Reduction of the valve clearance on the inlet side

Engines L 40/54, L+V 48/60 and L 58/64 Cus 165 : 08/98

New valve clearance on inlet valves With the information letter Cus 151 : 09/97, we advised you of the
necessity to reduce the valve clearance on the inlet valves and asked
you to set the reduced clearance of
0.2 0.05 mm
on the next occasion.
Request for reply As we consider the reduction of the valve clearance an important
measure to increase the operational reliability and economy, we kindly
ask you to inform us, when you set the new value. This information is
important for the assessment of operating results. For your reply, a
prepared telefax is enclosed to this information letter. Please fill in your
address, the plant names and engine works numbers and return it to our
Service Department in Augsburg. The telefax number is --821/322--3838.

New work cards/information plates With this information letter, we are sending you the revised work card
111.01. You can obtain a set of supplemented feeler gauges and new
information plates with fastener. For this purpose, we will contact you
within the next days. Please have these plates attached beside the plates
available on the cover of the first and last cylinder. This can be done by
means of notched nails (as shown in the sketch below) or using Loctite.

ST23/TKU

Figure 1. Attachment of the information plates (example 48/60)

MAN B&W Diesel Aktiengesellschaft : Postfach 10 00 80 : D-- 86135 Augsburg : Phone ++49 821 3 22-- 0 : Fax ++49 821 3 22 33 82
 Telefax to MAN B&W Diesel AG, Augsburg
Service Department ST23
Telefax - 821/322- 3838

The valve clearance of the inlet valves was set to 0.2 ™ 0.05 mm on the below--mentioned engines according to
the Diesel Customer Information Cus 151 : 09/97 --

L Yes

L No

L Will be done on the next occasion

Plant/s ................................................................
................................................................
................................................................
................................................................
................................................................
Engine works numbers ................................................................
................................................................
................................................................
................................................................
................................................................
Sender ................................................................
................................................................
................................................................
................................................................
................................................................
Telephone ................................................................
Telefax ................................................................

Signature ................................................................

MAN B&W Diesel Aktiengesellschaft : Postfach 10 00 80 : D-- 86135 Augsburg :Phone ++49 821 3 22-- 0 : Fax ++49 821 3 22 33 82
Rocker arm casing with rocker arms
Valve clearance
Removing, attaching, checking 111.01

Purpose of jobs to be done

Impart the required knowledge,

ensure correct execution of work.
Carry out the work in time according to the maintenance schedule,
enable/support economic operation,
prevent operating problems/damage.

Brief description

Rocker arm casings are to be disassembled within the scope of

maintenance and repair work.
The valve clearance is to be determined and, if necessary, to be corrected
at regular intervals.
The work/steps include:
removal of components,
attachment of components,
checking/adjusting of valve clearance.

Safety requirements

- Engine shut--down
- Engine secured against starting
- Operating media system closed/depressurised

Tools/appliances required

Quant Denomination No. Availability

1 Setting gauge 1.3 113.122 Standard
2 Connecting link 111.108 Standard
1 Suspension device 111.107 Standard
1 Pilot rod 009.064 Standard
1 Torque wrench 750--2000 Nm 008.005 Standard
1 Torque wrench 140--760 Nm 008.004 Standard
1 Torque wrench 20--200 Nm 008.002 Standard
1 Adapter 25x20 001.924 Standard
1 Extension piece 25x200 001.915 Standard
1 Screw driver insert 22x25 001.861 Standard
1 Socket wrench insert 46x25 001.785 Standard
1 Socket wrench insert 19x12.5 001.755 Standard
1 Set of feeler gauges 0.2 000.455 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Tommy bar 12 000.264 Standard

6619 111.01--02 E 01.98 L 58/64 101/ 05

 Quant Denomination No. Availability
2 Eye bolt M16 000.143 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Grease (acid--free) -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.30 000.31

Technical details

Term Information
Rocker arm casing with cylinder head cover 765 kg

Operating sequence 1 -- Checking

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Steps 1. Check valve clearance, screw connections and rocker arm lubrication
at the intervals specified in the maintenance schedule. Whenever
cylinder heads are removed and in the course of overhaul work,
check the individual parts for wear. In case the bearing clearance is
too large, renew the bearing bushes.
Blow the oil bores in the rocker arm (5, 6 and 7) on axles through with
compressed air.
Turn the engine by means of the turning gear, checking whether the
valves constantly follow the movements of the rocker arms or
whether they got stuck.

