Work card
NG
Work card
NI
AI
TR
2007-11-05 - de
R
32/40
FO
221.01
2 (6)
6629 221.06-02 EN
AI
TR
R
FO
2007-11-05 - de
4 Support adjusting crank
NI
1 Fuel injection pipe

3 Grinder
M5x10
Figure 1: Pressure pipe grinding fixture with fitted fuel injection line
6629 221.06-02 EN
32/40
NG
PU
RP
OS
E
ON
LY
Work sequence 1 - Attachment of the threaded piece to the pressure pipe grinding
device
221.06
MAN Diesel & Turbo
3 (6)
221.06
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
NI
5 Stop
Work steps
32/40
4 (6)
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).
When fixing the stop gauge on adapter flange, support with tommy bar
(000.262) on the threaded ring.
6629 221.06-02 EN
2007-11-05 - de
TR
AI
The pressure pipe grinding fixture must be installed and/or operated on

a firm base. Vibrations in the fixture will influence the surface quality of
the sealing surface to be ground.
The injection pressure pipes to be ground must be absolutely free of
lube oils and greases. Contamination of any kind, especially lubricants,
reduces the service life of the grinding wheels considerably.
FO

Figure 2: Pressure pipe grinding tool
221.06
MAN Diesel & Turbo
ON
LY
There is a left hand thread on the threaded piece on the injection valve
side.
4. Screw counter flange (434.042-21) on the threaded piece (1).
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).
RP
OS
E
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).
Work sequence 2 - Regrinding the seal faces on pressure pipe
R
FO
2007-11-05 - de
Starting position
Threaded piece is attached correctly to the pressure pipe grinding device.

Grinding wheel with new emery paper fitted to grinder.
Sealing faces are difficult to rework and this requires particular care.
We recommend you have this work carried out by a Service Centre or
MAN Diesel & Turbo personnel.
6629 221.06-02 EN
32/40
TR

Figure 3: Attachment of the threaded piece on the pressure pipe grinding device
AI
NI
NG
PU
12. Swing the bracket (434.042-12) up to the stop again and fix on the
slide with two clamping levers (434.042-41).
5 (6)
221.06
MAN Diesel & Turbo
Work steps
1. Swing the swivel arm (434.042-11) with grinder up to the right hand
stop (5).
ON
LY
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.
RP
OS
E
Wear safety goggles for grinding pressure tubes!
4. Provide electric power to the grinder and switch on.

5. Turn the threaded piece equally on the clamping piece (434.042-42)
whilst simultaneously moving the swivel arm with the grinder over the
sealing surface contour.
PU
The grinding wheel must not touch the adapter flange.
NG
6. The advance on the threaded ring (434.042-2) is effected by means of

the tommy bar (000.262). Maximum advance per work sequence is one
division of the scale on the threaded ring
NI
8. Evaluate the result of the grinding process. Repeat the grinding process
until the sealing face has a uniform polished appearance.
If the contact pattern required cannot be achieved with the pressure

pipe grinding device, it must given to a MAN customer service
workshop for repair.
Pull out used emery paper immediately and replaced by a new one.
32/40
9. Remove threaded piece from pressure pipe grinding device and remove
counter flange.
6 (6)
6629 221.06-02 EN
2007-11-05 - de
TR
AI
7. Move swivel arm up to the left hand stop, so that the grinding wheel
faces the threaded piece and switch the grinder off.
FO
The advance is not on the support adjusting crank. The adjusted

position remains unchanged during the entire grinding sequence.
Lightly rework the sealing faces, only smoothen removing as little
material as possible.
TR
R
FO
6632 280-289-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
280-289
MAN Diesel & Turbo
1 (2)
280-289
ON
LY
RP
OS
E
PU
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
NG
111
112
113/114
120
125
140
160-162
FO
MAN Diesel & Turbo
2 (2)
6632 280-289-05 EN
Charge air and exhaust pipe for emergency operation

converting
ON
LY
Summary

To enable emergency operation of the engine in the event of failure of a turbocharger, refitting must be done on the charge air and exhaust systems.

1 Technician
1 Assistant
3,5
3,5
PU
Tools/aids required
Duration in h
Quan- Designation
tity
Number
Status
280.024
Standard
1 Blind flange
280.025
Standard
Inventory
Inventory
1 Sealing compound
Inventory
NI
NG
1 Blind flange
AI
TR
Work card
Work card
Work card
000.31
Work sequence 1 - Refit charge air and exhaust line for emergency operation
(installation of the blind flanges)
Breakdown of a turbocharger. Cartridge and volute casing of relevant turbocharger removed, supply of lubricating oil to turbocharger interrupted.
FO
2009-03-09 - de
Starting position
6632 280.01-01 EN
V32/40
Engine stopped
RP
OS
E

fitting components.
Safety requirements
280.01
MAN Diesel & Turbo
1 (3)
280.01
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
NG
1 Turbocharger
2 Connector
3 Charge air cooler
4 Flange bolt
Figure 1: Attaching the blind flange
Axial compensator
Bypass pipe
Flange bolt
Solenoid valve M392
NI
1. Unscrew and remove flange bolts (4) between turbocharger (1) and
axial compensator (5).
V32/40
2 (3)
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
suitable equipment, or cut off the power supply to the solenoid valve
M392 (8).
Modified volume flows due to changeover!

As the defective turbocharger has been sealed off, the entire exhaust
gas volume flow is now directed via the turbocharger which is still
intact. And now supplies both cylinder rows with charge air via the
bypass pipe (6).
6632 280.01-01 EN
2009-03-09 - de
TR
AI
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).
FO
Work steps
5
6
7
8
Observe further instructions on emergency operation with a

faulty turbocharger!
Stay within limit values!
ON
LY
Refer to 010.005 Engine - Operating Instructions, Chapter 3.6.3 and

Operating Instructions of turbocharger for instructions on emergency
operation with faulty turbocharger.
280.01
MAN Diesel & Turbo
RP
OS
E
Make sure that all limit values are complied with to avoid damaging the
intact turbocharger.
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:
PU
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).
6632 280.01-01 EN
V32/40
R
FO
2009-03-09 - de
TR
AI
NI
NG
3. Check the flanged joints for leakage.
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Charge air bypass device

disassemble and assemble, renew sealing elements
ON
LY
Summary
Execute the work in time according to the maintenance schedule, ensure the
correct execution of work, ensure / restore operational safety. Control elements in the charge air/exhaust gas system are to be checked and, if necessary, replaced within the scope of maintenance and repair work.
Engine secured against starting
Engine stopped

1 Technician
PU
Tools/aids required
Quan- Designation
tity
Duration in h
Number
Status
002.121
Option
Inventory
1 Screwdriver (Set)
Inventory
Inventory
Inventory
NI
NG
1 Pliers for locking rings A 10-25
1. Disconnect control pipes (22) from the drive head (21).

2. Remove flange bolts (23) (see figure 1).
3. Dismantle any supports on the adapter flange (25).
4. Pull out deflection flap (20) with drive head from the flange connection,
taking care not to damage the seals (24).
Work sequence 2 - Replacing the sealing and wear part sets on the drive head
FO
2007-11-15 - de
Control pipes (22) and bypass pipes of the charge air bypass device are
pressureless.
TR
Starting position
AI
Work sequence 1 - Detaching the deflection flap with drive head
Work steps
1. Remove deflection flap (20) and drive head (21) from the adapter flange
(25).
2. Unscrew hexagon socket bolts (8) of both covers (7).
3. Remove cover (7) with cover packing (6) and pay attention to any existing reset springs (16). Remove reset springs (16) (see figure 2).
6682 280.02-01 EN
General
Safety requirements
RP
OS
E
The work/work steps include: Disassembling /separating components,