Operating sequence 2 - Removing the rocker arm casing

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), lube oil pump (if available) turned off, cylinder head cover
opened.

Steps 1. Loosen the supply pipe to the rocker arm lubrication. Fix rocker arms
(6 and 7) by means of link and knurled nut (111.108) - see Figure.
2. Screw out six hexagon socket screws (3) by means of screw driver
insert A/F 22.
3. Close the cylinder head cover, attach the suspension device
(111.107) to the bores (17) by means of four hexagon head bolts,
suspend it in lifting tackle and carefully lift it.
Important! The sleeves (18) must thereby not get tilted in the push
rod coverings.

6619 111.01--02 E 01.98 L 58/64 102/ 05

 1 Cylinder head cover 11 Parallel pin A Inlet valve clearance
2 Rocker arm casing 12 Washer B Exhaust valve clearance
3 Hexagon socket bolt 13 Valve adjusting screw C-D Possible displacement
4 Hexagon head bolt 14 Nut of the rocker arm
5 Rocker arm 15 Exhaust valve E Marking
6 Rocker arm (inlet) 16 Inlet valve J Axial clearance
7 Rocer arm (outlet) 17 Four bores for K Axial clearance
8 Axle suspension device
9 O-ring seal 18 Sleeve
10 Screw plug 19 Hexagon head bolt

Figure 1. Rocker arm casing with control levers and attached suspension device

Operating sequence 3 - Attaching the rocker arm casing

Starting condition Supporting faces cleaned. Sealing rings on the cylinder head and on the
sleeves (18) checked for damage and replaced, if necessary. Control
levers (6 and 7) fixed by means of link and knurled nut (111.108). Cylinder
head cover closed.

6619 111.01--02 E 01.98 L 58/64 103/ 05

Steps 1. When the rocker arm casing gets seated, pay attention to the fitted
pins and insert the sleeves (18) carefully into the push rod coverings.
For this purpose, possibly loosen the bolts on the push rod coverings
(see work card 112.01).
2. Tighten the hexagon socket screws to the specified torque (see work
card 000.30). Connect the lube oil pipe for lubricating the control
levers. Remove the connecting link (111.108).
3. After mounting, check the valve clearance and adjust it, if necessary
(see operating sequence7).

Operating sequence 4 - Shifting and fixation of the rocker arms (7) for removal of the exhaust valves

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Steps 1. Disk (12) removed.

2. Move the control lever from (C) to (D), fold it upwards and secure it
against dropping back by means of the tommy bar 12 dia. which is
passed through the bore in the control lever (7) and in the axle (8).
3. When remounting the disk (12), tighten the hexagon head bolt (19) to
the specified torque (see work card 000.30).

Operating sequence 5 - Removing and installing the rocker arms (5 and 6) for removal of the inlet
valves

Steps 1. Screw out three hexagon head bolts (4).

2. Using two eye bolts (000.143) and lifting tackle, completely remove
the control lever with support.
3. During installation, pay attention to the fixation of the bearing block
and tighten the hexagon head bolt (4) to the specified torque (see
work card 000.30).
4. Check valve clearance and axial clearance (I, K) - for clearances,
refer to operating manual/technical details.

Operating sequence 6 - Removing and installing the rocker arm axle (8)

Steps 1. Remove the washer.

2. Remove the screw plug (10) and the parallel pin (11).
3. Push the rocker arm axle (8) out to such an extent that an O-ring seal
(9) can be removed.
4. Remove axle (8) in the opposite direction, securing the control lever
with the rope.
5. During installation, mount the axle without O-ring seals. Afterwards,
move the axle towards the left and towards the right to such an
extent only that O-ring seals (9) can be installed.
6. Reinstall the washer (12) and tighten the hexagon head bolt (19) with
the specified torque (see work card 000.30).
Important! When installing new bearing bushes in rocker arm
(5, 6, 7), please observe: On the bush, there are various markings (E). It
must be installed in such a way that on the front face of lever and bush the
same markings (I or 0) are visible and positioned opposite each other, as
illustrated.

6619 111.01--02 E 01.98 L 58/64 104/ 05

Operating sequence 7 - Adjusting the valve clearance (A and B)

Starting condition Engine is cold (all engine parts have the same temperature).

▲ Attention! In case the engine has operating temperature, six

hours after shut-down at the earliest.
Running gear of the respective cylinder turned to ignition TDC position
(all valves closed), cylinder head cover opened.

Steps 1. Loosen hexagon nut (14) and screw back valve adjusting screw (A
and B).

Valve clearance
Exhaust valve 1.3 mm
Inlet valve 0.2 mm

1. Push the setting gauge (113.122) or feeler gauges (000.455) between

valve stem and ball cup.
2. Tighten the valve adjusting screw until setting gauge or feeler gauge
fits snugly.
3. With the gauge inserted, hold the valve adjusting screw and tighten
the hexagon nut

6619 111.01--02 E 01.98 L 58/64 105/ 05

Rocker arm casing with control levers
Valve clearance
Removing, attaching, checking 111.01

Purpose of jobs to be done

Impart the required knowledge,

ensure correct execution of work.
Carry out the work in time according to the maintenance schedule,
enable/support economic operation,
prevent operating problems/damage.

Brief description

Rocker arm casings are to be disassembled within the scope of

maintenance and repair work.
The valve clearance is to be determined and, if necessary, to be corrected
in regular intervals.
The work/steps include:
removal of components,
attachment of components,
checking/adjusting of valve clearance.

Safety requirements

- Engine shut--down
- Engine secured against starting
- Operating media system closed/depressurized

Tools/appliances required

Quant Denomination No. Availability

1 Setting gauge 0.9 113.139 Standard
2 Connecting link 111.115 Standard
1 Suspension device 111.113 Standard
1 Sealing cover 055.143 Standard
1 Pilot rod 034.006 Standard
1 Torque wrench 008.029 Standard
1 Torque wrench 008.017 Standard
1 Adapter 25x20 001.924 Standard
1 Adapter 12.5x10 001.922 Standard
1 Cross handle 001.891 Standard
1 Screw driver insert 22x25 001.861 Standard
1 Screw driver insert 8x12.5 001.854 Standard
1 Socket wrench insert 17x12.5 001.754 Standard
1 Ratchet 001.521 Standard
1 Set of feeler gauges 0.2 000.455 Standard

6624 111.01--04 E 11.97 L 48/60 101/ 06

 Quant Denomination No. Availability
1 Thickness gauges 0.05--1 000.451 Standard
1 Tommy bar 12 000.264 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Receptacle -- Inventory
1 Grease (acid--free) -- Inventory
1 Lifting takle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.30 000.31

Technical details

Term Information
Rocker arm casing with cylinder head cover 870 kg
and charge--air pipe section

Operating sequence 1 -- Checking

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Steps 1. Check valve clearance, screw connections and control lever

lubrication in the intervals specified in the maintenance schedule.
Whenever cylinder heads are removed and in the course of overhaul
work, check the individual parts for wear. In case the bearing
clearance is too large, renew the bearing bushes (14).
Blow the oil bores in the control levers (2, 5 and 6) and axles (17 and
18) through with compressed air.
Turn the engine by means of the turning gear, checking whether the
valves constantly follow the movements of the control levers or
whether they got stuck.

Operating sequence 2 -- Removing the rocker arm casing

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), lube oil pump (if available) turned off, cylinder head cover
opened.

Steps 1. Place the receptacle underneath the charge--air pipe section (1),
screw out the screw plug (31) and drain the condensed water from
the charge--air pipe section.
Screw the screw plug together with seal (32) back in, remove the
receptacle.
2. Loosen pipe couplings (15) and move them sidewards onto the
charge--air pipe sections of the neighbouring cylinders, direction of
dislocation (M--N). See Figure 1 .

6624 111.01--04 E 11.97 L 48/60 102/ 06

 Important! When removing the rocker arm casing situated next to
the charge--air cooler (34), screw hexagon head bolts (36) out and
separate the axial compensator (35) from the charge--air pipe section (1a).
See Figure 1 .
3. Remove the lube oil supply pipe (16) and secure it against
penetration of dirt.
4. Fix the control levers (2 and 6) by means of the connecting links
(111.115). See Figure 4 .
5. Loosen six hexagon socket screws (11) and screw them out.
6. Close the cylinder head cover (9). Fasten the suspension device
(111.113) to the rocker arm casing (22) by means of four hexagon
head bolts (20) and suspend in lifting tackle using the rope (33). See
Figure 4 .
▲ Attention! Note the suspension point.
7. Screw pilot rod (034.006) into suspension device.
8. Carefully lift and remove the rocker arm casing, guiding it by means
of the pilot rod.
9. Close the air inlet in the cylinder head (10) by means of the sealing
cover (055.143) so that no foreign particle can fall into the inlet duct.
10. Put complete rocker arm casing down onto wooden support.