Renewing sealing rings/sealing elements, Assembling/refitting components.
Work steps
280.02
MAN Diesel & Turbo
1 (4)
280.02
MAN Diesel & Turbo
Work on the drive head
ON
LY
4. Run both pistons (5) from the casing (10) of the drive head by rotating
the pinion shaft (11). When removing the two pistons, pay attention to
guide segments (9).
The two pistons of the drive head must never be run from the casing
by using compressed air!
Valid in general: Disconnect the connection to the compressed air
network during work on the drive head!
RP
OS
E
5. Disassemble guide rings (4) and O-ring seals (3).
6. Remove locking ring (1) with pliers for locking rings (002.121), pay
attention to the backing ring (2).
7. Press pinion shaft (11) from the casing (10).
8. Remove upper and lower slide ring (14 and 15) with O-ring seals (12
and 13).
9. Clean all components and check for wear.
PU
10. The assembly is done in reverse order of the dismantling. Use new set
of seals consisting of items 3, 6, 12, 13 and 17, as well as a wear parts
set consisting of items 4 ,9 , 14 and 15.
Locking ring
NG
Do not overextend locking ring (1) when fitting.
When inserting the piston (5) into the casing (10) ensure that the piston racks
engage correctly in the pinion shaft teeth (11) and travel symmetrically
together.
NI
Work steps
General
2 (4)
Tightness test for deflection flap and drive head carried out. Deflection flap
and drive head mounted on adapter flange.
1. Insert deflection flap (20) with drive head (21) in the correct position
between the flange connection of the bypass pipes, taking care not to
damage the seals (24).
2. Insert flange bolts (23) and tighten them crosswise.
3. Mount any existing holders on the adapter flange (25).
4. Attach control pipes (22) to the drive head (21) and check system for
tightness.
Faulty or leaky bypass flap

If bypass flap (20) is faulty or leaky, replace it completely!
6682 280.02-01 EN
2007-11-15 - de
TR
Starting position
AI
Work sequence 3 - Attaching the deflection flap with drive head
FO
Attach the cover (7) with cover packing (6) in the correct position on the casing (10). Observe identification "UP" on cover.
RP
OS
E
ON
LY
280.02
MAN Diesel & Turbo
23 Flange bolt
24 Seal
25 Adapter flange
6682 280.02-01 EN
General
R
FO
2007-11-15 - de
TR
AI
NI
NG
PU
20 Bypass flap
21 Drive head
22 Control pipes
Figure 1: Charge air bypass device
3 (4)
280.02
NI
Hexagon socket bolt

Guide segment
Casing
Pinion shaft
O-ring seal
O-ring seal
upper slide ring
15
16
17
18
19
lower slide ring

Reset spring
O-ring seal
Cap nut
Set screw
2007-11-15 - de
TR
AI
8
9
10
11
12
13
14
General
FO
1 Locking ring
2 Backing ring
3 O-ring seal
4 Guide ring
5 Piston
6 Cover packing
7 Cover
Figure 2: Drive head
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo
4 (4)
6682 280.02-01 EN
Summary
ON
LY
Exhaust pipe
inspecting
Execute work on time according to the maintenance schedule, ensure correct 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.
Tools/aids required
Quan- Designation
tity
RP
OS
E

Inspection of parts/ components,
Dismantling and assembling of components.
Number
Status
008.017
Standard
000.142
Standard
Inventory
Inventory
Inventory
1 Torque wrench
PU
1 Wire brush
Work card
289.01
MAN Diesel & Turbo
Work card
Work card
NG
000.30
Work sequence 1 - Checking and dismantling of the exhaust pipe
NI
Covering of the exhaust gas pipe removed at the respective points.
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
section (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).
5. Clean the exhaust pipe sections and compensators.
6632 289.01-01 EN
V32/40
R
FO
2007-07-17 - de
TR
Leaky exhaust pipes can be seen by the black colouring at the

corresponding places on the insulation.
1. Check the exhaust pipe for leakages the flanged joints and expansion
joints.
AI
Starting position
Work steps
1 (3)
289.01
RP
OS
E
ON
LY
MAN Diesel & Turbo
5 Pipe clamp
6 Section of exhaust pipe
11 Direction of flow
12 Eye
NI
AI
TR
2007-07-17 - de
R
V32/40
FO
NG
PU
1 Y-pipe
2 Connection for air bypass pipe
3 Connection for exhaust blow-off
pipe
4 Expansion compensator
Figure 1: Exhaust pipe
2 (3)
6632 289.01-01 EN
RP
OS
E
ON
LY
289.01
MAN Diesel & Turbo
PU
1 Y-pipe
4 Expansion compensator
5 Pipe clamp
6 Section of exhaust pipe
Figure 2: Exhaust pipe - Installation
7
8
9
10
Exhaust turbocharger
Hexagon nut
Cylinder head
Hexagon nut
NG
Work sequence 2 - Assembly of the exhaust pipe

The assembly is done in reverse order of dismantling. In doing so, observe
the following points:
R
FO
2007-07-17 - de
TR
Check the exhaust pipe for foreign bodies after damage to piston or
valve. Broken pieces can be drawn from the exhaust flow into the
turbine and cause serious damage.
6632 289.01-01 EN
V32/40
AI
2. Tighten pipe clamps (5) with the specified torque (see Work Card
000.30).
NI
1. When installing the compensators (4), ensure that the mounting position
is correct (protecting sleeve inside in the direction of flow, see figure 1).
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
TR
R
FO
6632 300/350-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
300/350
MAN Diesel & Turbo
1 (2)
300/350
ON
LY
RP
OS
E
PU
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
NG
111
112
113/114
120
125
140
160-162
FO
MAN Diesel & Turbo
2 (2)
6632 300/350-05 EN

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.
1 Technician
1 Assistant
PU
Tools/aids required
Quan- Designation
tity
Status
009.340
Option
1 Counter support
009.340-1
1
Option
1 Forcing-off device
009.331
Option
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 Torque wrench
008.017
Standard
1 Power amplifier
008.030
Standard
1 Adapter 12.5x20
001.927
Standard
1 Adapter 25x20
001.924
Option
1 Adapter 20x12.5
001.923
Standard
1 Cross handle
001.892
Option
1 Cross handle
001.891
Standard
001.804
Option
001.753
Standard
001.759
Standard
000.293
Standard
NG
NI
AI
TR
R
FO
Number
2008-01-08 - de
Duration in h
6682 300.01-04 EN
32/40;48/60;L32/44CR;L58/64
RP
OS
E

Separating and assembling,
Refitting components.
Summary
ON
LY

300.01
MAN Diesel & Turbo
1 (6)
300.01
MAN Diesel & Turbo

Number
Status
Inventory
1 Depth gauge
Inventory
Standard
Inventory
Inventory
Inventory
Inventory
ON
LY
Quan- Designation
tity
2 Threaded rod
1 Collecting tank

Work card
000.30
Preliminary remarks
RP
OS
E
1 Sealing compound
Work card
Work card
The lube oil pump consists of two separate pumps which are similar in structure and which are connected by an intermediate washer (17).
PU
Work sequence 1 - Removing and dismantling the lube oil pump
NG

suspended loads!
Work steps
NI
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.
AI
3. Unscrew fastening screws on drive cover (3), remove pump carefully

and place on a wooden support.
2 (6)
5. Mount forcing-off device (009.331-3) on driving pinion (2), insert pipe

(009.331-6) and unscrew nut (1).
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.
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.
6682 300.01-04 EN
2008-01-08 - de
FO
TR
4. Remove cylinder screw (24) for securing the nut (1) with screwdriver
(000.293).
32/40;48/60;L32/44CR;L58/64
2. Hang pump with rope onto lifting tackle and tighten rope.
12. Extract the taper pins from the drive cover (3) with suitable material and
remove the drive cover with fitted bearing unit.
ON
LY
13. Unscrew the hexagon bolts (9) and separate the pressure limiting valve
from pump 2, taking care with the parallel pins.
300.01
MAN Diesel & Turbo
Only disassemble pressure limiting valve if malfunctions are observed.

In this case proceed as follows:
RP
OS
E
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).
PU
Do not unscrew sealing screw (16). Do not unscrew or adjust lock

screw.
NG
18. Clean all parts, check for damage. Check bearing and sliding surfaces
for running pattern and wear. Renew all sealing rings, seals and hightension rings.
Starting position

suspended loads!
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:
1. Lubricate all moving parts with oil.
6682 300.01-04 EN
32/40;48/60;L32/44CR;L58/64
R
FO
2008-01-08 - de
Work sequence 2 - Assembly and installation of the lube oil pump
TR
AI
NI
If there is bearing damage, replace the complete lube oil pump.
3 (6)
300.01
MAN Diesel & Turbo
2. Do not readjust the setting of the pressure-limiting valve

(set opening pressure 7.5 bar).
ON
LY
3. Do not put any paper gaskets between the drive cover, casing and
pressure 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.
RP
OS
E
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 torque (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
measurement according to work sequence 2 point 9 and compare both
values.
Distance (A) must have increased by minimum 0.6 mm to max. 1.2 mm.
PU
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.
NG
14. Connect the pipes without tension onto the pump, screw the blind
flange (4) in position.
NI
AI
TR
2008-01-08 - de
FO
32/40;48/60;L32/44CR;L58/64
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.
4 (6)
6682 300.01-04 EN
R
FO
2008-01-08 - de
TR
AI
7 Sealing ring
8 Bearing unit (2-part)
9 Hexagon bolt
10 Valve casing
11 Valve plate
Figure 1: Lube oil pump (2-stage)
6682 300.01-04 EN
13
14
15
16
17
19
20
22
23
Sealing ring
Hexagon bolt
Valve cover
block
Intermediate washer
Drive shaft
Impeller axle
Sleeve
Hexagon bolt
32/40;48/60;L32/44CR;L58/64
Drive cover
Blind flange
Pump casing
Sealing ring
NI
3
4
5
6
NG
PU
RP
OS
E
ON
LY
300.01
MAN Diesel & Turbo
5 (6)
MAN Diesel & Turbo
RP
OS
E
ON
LY
300.01
A Distance
NI
AI
TR
2008-01-08 - de
FO
32/40;48/60;L32/44CR;L58/64
NG
PU
1 Nut
24 Cylinder screw
2 Driving gearwheel
Figure 2: Forcing-off device for lube oil pump gearwheel
6 (6)
6682 300.01-04 EN

assessing the individual parts
ON
LY
Summary
300.02
MAN Diesel & Turbo
Check components for consistency/wear condition, ensure/restore operational safety.