Operating sequence 3 -- Attaching the rocker arm casing

Starting condition Control lever fixed by means of connecting links, cylinder head cover
closed, suspension device fastened to rocker arm casing, pilot rod
screwed into suspension device.

Steps 1. Clean the sealing lips on the pipe couplings (15) and check them for
damage, renew pipe couplings if necessary.
2. Clean the contact faces on the cylinder head (10).
3. Suspend the attached suspension device (111.113) in the lifting tackle
by means of the rope (33).
▲ Attention! Note the suspension point. See Figure 4 .
4. Lift the rocker arm casing (22).
5. Clean the supporting face on the rocker arm casing.
Important! When attaching the rocker arm casing which is situated
next to the charge--air cooler (34), also clean the contact face between
charge--air pipe section (1a) and exhaust gas compensator (35).
6. Insert new O--ring seals (29 and 30), which have been lubricated with
acid--free grease, in the groove, taking note that they are not
distorted.
7. Run the rocker arm casing over the cylinder, remove the sealing
cover (055.143) and lower the rocker arm casing carefully onto the
cylinder head, paying attention to the two cylindrical pins (12) in the
cylinder head. See Figure 3 .
Important! When lowering the rocker arm casing, guide it by
means of the pilot rod.
8. Remove the suspension device.
9. Open the cylinder head cover (9).
10. Verify that the thrust pieces of the control levers (2 and 5) are seated
on the thrust cups of the push rods.
11. Remove the connecting links (111.115).
12. Apply MoS2 lubricant to the threads and contact faces of the hexagon
socket screws (11).
13. Screw six hexagon socket screws in, hand--tight, and tighten at the
specified torque (see work card 000.30).

6624 111.01--04 E 11.97 L 48/60 103/ 06

 14. Attach the lube oil supply pipe (16) to the rocker arm casing.
15. Slip the pipe coupling over the parting line, apply MoS2 lubricant to
the threads and contact faces of the hexagon socket screws and
tighten at the specified torque (see work card 000.30). See
Figure 2 .
Important! When attaching the rocker arm casing positioned next
to the charge--air cooler, fasten axial compensator to charge--air pipe sec-
tion. For this purpose, insert hexagon head bolts (36) from the compensa-
tor side, screw them in and tighten them. See Figure 1 .
16. Check the valve clearance (A) on the inlet and exhaust valves, and
readjust it, if necessary -- see operating sequence 4.

1 Charge--air pipe section 35 Axial compensator M-N Displacement of the pipe

15 Pipe coupling 36 Hexagon head bolt coupling
34 Charge--air cooler

Figure 1. Charge--air cooler and charge--air pipe

6624 111.01--04 E 11.97 L 48/60 104/ 06

 1 Charge--air pipe
section
15 Pipe coupling

Figure 2. Pipe coupling between the charge--air pipe sections (sectional drawing)

1 Charge--air pipe
section
2 Control lever
3 Hexagon nut
4 Valve adjusting screw
5 Control lever
6 Control lever
7 Plate
8 Hexagon head bolt
9 Cylinder head bolt
10 Cylinder head
11 Hexagon socket screw
12 Cylindrical pin
13 Spacer ring
14 Bearing bush
15 Pipe coupling
16 Lube oil supply pipe
17 Axle
18 Axle
29 O--ring seal
30 O--ring seal
31 Screw plug
32 Seal

A Valve clearance
B-C Possible displacement
of the control lever (6)
D Bore for fixation

Figure 3. Attached rocker arm casing with control levers and charge--air pipe section

6624 111.01--04 E 11.97 L 48/60 105/ 06

 2 Control lever
6 Control lever
20 Hexagon head bolt
M16x45
21 Hexagon nut M24
22 Rocker arm casing
33 Rope

Figure 4. Rocker arm casing with attached suspension device

Operating sequence 4 -- Adjusting of the valve clearance

Starting condition Engine is cold (all engine parts have the same temperature).

▲ Attention! In case engine has operating temperature, six hours

after shut- down at the earliest.

Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Steps 1. Loosen hexagon nut (3) and screw back valve adjusting screw (4).
2. Push setting gauge (113.139, exhaust valve) or a thickness gauge
from the set of feeler gauges (000.455, inlet valve) between valve
shaft and ball cup.

Valve clearance: Exhaust valve . . . 0.9 mm

Inlet valve . . . . . . 0.2 mm

3. Tighten valve adjusting screw until setting gauge or thickness gauge

fits snugly.
4. With the setting gauge or thickness gauge inserted, hold the valve
adjusting screw and tighten the hexagon nut.

Operating sequence 5 -- Shifting and fixation of the control levers (6) for removal of the exhaust valves

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Steps 1. Screw out the hexagon head bolts (8) and remove the plate (7).
2. Move the control lever (6) from position (B) to position (C), fold it
upwards and secure it against dropping back by means of the tommy
bar (000.264) which is passed through the bore in the control lever
and in the axle (18).

For shifting back, proceed in the reverse order. After shifting back,
tighten the hexagon head bolts (8) at the specified torque (see work
card 000.31). Check the valve clearance, readjust it, if necessary --
see operating sequence 4.

6624 111.01--04 E 11.97 L 48/60 106/ 06

Rocker arm casing with rocker arms
Valve clearance
Removing, attaching, checking 111.01

Purpose of jobs to be done

Impart the required knowledge,

ensure correct execution of work.
Carry out the work in time according to the maintenance schedule,
enable/support economic operation,
prevent operating problems/damage.

Brief description

Rocker arm casings are to be disassembled within the scope of

maintenance and repair work.
The valve clearance is to be determined and, if necessary, to be corrected
at regular intervals.
The work/steps include:
removal of components,
attachment of components,
checking/adjusting of valve clearance.

Safety requirements

- Engine shut--down
- Engine secured against starting
- Operating media system closed/depressurised

Tools/appliances required

Quant Denomination No. Availability

1 Foot board 456.004 Standard
1 Foot board 456.002 Standard
1 Foot board 456.001 Standard
1 Setting gauge 0.9 113.139 Standard
2 Connecting link 111.115 Standard
1 Suspension device 111.113 Standard
1 Sealing cover 055.143 Standard
1 Pilot rod 034.006 Standard
1 Torque wrench 008.029 Standard
1 Torque wrench 008.017 Standard
1 Adapter 12.5x20 001.927 Standard
1 Adapter 25x20 001.924 Standard
1 Adapter 20x12.5 001.923 Standard
1 Adapter 12.5x10 001.922 Standard
1 Extension piece 12.5x250 001.912 Standard

6647 111.01--01 E 05.98 V 48/60 101/ 08

 Quant Denomination No. Availability
1 Cross handle 001.891 Standard
1 Screw driver insert 22x25 001.861 Standard
1 Screw driver insert 8x12.5 001.854 Standard
1 Socket wrench insert 17x12.5 001.754 Standard
1 Ratchet 001.521 Standard
1 Set of feeler gauges 0.2 000.455 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Tommy bar 12 000.264 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Receptacle -- Inventory
1 Grease (acid--free) -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.30 000.31

Technical details

Term Information
Rocker arm casing with cylinder head cover 910 kg
and charge air pipe section

Operating sequence 1 -- Checking

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Steps 1. Check valve clearance, screw connections and control lever

lubrication in the intervals specified in the maintenance schedule.
Whenever cylinder heads are removed and in the course of overhaul
work, check the individual parts for wear. In case the bearing
clearance is too large, renew the bearing bushes (14).
Blow the oil bores in the control levers (2, 5 and 6) and axles (17 and
18) through with compressed air.
Turn the engine by means of the turning gear, checking whether the
valves constantly follow the movements of the control levers or
whether they got stuck.

Operating sequence 2 -- Removing the rocker arm casing

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), lube oil pump (if available) turned off, cylinder head cover
opened.