Lube oil pumps are largely 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.

1 Technician
Tools/aids required
Duration in h
Number
Status
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
NI
NG
PU
Quan- Designation
tity
RP
OS
E

Work card
Work card
TR
300.01
R
FO
2007-04-18 - de
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 assumption 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 temperatures that occur and loads on the pumps.
Components about which there is uncertainty in respect of their continued
use, are generally to be replaced or otherwise the interval to the next pump
inspection should be shortened, to avoid the risk of an unexpected pump
failure.
6682 300.02-01 EN
32/40;48/60;L32/44CR;L40/54;L58/64
Work card
AI
1 (5)
300.02
MAN Diesel & Turbo
Correct tools must be used right from the disassembly of components, so as

not to damage the parts during disassembly.
Assessment criteria for wear parts on lube oil pumps

1. Seals
ON
LY
Parts to be assessed must be cleaned carefully once they have been

removed. When assembling the pump, in addition to observing utmost
cleanliness, care must be taken to ensure that all reused components are
mounted in their original position inside the pump.
RP
OS
E
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
NI
1 Tooth flanks
2 Axial butting surface
3 Tooth crest
2 (5)
It is only necessary to replace the gear shafts as a result of damage in the

area of the gear teeth, if spalling at the tooth crest > 3 mm is evident in the
longitudinal direction of the gear shaft.
The gear shafts can remain in service if
the tooth flanks are scored or scratched, even if this is clearly visible and
tangible. If you intend to continue using the gear shaft in this condition,
any sharp burrs on the gear teeth, particularly on tooth crests, should be
removed or smoothed off whenever possible using a scraper, oil stone or
emery cloths to ensure smooth meshing with the second gear shaft.
Individual pressure points < 1 cm2 on tooth flanks.
Spalling < 1 cm2 in the transitional area between the axial butting surface
and tooth flank
6682 300.02-01 EN
2007-04-18 - de
FO
TR
AI
Figure 1: Gear shaft
32/40;48/60;L32/44CR;L40/54;L58/64
NG
PU
2.1 Gearing
ON
LY
2.2 Bearing journals
300.02
MAN Diesel & Turbo
Figure 2: Bearing journals
RP
OS
E
4 Bearing journals
It will not be possible to use the gear shafts due to damage in the area of the
bearing journals if
scoring, scratches or spalling on the bearing journal are deep enough to

be felt out by fingernails or the point of a pencil.
welding build up or a noticeable bluish discolouration is evident on the

bearing journal.
2 Axial butting surfaces
NI
NG
PU
2.3 Axial butting surfaces
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
therefore 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.
FO
2007-04-18 - de
TR
6682 300.02-01 EN
32/40;48/60;L32/44CR;L40/54;L58/64
AI
It will not be possible to use the gear shafts or bearing flanges due to damage in the area of the axial butting surfaces if
Figure 3: Front surface of gear shaft
3 (5)
300.02
MAN Diesel & Turbo
3. Bearing bushes
3.1 Design and wear characteristics
RP
OS
E
ON
LY
The bearing bushes of the lubricating oil pumps are manufactured using a
steel bush to which a sintered bronze layer has been applied. The pores of
the bronze layer facing the shaft contain a mixture of PTFE and lead which
forms a grey-green shimmering sliding layer against the bearing journals of
the gear shafts.
When the pumps are in operation, this gradually wears off and the bronze
layer underneath becomes increasingly visible. Following a short run-in
phase, during which material from the sliding layer may be deposited in small
amounts on the bearing journals (harmless), a more or less linear relationship
subsequently exists between the rate at which material is removed from the
sliding layer and the operating time, assuming the stresses acting on the
bearing and the operating conditions remain the same.
6 Bronze layer
7 Sliding layer
NG
PU
3.2 Visual appraisal of bearing bushes
Figure 4: New bearing bush
The bearing bushes must be replaced if the metallic bronze layer is showing
on approx. 70% of the interior surface of the bush.
NI
there is less than 35% visible bronze in the running surface.
the bearing bushes are otherwise in good condition, i.e. the bronze is not
exposed by scratches or scoring in the grey-green sliding layer.
AI
the next maintenance interval is the same as the operating time of the
previous maintenance interval.
FO
2007-04-18 - de
TR
32/40;48/60;L32/44CR;L40/54;L58/64
The bearing bushes can remain in service if
4 (5)
6682 300.02-01 EN
RP
OS
E
ON
LY
3.3 Assessing the condition of the bearing bush by measuring the

bearing clearance
300.02
MAN Diesel & Turbo
A Inner diameter of bearing bush

B Outer diameter of bearing journal
Figure 5: Diameters used to determine the bearing clearance
If you are unsure whether you can assess the wear based on the visible indicators, you can obtain more accurate information on the condition of the
bushes by measuring the bearing clearance.
This is done by measuring the inner diameter (A) of the bearing bushes and
the outer diameter (B) of the corresponding bearing journal (4).
The bearing bushes can remain in service if
with a shaft diameter of 60 mm: A - B < 0.36 mm
with a shaft diameter of 50 mm: A - B < 0.34 mm
R
FO
2007-04-18 - de
The diameter must be measured at both measuring planes (C, D) of the

bearing bush and the bearing journal. The bush must also be replaced
even if the limit for continued use is exceeded at only one of the two
front ends.
3.4 Inspecting scoring or scratches in the bearing bushes in order to

assess their condition
The bearing bushes can remain in service if there are individual scores or
scratches on the grey-green sliding layer, providing the assessment criterion
stated under 3.2 is satisfied.
However, if the bronze layer or steel casing has been exposed by scores or
scratches on the inner surface of the bushes, they must be replaced.
6682 300.02-01 EN
32/40;48/60;L32/44CR;L40/54;L58/64
AI
TR
Figure 6: Measuring planes used to determine bearing clearance
C, Measuring plane
D
NI
NG
PU
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Cooling water pump

Number
Status
350.011
Option
350.011-1
Option
350.011-3
Option
009.331
Option
009.331-3
Option
1 Pipe
009.331-6
Option
1 Forcing-off disc
009.331-8
Option
NG
Tools/aids required
Quan- Designation
tity
RP
OS
E

Separating and assembling,
Refitting components.
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
001.911
Standard
001.758
Standard
001.757
Standard
Inventory
Inventory
Inventory
1 Sealing compound
Inventory
Inventory
1 Forcing-off bolt
1 Forcing-off disc
TR
AI
NI
PU
FO
2007-10-23 - de

Work card
Work card
Work card
000.30
Work sequence 1 - Removing and dismantling the cooling water pump

Starting position
Cooling water is blocked off and the cooling water pump is lowered down,
engine secured against inadvertent starting.
6629 350.01-07 EN
32/40

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.
ON
LY
Summary
350.01
MAN Diesel & Turbo
1 (5)
350.01
Shaft
Bearing casing
Ball bearing
Locking ring
PU
3
4
5
6
RP
OS
E
ON
LY
MAN Diesel & Turbo
34
35
36
A
Washer
Hexagon bolt
Hexagon bolt
Clearance
AI
1. Release and remove oil and water pipes on the cooling water pump,
taking care with the seals.
2. Hang cooling water pump with rope onto lifting tackle and tighten rope.
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).
6. Release hexagon nuts (21), unscrew and remove spiral casing (19).
Take care with the seal (10) and washer (22).
32/40
7. Release impeller nut (15) whilst holding against the gearwheel (33) with
the forcing-off device (009.331-3) (see figure 3).
2 (5)
6629 350.01-07 EN
2007-10-23 - de
TR
FO
Work steps
Seal
Flange
Spiral casing
block
21 Hexagon nut
22 Washer
33 Gear wheel
NI
NG
8 Ball bearing
10 Seal
11 sealing screw on distribution
block
12 Hexagon nut
13 Washer
15 Impeller nut
16 Impeller
Figure 1: Cooling water pump
17
18
19
20
ON
LY
According to the direction of rotation of the cooling water pump the

impeller nut has a right or left-hand thread.
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.
Shaft
Bearing casing
Impeller
Slide sealing ring
Thrust ring
Seat ring
Shaft seal
R
FO
2007-10-23 - de
16 Impeller
31 Hexagon bolt M8x90 or M10x90
Figure 3: Removing the impeller
32 Hexagon bolt M10x120/

M16x100/
M10x90
33 Gear wheel
1. Release hexagon bolt (35) whilst holding with the forcing-off device
(009.331-3) (see figure 4).
2. Push off gearwheel (33) (see figure 4).
3. Remove snap ring (6) and remove shaft (3) including ball bearing (5).
4. Remove shaft seal (30) if necessary.
5. Check ball bearings (8 and 5), replace if necessary.
6. Clean all parts, check for wear, renew damaged or worn parts.
6629 350.01-07 EN
32/40
TR
4 Bearing casing
AI
NI
NG
PU
RP
OS
E
3
4
16
25
26
27
30
Figure 2: Set of shaft seals
350.01
MAN Diesel & Turbo
3 (5)
MAN Diesel & Turbo
RP
OS
E
ON
LY
350.01
3 Shaft
4 Bearing casing
Figure 4: Removing the gearwheel
32 Hexagon bolt
33 Gear wheel
34 Washer
35 Hexagon bolt
Work sequence 2 - Assembly and fitting the cooling water pump

Starting position
PU
The assembly or fitting is done in reverse order of the removal or dismantling.

In doing this observe the following points:
1. Insert shaft (3) before shaft seal ring (30), if it was removed.
2. When fitting the shaft seal ring, take account of the following points (3 5):
NG
3. Check the sealing lip for damage, remove contamination.

4. Grease the shaft seal and knead a little by hand.
5. Insert shaft seal ring correctly (sealing lip must point to the ball bearing).
Make sure that the sealing lip is not damaged.
NI
6. Remove the gearwheel (33) as follows (point 7 - 11):
AI
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).
When measuring the axial clearance must be each on the same side,
pull the shaft outwards until it abuts!
4 (5)
6629 350.01-07 EN
2007-10-23 - de
TR
R
Use thin oil! Gearwheel is fixed only after pushing out the oil film on the
shaft cone!
32/40
FO
7. Lightly oil the shaft cone and slide the gearwheel up tight.
10. Tighten hexagon bolt with specified end torque (see Work Card
000.30).
ON
LY
11. Repeat measurement as per point 9 and compare both values. Gap (A)
must have reduced by 0.8 to 0.9 mm.
350.01
MAN Diesel & Turbo
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.
RP
OS
E
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!
16. Remove the impeller (16) as follows (point 17, 18):
PU
17. Clean shaft and impeller cone and dry them, do not oil! Slide running
ring in position.
18. Coat the thread and nut contact surface with Loctite 243, screw the
impeller nut (15) in position and tighten with the prescribed torque and
turning angle (see Work Card 000.30).
NG
19. Check shaft for ease of movement.

20. Coat the sealing face between the bearing casing (4) and cylinder
crankcase with Hylomar sealing compound before fitting to the engine.
NI
21. Fill the cooling water pump with water before connecting the water
pipe.
6629 350.01-07 EN
32/40
R
FO
2007-10-23 - de
TR
AI
22. Check cooling water pump and pipe connections for leaks after a brief
operating period.
5 (5)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
322
TR
R
FO
6632 322-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
Charge air cooler
MAN Diesel & Turbo
1 (2)
322
PU
NG
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
FO
111
112
113/114
120
125
140
160-162
RP
OS
E
ON
LY
Charge air cooler
MAN Diesel & Turbo
2 (2)
6632 322-05 EN
Summary
ON
LY
Charge air cooler

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.
Safety requirements
PU
1 Technician
1 Assistant
NG
Tools/aids required
Status
322.041
Option
1 Bracket
322.041-1
Option
1 Wire rope
322.041-1
5
Option
1 Axle
322.041-2
8
Option
2 Rope guide
322.043
Option
1 Ratchet hoist
002.552
Option
2 Shackle A0.6
002.452
Standard
000.143
Standard
000.142
Standard
Inventory
Inventory
1 Pipe brush
Inventory
Inventory
1 Cleaning medium
Inventory
1 Sealing compound
Inventory
AI
TR
R
FO
2008-01-08 - de
Number
NI
Quan- Designation
tity
Duration in h
6632 322.01-02 EN
V32/40
RP
OS
E

Checking operating data,
Cleaning parts chemically/ mechanically,
Fitting components.
Charge air cooler
322.01
MAN Diesel & Turbo
1 (6)
Charge air cooler
322.01
MAN Diesel & Turbo
Technical data
Information
Charge air cooler
ON
LY
Designation
210 kg
Work sequence 1 - Checking the operating data
RP
OS
E
Check cooling water inlet and outlet temperature during operation. Record
charge air temperature before and after cooler, note differential pressure for
the same load point in the upper load range regularly, to always have control
over the power of the cooler.
PU
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
pressure measuring unit. Instead of the sealing screws quick-acting
couplings can be provided.
Work sequence 2 - Removing charge air cooler
1. Isolate the cooling water feed and return flows and remove the cooling
water pipes on the charge air cooler.
NI
Work steps
NG

suspended loads!
V32/40
2 (6)
4. Fasten rope guides (322.043) on cooling water pipes (11) by means of

hexagon bolts (9). Make sure that these are aligned flush with the lifting
eye bolt on the charge air cooler and breakthrough in the charge air
cooler casing (3).
5. Screw bracket (322.041-1) onto charge air cooler casing with hexagon
bolts (13). Take care with locking pins (14).
6. Suspend the wire rope (322.041-15) on the lifting eye bolt (000.143)
with the snap hook (12) and guide the wire rope over the rope guides
and breakthrough in the charge air cooler casing (see figure 2).
7. Suspend the ratchet hoist (002.552) on the bracket and suspend the
wire rope and tension slightly.
8. Unscrew hexagon bolts (2), release the locknut on the clamping device
(5) and turn back several rotations.
6632 322.01-02 EN
2008-01-08 - de
TR
AI
3. Remove cap (4) and screw the lifting eye bolt (000.143) in the charge air
cooler (1).
FO
2. Remove all connections on the charge air cooler (1).
9. Pull the charge air cooler forwards by about 500 mm with the ratchet
hoist.
ON
LY
10. Insert the axle (322.041-28) in the spindles (7) and move with the thrust
screws (8) until it stops against the charge air cooler (see figure 3 and
4).
Charge air cooler
322.01
MAN Diesel & Turbo
11. Pull the charge air cooler forwards to the stop with the ratchet hoist.
12. Release the wire rope (322.041-15) with ratchet hoist and separate
from the charge air cooler with the snap hook (12).
13. Screw the lifting eye bolts (000.142) into the charge air cooler diagonally
(front-left and back-right) (see figure 2).
RP
OS
E
14. Fasten cable with shackle (002.452) on lifting eye bolts and suspend
rope from lifting tackle.
6632 322.01-02 EN
V32/40
R
FO
2008-01-08 - de
TR
AI
NI
1 Charge air cooler

4 Cover
2 Hexagon bolt
5 Clamping device with locknut
3 Charge air cooler casing
Figure 1: Sectional view charge air cooler in the fitted condition
NG
PU
15. Lift the charge air cooler and place in the cleaning bath.
3 (6)
322.01
NG
PU
RP
OS
E
ON
LY
Charge air cooler
MAN Diesel & Turbo
NI
2008-01-08 - de
TR
AI
10 Turbocharger
11 Cooling water pipe
12 Snap hook
V32/40
FO
1 Charge air cooler

7 Spindle
Figure 2: Charge air cooler with fitted removal and fitting fixture
4 (6)
1 Charge air cooler

Figure 3: Inserting the axle in the spindle
7 Spindle
6632 322.01-02 EN
8 Thrust screw
322.01
RP
OS
E
ON
LY
Charge air cooler
MAN Diesel & Turbo
PU
1 Charge air cooler

8 Thrust screw
14 Dowel pin
7 Spindle
Figure 4: Sectional view charge air cooler with fitted removal and fitting fixture
Work sequence 3 - Cleaning the charge air cooler (air side)
NG
1. Paint finned tubes with cleaning fluid or rinse in undiluted solvent (see
table).
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
6632 322.01-02 EN
V32/40
R
FO
2008-01-08 - de
TR
AI
Some cleaning agents cause itching on the skin when undiluted, so

wear protective goggles and gloves when using them. Follow
instructions by the manufacturing company.
NI
If there is heavy dirt or encrusting of the finned tubes the lining should
be softened for several hours in the cleaning fluid.
5 (6)
322.01
Manufacturer
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
Air Cooler Cleaner

"Sea Shield" ACC 79101
Nalfleet Marine Chemicals

Northwich, Cheshire
CW8 4DX/U.K.
Norus Degreaser
Norus Sales Co.