6647 111.01--01 E 05.98 V 48/60 102/ 08

Steps 1. Place the receptacle underneath the charge-air pipe section (1),
screw out the screw plug (31) and drain the condensed water from
the charge-air pipe section.
Screw the screw plug together with seal (32) back in, remove the
receptacle.
2. Loosen pipe couplings (15) and move them sidewards onto the
charge-air pipe sections of the neighbouring cylinders, direction of
dislocation (M-N). See Figure 1 .
Important! When removing the rocker arm casing situated next to
the charge-air cooler (35), screw hexagon head bolts (37) out and
separate the axial compensator (36) from the charge-air pipe section (1a).
See Figure 1 .
3. Remove the lube oil supply pipe (16) and secure it against
penetration of dirt.
4. Fix the control levers (2 and 6) by means of the connecting links
(111.115). See Figure 4 .
5. Loosen six hexagon socket screws (11) and screw them out.
6. Close the cylinder head cover (9). Fasten the suspension device
(111.113) to the rocker arm casing (22) by means of four hexagon
head bolts (20) and suspend in lifting tackle using the rope (33). See
Figure 4 .
▲ Attention! Note the suspension point.
7. Screw pilot rod (034.006) into suspension device.
8. Carefully lift and remove the rocker arm casing, guiding it by means
of the pilot rod.
9. Close the air inlet in the cylinder head (10) by means of the sealing
cover (055.143) so that no foreign particle can fall into the inlet duct.
10. Put complete rocker arm casing down onto wooden support.
▲ Achtung! If further work is done on the cylinder (removal of the
cylinder head, removal of the piston and cylinder liner) a foot board
(456.001, 456.002 - last cylinder of B-bank, 456.004 - A1 cylinder with
turbocharger at free engine end) is to be inserted between the gal-
lery supports (34). See Figure 5 .

Operating sequence 3 -- Attaching the rocker arm casing

Starting condition Control lever fixed by means of connecting links, cylinder head cover
closed, suspension device fastened to rocker arm casing, pilot rod
screwed into suspension device.

Steps 1. Clean the sealing lips on the pipe couplings (15) and check them for
damage, renew pipe couplings if necessary.
2. Clean the contact faces on the cylinder head (10).
3. Suspend the attached suspension device (111.113) in the lifting tackle
by means of the rope (33).
▲ Attention! Note the suspension point. See Figure 4 .
4. Lift the rocker arm casing (22).
5. Clean the supporting face on the rocker arm casing.
Important! When attaching the rocker arm casing which is situated
next to the charge-air cooler (35), also clean the contact face between
charge-air pipe section (1a) and exhaust gas compensator (36).
6. Insert new O-ring seals (29 and 30), which have been lubricated with
acid-free grease, in the groove, taking note that they are not
distorted.

6647 111.01--01 E 05.98 V 48/60 103/ 08

 7. Run the rocker arm casing over the cylinder, remove the sealing
cover (055.143) and lower the rocker arm casing carefully onto the
cylinder head, paying attention to the two cylindrical pins (12) in the
cylinder head. See Figure 3 .
Important! When lowering the rocker arm casing, guide it by
means of the pilot rod.
8. Remove the suspension device.
9. Open the cylinder head cover (9).
10. Verify that the thrust pieces of the control levers (2 and 5) are seated
on the thrust cups of the push rods.
11. Remove the connecting links (111.115).
12. Apply MoS2 lubricant to the threads and contact faces of the hexagon
socket screws (11).
13. Screw six hexagon socket screws in, hand-tight, and tighten at the
specified torque (see work card 000.30).
14. Attach the lube oil supply pipe (16) to the rocker arm casing.
15. Slip the pipe coupling over the parting line, apply MoS2 lubricant to
the threads and contact faces of the hexagon socket screws and
tighten at the specified torque (see work card 000.30). See
Figure 2 .
Important! When attaching the rocker arm casing positioned next
to the charge-air cooler, fasten axial compensator to charge-air pipe sec-
tion. For this purpose, insert hexagon head bolts (37) from the compensa-
tor side, screw them in and tighten them. See Figure 1 .
16. Check the valve clearance (A) on the inlet and exhaust valves, and
readjust it, if necessary - see operating sequence 4.

Operating sequence 4 -- Adjusting of the valve clearance

Starting condition Engine is cold (all engine parts have the same temperature).

▲ Attention! In case engine has operating temperature, six hours

after shut-down at the earliest.

Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Steps 1. Loosen hexagon nut (3) and screw back valve adjusting screw (4).
2. Push setting gauge (113.139, exhaust valve) or a thickness gauge
from the set of feeler gauges (000.455, inlet valve) between valve
shaft and ball cup.