Stabekk/Norway
ON
LY
Designation
RP
OS
E
Charge air cooler
MAN Diesel & Turbo
Table 1: Cleaning agent/Manufacturer
Work sequence 4 - Cleaning the charge air cooler (water side)
PU
1. Remove water boxes on the charge air cooler.
2. Loosen deposits in finned tubes with wire brush and rinse with strong
water jets. For the removal of lime deposits, see Work Card 000.08.
NG
Work sequence 5 - Installing the charge air cooler
NI
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.
2008-01-08 - de
TR
AI
The installation of the charge air cooler is done in reverse sequence. In doing
so, observe the following points:
V32/40
FO

suspended loads!
6 (6)
6632 322.01-02 EN
Charge air cooler

check, clean air system
ON
LY
Summary
Charge air cooler
322.01
MAN Diesel & Turbo
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.
Safety requirements
RP
OS
E

Checking operating data,
Partitioning and cleaning of the charge air cooler,
Emptying the partitioned space and Refitting after cleaning.
Quan- Designation
tity
Number
Status
322.051
Standard
2 Flange with seal
322.051-1
4
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
Inventory
Inventory
1 Sealing compound
Inventory
AI
NI
NG
PU
1 Cleaning device
TR
Work card
Work card
Work card
000.30
FO
2007-07-17 - de
Work sequence 1 - Checking the operating data

Check cooling water inlet and outlet temperature during operation. Record
charge air temperature before and after cooler, note differential pressure for
the same load point in the upper load range regularly, to always have control
over the power of the cooler.
6632 322.01-03 EN
V32/40
Tools/aids required
1 (4)
322.01
MAN Diesel & Turbo
ON
LY
Charge air cooler
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 pressure measuring unit. Instead of the
sealing screws quick-acting couplings can be provided.
NI
AI
1
2
3
4
Turbocharger
Hexagon bolt
Hexagon nut
Axial compensator
Air intake casing

Ventilation
Drain for cleaning fluid
Connection numbers in accordance with charge air cooler
cleaning system
Figure 1: Isolation of the charge air cooler
See its own system and operation description to carry out the cleaning process.
Secure the engine from inadvertent starting.
V32/40
2 (4)
6
9298*
9299*
*
6632 322.01-03 EN
2007-07-17 - de
TR
Starting position
FO
NG
PU
RP
OS
E
Work sequence 2 - Attachment of blind flanges
Work steps
1. Remove all connections from the connection plate (9) and close the
thread with sealing screws and seal.
ON
LY
If this point is ignored cleaning fluid is transferred to the turbocharger

during the cleaning process. This would mean that the turbocharger
would have to be dismantled.
Charge air cooler
322.01
MAN Diesel & Turbo
RP
OS
E
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 bypass pipe, from connection (9271) and fit the flange (322.040) with seal
(see figure 2).
Turbocharger
Hexagon bolt
Hexagon nut
Axial compensator
Air intake casing
7
8
9271*
9298*
*
6632 322.01-03 EN
Charge air cooler

Hexagon bolt
Connection for air bypass pipe
Ventilation
cleaning system
V32/40
1
2
3
4
6
R
FO
2007-07-17 - de
TR
AI
NI
NG
PU
6. Remove the condensed water pot (if fitted) on connection (9299) and fit
flange (322.051-14) with seal on connection (9299).
3 (4)
322.01
4
6
7
8
RP
OS
E
ON
LY
Charge air cooler
MAN Diesel & Turbo
Axial compensator
Air intake casing
Charge air cooler
Hexagon bolt
9
9298*
9299*
*
Connection plate
Ventilation
Drain for cleaning fluid
cleaning system
Work sequence 3 - Refitting after cleaning and draining the partitioned space
PU
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.
NG
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
see Work Card 000.30).
NI
AI
TR
2007-07-17 - de
R
V32/40
FO
4. Check all connections for leakage.
4 (4)
6632 322.01-03 EN
434
TR
R
FO
6632 434-05 EN
NI
NG
PU
Piston/Piston rings
AI
000
009
012
020
021
027
030
034
050
055
071
073
100
101/102
101
RP
OS
E
ON
LY
MAN Diesel & Turbo
1 (2)
434
ON
LY
RP
OS
E
PU
TR
AI
NI
200
203
221
280-289
300/350
322
434

Push rods
Operating device
Speed regulation
Charge air cooler
NG
111
112
113/114
120
125
140
160-162
FO
MAN Diesel & Turbo
2 (2)
6632 434-05 EN
Fuel injection pipe

ON
LY
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.
RP
OS
E

removing the components,
refitting the components.
Engine stopped
PU
1 Technician
Duration in h
Tools/aids required
Number
Status
1 Plate for adjustable wrench 32
009.088
Standard
1 Ratchet tool
008.023
Standard
1 Torque wrench
008.011
Standard
1 Adapter 20x12.5
001.923
Standard
1 Extension
001.913
Inventory
Inventory
Inventory
Inventory
Inventory
TR
AI
NI
NG
Quan- Designation
tity
0,5
FO
2008-05-21 - de

Work card
Work card
Work card
000.30
221.01
434.02
6629 434.01-02 EN
32/40
Safety requirements
434.01
MAN Diesel & Turbo
1 (4)
434.01
MAN Diesel & Turbo
PU
RP
OS
E
ON
LY
Work sequence 1 - Removal of the fuel injection pipe
Casing on the exhaust counter side removed, shut-off valves on the fuel
pipes closed, cylinder head cover removed.
AI
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.
32/40
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.
2 (4)
6629 434.01-02 EN
2008-05-21 - de
TR
Work steps
FO
Starting position
NI
NG
1 Cylinder head
7 Hexagon nut
13 Charge air pipe
2 Threaded piece
8 Pressure tube
14 Covering upper part
3 O-ring seal
15 Leakage fuel drain pipe
10 Covering lower part
16 Hexagon bolt
5 Nut
11 Hexagon bolt
17 Washer
6 Set screw
12 Hexagon nut
18 Nut (left-hand thread)
Figure 1: Fuel injection pipe (figure shows covering without socket for engine diagnosis system)
ON
LY
If several fuel injection pipes are removed, label these first so that each
pipe is subsequently re-attached at the same cylinder.
8. Unscrew hexagon bolts, remove washers (17) and adaptor.

9. Clean fuel injection pipe on the outside.
10. Clean sealing faces on pressure pipe (8) and check for damage, rework
if necessary (see Work Card 434.03).
RP
OS
E
11. Protect the connection socket on the injection pump (9) from damage
and dirt contamination.
Work sequence 2 - Fitting the fuel injection pipe

Starting position
Work steps
434.01
MAN Diesel & Turbo
Fuel injection pipe cleaned.
1. Clean sealing faces on threaded piece (2) and fuel injection pump (9)
and check for damage, rework if necessary (see Work Card 221.06).
2. Place new O-ring coated with acid-free grease in ring groove, ensuring
that it is not twisted.
PU
3. Screw adaptor (4) on threaded piece (2) and loosely screw the hexagon
bolts (16) including washers (17) in position.
NG
Before fitting the fuel injection pipe, check the nuts (18) for secure fit on
the thrust piece (8). (see Work Card 434.02)
4. Apply MoS2 lubricant on threads of the nuts (5).
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 injection valve with MoS2 lubricant, screw them finger-tight onto the stud
bolts and, working in an alternating sequence, tighten them in several
stages to the specified torque (see Work Card 000.30).
6629 434.01-02 EN
32/40
R
FO
2008-05-21 - de
TR
AI
It is important to start the fitting at the injection pump.
NI
5. Place thrust piece (8) with covering on injection pump (9) and screw the
nut on by two or three turns.
3 (4)
434.01
MAN Diesel & Turbo
ON
LY
If the fuel injection valve is installed in a cylinder head which is at

operating 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.
RP
OS
E
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.
PU
The covering must be securely fixed.
14. On engines with engine diagnosis system (MODIS) place the plug in the
socket.
NG
15. Fit the fuel drain pipe on the covering.

16. Attach the casing on the exhaust counter side.
NI
AI
TR
2008-05-21 - de
R
32/40
FO
17. Attach the cylinder head cover.
4 (4)
6629 434.01-02 EN
Fuel injection pipe

ON
LY
Summary
Check components for consistency/wear condition, ensure/restore operational safety.

The fuel injection pipes must be dismantled for checking and reworking of
the pressure pipe sealing faces.
Quan- Designation
tity
RP
OS
E

disassembling components,
assembling components.
Tools/aids required
Number
Status
434.041
Standard
Inventory
Inventory
PU
1 Spanner
434.02
MAN Diesel & Turbo
Work card
Work card
434.01
434.03
Work card
Starting position
Work steps
NG
Work sequence 1 - Dismantling the fuel injection pipe

Injection line is detached.
1. Slide back nuts (5), until nuts (18) are accessible.
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).
On engines with engine diagnosis system (MODIS) when cleaning

ensure that the feed pipe of the strain gauge to the socket is not
damaged or ripped off.
6629 434.02-02 EN
32/40
R
FO
2007-07-18 - de
TR
AI
On engines with engine diagnosis system (MODIS) the covering (10

and 14) must not be dismantled (point 3 and 4) in order not to damage
or pull off the pipe of the strain gauge to the socket.
NI
2. Unscrew the nuts (18) with spanner (434.041) (left-hand thread!), pull of
the nuts (5).
1 (3)
434.02
MAN Diesel & Turbo
RP
OS
E
ON
LY
6. If necessary, rework sealing faces on pressure tube (see Work Card

434.03).
PU
5 Nut
14 Covering upper part
8 Pressure tube
18 Nut (left-hand thread)
10 Covering lower part
19 O-ring seal
11 Hexagon bolt
20 O-ring seal
12 Hexagon nut
Figure 1: Fuel injection line (figure shows covering without socket for engine diagnosis
system)
NG
Work sequence 2 - Assembling the fuel injection pipe

Starting position
Individual parts are cleaned, damaged sealing faces on pressure tube, if any,
are reworked.
32/40
2 (3)
1. Place new O-ring (20) coated with acid-free grease in ring groove,
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,
5. Place nuts (5) on pressure pipe.
6. Screw nuts (18) on pressure pipe with spanner (434.041) until they abut
(left-hand thread!), (see figure 1, Detail Y).
6629 434.02-02 EN
2007-07-18 - de
TR
AI
On engines with engine diagnosis system (MODIS) start assembly at

point 4.
FO
Work steps
NI
On engines with engine diagnosis system (MODIS) covering (10 and 14) not
dismantled.
6629 434.02-02 EN
32/40
R
FO
2007-07-18 - de
TR
AI
NI
NG
PU
RP
OS
E
ON
LY
If the fuel injection pipe is fitted at a later date, pull the nuts (5) over the
ends of the pressure pipe to protect the sealing faces on the pressure
pipe.
434.02
MAN Diesel & Turbo
3 (3)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Tools/aids required
Quan- Designation
tity
RP
OS
E
The work includes:

Number
Status
1 Pressure pipe grinding device
434.042
Option
1 Adapter plate
434.042-1
Option
434.042-2
Option
434.042-3
Option
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
434.042-1
0
Option
1 Swivel arm
434.042-1
1
Option
1 Bracket
434.042-1
2
Option
1 Stop
434.042-1
3
Option
1 Stop gauge (Pressure tube)
434.042-1
4
Option
1 Grinding wheel
434.042-1
6
Option
1 Baseplate
434.042-1
7
Option
1 Carriage
434.042-1
8
Option
1 Shaft
434.042-1
9
Option
1 Stop
434.042-2
0
Option
2 Ball bearing
434.042-2
4
Option
1 Threaded ring
1 Bearing ring
R
FO
2007-09-21 - de
TR
AI
NI
NG
PU
1 Bearing flange
6629 434.03-02 EN
32/40
Checking components for consistency/wear condition, ensure/restore operational 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 necessary.
Summary
ON
LY
Fuel injection pipe

Grind sealing faces on pressure tube
434.03
MAN Diesel & Turbo
1 (7)
434.03
MAN Diesel & Turbo
Quan- Designation
tity
Status
434.042-2
5
Option
434.042-3
7
Option
434.042-3
8
Option
434.042-4
1
Option
434.042-4
4
Option
ON
LY
2 Ball bearing
Number
1 Hook wrench
1 Face spanner
2 Clamping lever
Work card
RP
OS
E
5 Emery paper
434.01
434.02
000.294
Standard
000.293
Standard
1 Tommy bar, 8
000.262
Standard
1 Cleaning medium
Inventory
1 Safety goggles
Inventory
Work card
Work card
NI
AI
TR
2007-09-21 - de
R
32/40
FO
NG
PU
2 (7)
6629 434.03-02 EN
NI
NG
PU
RP
OS
E
ON
LY
Work sequence 1 - Attachment of the fuel injection pipe to the pressure pipe grinding
fixture
434.03
MAN Diesel & Turbo
6629 434.03-02 EN
32/40
R
FO
2007-09-21 - de
TR
AI

3 Grinder
4 Support adjusting crank
Figure 1: Pressure pipe grinding fixture with fitted fuel injection line
3 (7)
434.03
NG
PU
RP
OS
E
ON
LY
MAN Diesel & Turbo

Figure 2: Pressure pipe grinding tool
NI
Fuel injection pipe is partially dismantled and cleaned (see Work Card
434.02).
The pressure pipe grinding fixture must be installed and/or operated on

a firm base. Vibration of the fixture affects the surface quality of the
sealing faces to be ground.
The fuel injection pipes to be ground must be absolutely free from
lubricating oils and greases. Contamination of any kind, especially
lubricants, reduces the service life of the grinding wheels considerably.
AI
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).
32/40
3. Fasten stop gauge (434.042-14) on adaptor flange with two hexagon

socket bolts (6).
4 (7)
6629 434.03-02 EN
2007-09-21 - de
TR
R
Work steps
FO
Starting position
5 Stop
ON
LY
When fixing the stop gauge on adapter flange, support with tommy bar
(000.262) on the threaded ring.
434.03
MAN Diesel & Turbo
4. Screw counter-flange (434.042-6) on the threaded insert (1).
RP
OS
E
There is a left-hand thread on the pressure pipe of the fuel injection

line.
5. Screw in the fuel injection pipe in the adaptor flange by using counterflange, 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.
PU
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).
Starting position
Fuel admission pipe correctly attached to delivery pipe grinding device.

Grinding wheel mounted with new emery paper on grinder.
6629 434.03-02 EN
32/40
Work sequence 2 - Regrinding the sealing faces on pressure pipe
FO
2007-09-21 - de

Figure 3: Attachment of the fuel injection pipe on the pressure pipe grinding fixture
TR
AI
NI
NG
11. Swing the bracket (434.042-12) up to the stop again and fix on the
slide with two clamping levers (434.042-41).
5 (7)
434.03
MAN Diesel & Turbo
ON
LY
Sealing faces are difficult to rework and this requires particular care.
We recommend you have this work carried out by a Service Centre or
MAN Diesel & Turbo personnel.
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.
RP
OS
E
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.
Wear safety goggles when grinding delivery pipes!
4. Connect the grinder to the power supply and switch it on.
PU
5. Turn the fuel admission pipe evenly while moving the swivel arm with
grinder around the contour of the sealing face.
NG
Do not allow the grinding wheel to come into contact with the adapter
flange.
NI
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.
32/40
If you cannot obtain the required wear pattern using the delivery pipe
grinding device, have this repair carried out by a MAN Service Centre.
6 (7)
6629 434.03-02 EN
2007-09-21 - de
TR
AI
This is not carried out at the support adjusting crank. The position set
remains unchanged throughout the entire grinding operation. Gently
rework sealing faces; smooth them down and remove as little material
as possible.
FO
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
ON
LY
Remove used emery paper immediately and replace with new emery
paper.
434.03
MAN Diesel & Turbo
6629 434.03-02 EN
32/40
R
FO
2007-09-21 - de
TR
AI
NI
NG
PU
RP
OS
E
9. Detach the fuel admission pipe from the delivery pipe grinding device
and remove the counter flange.
7 (7)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Summary
ON
LY
Buffer piston
inspecting
Check buffer piston at regular intervals. Renew the set of piston seals.
Tools/aids required
Number
Status
000.451
Option
Inventory
1 Screwdriver (Set)
Standard
Inventory
1 Lubricant (Copa Slip)
Inventory
1 Locking wire
Inventory
1 Pliers for locking wire
Inventory
2 Strip (Nylon)
Inventory
R
FO
2007-07-18 - de
TR
AI
NI
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
even with a tight piston. Higher leakage fuel occurrence can be attributed to
damaged OMEGAT set of piston seals (2) or wear of piston (1) and bush (3).
The buffer piston must be dismantled without delay under such circumstances.
6629 434.04-01 EN
General
Preliminary remarks
NG
PU
Quan- Designation
tity
RP
OS
E

Removing/disassembling components,
Replacing sealing rings/elements,
Assembling/fitting components.
434.04
MAN Diesel & Turbo
1 (4)
434.04
RP
OS
E
ON
LY
MAN Diesel & Turbo
7
8
10
11
12
External spring
Hexagon nut
Securing wire
Seal
Connection for leakage fuel pipe
PU
1 Piston
2 OMEGAT set of piston seals
3 Sleeve
4 Cover
5 Stop screw
6 Internal spring
Figure 1: Sectional view of the buffer piston
Work sequence 1 - Checking the buffer piston (whilst running)

Starting position
Work steps
Engine in warmed-up condition.
NG
1. Remove the securing wire (10) for checking the function of the piston (1)
and carefully unscrew stop screw (5).
2. Insert test pin (e.g. long screwdriver) in the cover (4) and find out
whether the piston carries out a pulsing movement.
NI
AI
4. For checking the OMEGAT piston seal set (2) carefully remove the leak
oil pipe on the connection (12).
TR
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
General
2 (4)
Engine stopped, fuel pipes blocked off.

1. Release the hexagon nuts (8) evenly and unscrew them, remove the
cover (4). Take care with seal ring (11).
The springs (6 and 7) are normally released before removing the
hexagon nuts (8). With the piston (1) firmly at the end position however,
there are still spring forces on the cover even on removing the hexagon
nuts. It is therefore advisable to avoid anybody's presence in the axial
direction of the buffer piston when opening, danger of injury!
6629 434.04-01 EN
2007-07-18 - de
Starting position
Work steps
FO
3. Screw the stop screw back in position and secure with locking wire
(see figure 1).
Manufacturing clearance
Maximum clearance
Piston
90 f7
0,036 ... 0.106 mm 0.250 mm
Sleeve
90 H7
ON
LY
New dimension
434.04
MAN Diesel & Turbo
Table 1: Dimensions and clearances of the buffer piston components
1. Remove springs (6 and 7) and inspect for cracks or fractures.
2. Screw the hexagon bolt M10x200 in the thread on the base of the piston and pull out the piston.
RP
OS
E
3. Remove OMEGAT set of piston seals (2), check piston and bush for
ease of movement, measure wear with feeler gauge (000.451).
Use new parts if the maximum piston clearance is exceeded. Grooved

bushes must be replaced because of increased leak fuel collection.
Renew OMEGAT set of piston seals at each inspection of the buffer
piston.
Work sequence 3 - Replacing the OMEGAT set of piston seals
Old set of piston seals removed. Ring groove of the piston cleaned.
PU
Starting position
Work steps
1. Screw hexagon bolt M10x200 in piston skirt and clamp hexagon bolt in
the vice. Pay attention to piston (1) and do not damage it.
6629 434.04-01 EN
General
Figure 2: Fitting a new OMEGAT set of piston seals
1 Piston
2 OMEGAT set of piston
seals
9 Nylon strip
FO
2007-07-18 - de
TR
AI
NI
NG
2. Insert OMEGAT set of piston seals (2) as far as possible in the ring
groove.
Place 2 nylon strips at a pitch of approx. 120 around the OMEGAT piston seal set (see figure 2). Pull the OMEGAT set of piston seals over the
piston edge into the groove carefully using the strip. Then carefully
remove the strips. Also ensure that the set of seals is not twisted.
3 (4)
434.04
MAN Diesel & Turbo
Work sequence 4 - Assembly of the buffer piston
ON
LY

1. Treat the piston running surface and bush with copa slip before assembly.
2. When inserting the piston do not damage the OMEGAT set of piston
seals.
3. Lock the stop screw (5) with locking wire (see figure 1).
NI
AI
TR
2007-07-18 - de
R
General
FO
NG
PU
RP
OS
E
4. Fit the leakage fuel pipe on connection (12).
4 (4)
6629 434.04-01 EN
RP
OS
E
ON
LY
MAN Diesel & Turbo
PU
1 Introduction

NG
blies
Appendix
FO
TR
AI
NI
4 Appendix
6632 4 B2-05 EN
1 (1)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
4.1
Appendix
FO
TR
AI
NI
NG
4.1 Insulation
PU
RP
OS
E
ON
LY
Insulation
MAN Diesel & Turbo
6632 4.1-05 EN
1 (1)
FO
NI
AI
TR
NG
RP
OS
E
PU
ON
LY
Checklisten-Nr.:
Version 1
ON
LY
Checkliste
RP
OS
E
Wartungshinweise zur Visuellen Prfung von

Isolationsbauteilen an Motor, Abgasanlagen, Turbolader etc.
Smtliche Isolierungsteile sind in regelmigen Zeitabstnden zumindest visuell auf
Schden, Funktion oder vernderte Position zu prften. Ganz besonders jene
Isolationen, die auf stark vibrierenden oder beanspruchten Motorelementen
angebracht sind, sind einer stndigen Kontrolle zu unterziehen.
NG
PU
Diese Anleitung soll dabei eine Hilfestellung sein.
NI
Details for maintenance and visual control of insulation

parts on engine, exhaust gas plants, turbo charger etc.
TR
AI
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.
FO
This instruction is supposed to be a basic assistance.
Erstellt:
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Freigegeben:
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R. Lasner
--Revision: 000
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LY
Checkliste
Generelle Schden wie Beulen, Eindrcke

oder Risse knnten durch grobe Arbeiten
an Motor und Rohrleitungen auftreten oder
durch starke Vibration hervorgerufen
werden. Hier soll dringend berprft
werden, ob eventuell innen liegende
Dmmung beschdigt wurde. Stark
verbogene Verkleidungen mssen
ausgetauscht werden.
Intervall: Sichtung jeweils nach 250
Betriebsstunden
RP
OS
E
1. Generelle Schden
PU
Beschdigtes Gehuse - sollte getauscht werden.

Damaged Casing for exchange
NG
General damages
TR
AI
NI
General damages such as buckles, bumps

or cracks could occur during assembling
or maintaining works in the engine or
piping area or because of strong engine
vibrations. It is highly recommended to
check inlaying insulation parts of their
intactness. Heavy damaged casing parts
need to be exchanged.
FO
Interval: Inspection at any 250 hours of

operation
Gebrochene oder gerissene Verkleidungsteile.

Broken or cracked cladding parts.
Erstellt:
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Checkliste
2. Schraubverbindungen
RP
OS
E
Sollten lockere Schrauben festgestellt

werden, so mssen diese umgehend fest
gezogen, bzw. fehlende Schrauben ersetzt
werden.
Betriebsstunden
Screwed joints
PU
Lockere Schrauben mssen festgezogen werden.

Loose screws need to get tightened.
NG
If loose screw fittings will be found, an

immediate tightening is necessary. Lost
screws need to get replaced.
TR
AI
NI

operation
FO
Verlorene Schrauben ersetzen!

Replacing lost screws!
Erstellt:
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Checkliste
Durch nicht fachgerechtes Schlieen kann

sich der Bgel verziehen oder nicht
gerade aufliegen. Hier bitte korrigieren.
Durch mehrmaliges ffnen kann sich die
Verbindung lockern. In diesem Fall muss
die Schraube enger gestellt werden.
Clip and rocker arm locks
PU

Betriebsstunden
RP
OS
E
3. Hebel- und Bgelverschlsse
Prfen auf korrekten und kraftschlssigen Sitz.

Checking for correct force-fit.
AI
NI
NG
When closing these locks in an incorrect

way the rocker arm could get warped or
does not bear on correctly anymore.
Please correct it in that case.
Because of constant opening and closing
the connection can get loose. In that case
the rocker arm screw must be tightened.
FO
TR

operation
Erstellt:
Gendert:
Freigegeben:
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--Revision: 000
Seite: 4von 10
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ON
LY
Checkliste
Bei Mattenisolierungen wird diese

Variante zum schlssigen Verspannen
verwendet. Bei der Wiedermontage
werden die Haken oftmals fehlerhaft
miteinander verbunden.
Achten Sie darauf, dass die Haken sich
korrekt gegenber liegen und einzeln mit
einem Draht verzurrt sind. Korrigieren Sie
entsprechend.
Fehlerhaftes Verzurren fhrt zum Verzug
der gesamten Isolation und zur
eventuellen Unwirksamkeit.
RP
OS
E
4. Hakenverschlsse
PU
Beispiel fr perfekten Sitz

An example for a perfect fit.
NI
Hook connections
NG

Betriebsstunden
FO
TR
AI
For mat insulations this type is used for

tightened bracing. During reassembling
works the hooks often get connected in an
incorrect way. Please take care of the
hooks lay opposite to each other and
being pairwise connected by a wire.
Please correct if necessary.
An incorrect rigging could cause the whole
insulation to be spoilt and get effectless.
operation
Erstellt:
Gendert:
Freigegeben:
11.11.05
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Fehlerhaftes Beispiel.
Example for an incorrect bracing.
Isolation ist verzogen und undicht.
Insulation is spoilt and leaky.
R. Lasner
--Revision: 000
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Version 1
ON
LY
Checkliste
Mattenisolierungen unterliegen nur einer

begrenzten Haltbarkeit und werden je
nach Belastung schnell oder langsam
abgenutzt. Hier muss routinemig geprft
und entsprechend beschdigte Teile
dringend ersetzt werden.
Durch beschdigte Oberflchen kann sich
eine Isoliermatte mit z.B. brennbarer
Flssigkeit voll saugen.
NG
Damages on insulation mats
Intakte Isolierung einer Umblaseleitung.

Intact insulation of a by-pass exhaust pipe.
PU

Betriebsstunden
RP
OS
E
5. Beschdigte Isoliermatten
AI
NI
Insulation mats have a limited durability

and getting used up depending upon their
load in a faster or slower way. These parts
have to be checked as a matter of routine.
Affected parts have to be urgently
replaced.
Defekte Isolierung muss ausgetauscht werden.

Defective insulation need to get exchanged.
TR
Because of a damaged surface an

insulation mat could soak up e.g.
combustible fluids.
FO

operation
Defekte Isolierung muss ausgetauscht werden.

Defective insulation need to get exchanged.
Erstellt:
Gendert:
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ON
LY
Checkliste
6. Korrekter Sitz der Isolierung
RP
OS
E
Durch die teilweise starke Vibration der

Motoren kann sich auch die Isolierung
nach einiger Zeit lockern und eventuell
nicht mehr richtig aufliegen.
Betroffene Teile mssen hier erneut
korrekt montiert und eventuell strker
verzurrt werden.
Betriebsstunden
PU
Diese Isolierung sitzt perfekt.

This insulation fits correctly.
NG
Correct fit of insulation elements
TR
AI
NI
Because of the strong vibration of the

engine insulation parts can get loose and
do not bear on correctly anymore.
These particular parts have to be
reassembled and eventually clamped in a
stronger way.
operation
FO
Diese Isolierung ist verrutscht. Neu-Montage

This insulation has moved. Reassembling.
Erstellt:
Gendert:
Freigegeben:
11.11.05
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Checkliste
Sollten Russ-Spuren auf der Isolation zu

sehen sein, ist dies ein Anzeichen dafr,
dass sich unterhalb ein Abgasleckage
befinden knnte. Ein solche Leckage fhrt
zur Entstehung schwefliger Sure, die zur
Zerstrung der Isolierung fhrt. In solchen
Fllen muss die Leckage zunchst
umgehend geschlossen und anschlieend
die Isolierung ersetzt werden. Betroffene
Isoliermatten drfen nicht wieder
verwendet werden.
Beispiel fr Russ-Spuren. Dringender Austausch!

Example for soot marks. Urgent exchange!
NI
Soot / Scorch marks
NG
PU

Betriebsstunden
RP
OS
E
7. Russ- / Brandspuren auf der

Isolierung
FO
TR
AI
If soot marks appear on the insulations

surface could this be a sign for an exhaust
gas leakage underneath. Leaking exhaust
gas causes the production of sulphuric
acid and destroys the insulation. In such
cases the leakage should get closed first.
All affected insulation parts need to be
replaced. Reusing such parts is not
possible.
operation
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8. Sicherheit der Isolation

gegen Eindringen brennbarer
Flssigkeiten
RP
OS
E
Achten Sie dringend darauf, dass

Isolierungen, die mit einer berlappung
versehen sind, nie mit der ffnung nach
oben montiert werden. Durch die ffnung
nach oben kann z.B. brennbare
Flssigkeit eindringen.
Betriebsstunden
PU
Safety of Insulation against

intrusion of combustible fluids
Vorsicht! Hier knnen Flssigkeiten eindringen!

Caution! Here, fluids could enter!
NI
NG
Please urgently, pay attention that

overlapping insulation parts do not upturn
the open side. This way combustible fluids
could drain in.
The opening always needs to be
assembled in downward direction.
FO
TR
AI

operation
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Prfen durch Demontage der Verkleidung.

Check after disassembling the cladding parts.
NG
Resistance of lagged / inside

insulation materials
PU

Betriebsstunden
RP
OS
E
Bei einer als Blechsandwich aufgebauten

Isoliervariante mit innen liegendem
Dmmstoff muss regelmig geprft
werden, ob der Dmmstoff noch in seiner
ursprnglichen Form vorhanden oder
eventuell in sich zerfallen oder beschdigt
ist.
ON
LY
9. Bestndigkeit innen liegender

Isoliermaterialen
AI
NI
If an insulation has been arranged as a

sheet sandwich with inlaying insulation
material, this material has to be checked
regularly of its natural form or of being
decomposed or even damaged.
TR

operation
FO
Diese Matte ist in einwandfreiem Zustand.

This mat is in perfect shape.
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Working Instructions MAN 32/40

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Working Instructions MAN 32/40

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MAN Diesel & Turbo

Engine ................................................ V32/40

Works No. of engine ........................... 1065270

Plant No. ............................................ 4302268

Translation of the original instructions

MAN Diesel & Turbo

MAN Diesel & Turbo SE

Copyright MAN Diesel & Turbo

Work Cards, Classified by Subjects

Operating media systems/Pipes

MAN Diesel & Turbo

MAN Diesel & Turbo

Work Cards, classified into sub-assemblies

Hydraulic tensioner bleeding, testing, renewing sealing rings

Piston/Piston rings inspecting

MAN Diesel & Turbo

MAN Diesel & Turbo

Valve seating surface inspecting

Lubricating oil pump assessing the individual parts

MAN Diesel & Turbo

MAN Diesel & Turbo

2 Work Cards, Classified by Subjects

MAN Diesel & Turbo

MAN Diesel & Turbo

In general, the Work Cards contain the following information:

the required tools and auxiliary equipment,

possible supplementary details /technical data and

How are the required Work

For directly imminent dangers! Possible consequences: Death or

Potentially dangerous situations

Possibly dangerous situations

For potentially dangerous situations! Possible consequences: Severe

MAN Diesel & Turbo

For tips on error sources.

For application tips and supplementary information.

Clearances and tolerances, temperatures and pressures are listed in Volume

Clearances and tolerances,

Status/Availability Required Tools/Auxiliary Equipment

1 Open-end wrench and ring spanner (set)

1 Hexagon screwdriver (set)

1 Lifting tackle with rope

1 Removal and mounting device

Table 1: Example: list of tools/aids required

Option: describes a tool/aid that is not included in the standard scope of

Standard: refers to a tool/aid that is included as standard in the scope of

MAN Diesel & Turbo

MAN Diesel & Turbo

Complete basic tool set

Socket spanner (set) (10x12.5 - 34x12.5)

socket spanner insert DIN 3124 - 16x12.5

socket spanner insert DIN 3124 - 17x12.5

socket spanner insert DIN 3124 - 18x12.5

socket spanner insert DIN 3124 - 19x12.5

socket spanner insert DIN 3124 - 21x12.5

socket spanner insert DIN 3124 - 22x12.5

socket spanner insert DIN 3124 - 24x12.5

socket spanner insert DIN 3124 - 27x12.5

socket spanner insert DIN 3124 - 30x12.5

socket spanner insert DIN 3124 - 32x12.5

socket spanner insert DIN 3124 - 34x12.5

socket spanner insert DIN 3124 S - 36x20

socket spanner insert DIN 3124 S - 41x20

Cross handle DIN 3122A - 12.5

Socket spanner insert DIN 3124 - 10x12.5