Valve clearance: Exhaust valve . . . 0.9 mm

Inlet valve . . . . . . 0.2 mm

3. Tighten valve adjusting screw until setting gauge or thickness gauge

fits snugly.
4. With the setting gauge or thickness gauge inserted, hold the valve
adjusting screw and tighten the hexagon nut.

Operating sequence 5 -- Shifting and fixation of the control levers (6) for removal of the exhaust valves

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Steps 1. Screw out the hexagon head bolts (8) and remove the disc (7).
2. Move the control lever (6) from position (B) to position (C), fold it
upwards and secure it against dropping back by means of the tommy

6647 111.01--01 E 05.98 V 48/60 104/ 08

 bar (000.264) which is passed through the bore in the control lever
and in the axle (18).

For shifting back, proceed in the reverse order. After shifting back,
tighten the hexagon head bolts (8) at the specified torque (see work
card 000.31). Check the valve clearance, readjust it, if necessary -
see operating sequence 4.

1 Charge-air pipe section 36 Axial compensator M-N Displacement of the pipe

15 Pipe coupling 37 Hexagon head bolt coupling
35 Charge-air cooler

Bild 1. Charge-air cooler and charge-air pipe

6647 111.01--01 E 05.98 V 48/60 105/ 08

 1 Charge-air pipe section
15 Pipe coupling

Bild 2. Pipe coupling between the charge-air pipe sections (sectional drawing)

1 Charge-air pipe section

2 Control lever
3 Hexagon nut
4 Valve adjusting screw
5 Control lever
6 Control lever
7 Disc
8 Hexagon head bolt
9 Cylinder head bolt
10 Cylinder head
11 Hexagon socket screw
12 Cylindrical pin
13 Spacer ring
14 Bearing bush
15 Pipe coupling
16 Lube oil supply pipe
17 Axle
18 Axle
29 O-ring seal
30 O-ring seal
31 Screw plug
32 Seal

A Valve clearance
B-C Possible displacement
of the control lever (6)
D Bore for fixation

Bild 3. Attached rocker arm casing with control levers and charge-air pipe section (Figure shows in-line engine)

6647 111.01--01 E 05.98 V 48/60 106/ 08

 2 Control lever
6 Control lever
20 Hexagon head bolt
M16x45
21 Hexagon nut M24
22 Rocker arm casing
33 Rope

Bild 4. Rocker arm casing with attached suspension device

6647 111.01--01 E 05.98 V 48/60 107/ 08

 34 Gallery

Bild 5. Gallery with foot board laid in

6647 111.01--01 E 05.98 V 48/60 108/ 08

Rocker arm casing with control levers
Valve clearance
Removing, attaching, checking 111.01

Purpose of jobs to be done

Impart the required knowledge,

ensure correct execution of work.
Carry out the work in time according to the maintenance schedule,
enable/support economic operation,
prevent operating problems/damage.

Brief description

Rocker arm casings are to be disassembled within the scope of

maintenance and repair work.
The valve clearance is to be determined and, if necessary, to be corrected
in regular intervals.
The work/steps include:
removal of components,
attachment of components,
checking/adjusting of valve clearance.

Safety requirements

- Engine shut--down
- Engine secured against starting
- Operating media system closed/depressurized

Tools/appliances required

Quant Denomination No. Availability

1 Setting gauge 0.8 113.130 Standard
1 Connecting link 111.111 Standard
1 Suspension device 111.110 Standard
1 Sealing cover 055.148 Standard
1 Pilot rod 034.006 Standard
1 Torque wrench 008.029 Standard
1 Torque wrench 008.017 Standard
1 Adapter 12.5x20 001.927 Standard
1 Adapter 20x12.5 001.923 Standard
1 Adapter 12.5x10 001.922 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Cross handle 001.891 Standard
1 Screw driver insert 19x20 001.868 Standard
1 Screw driver insert 8x12.5 001.854 Standard
1 Ratchet 001.521 Standard

6621 111.01--03 E 02.98 L 40/54 101/ 07

 Quant Denomination No. Availability
1 Set of feeler gauges 0.2 000.455 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Tommy bar 12 000.264 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Grease (acid--free) -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.30 000.31

Technical details

Term Information
Rocker arm casing with cylinder head cover 485 kg
and charge--air pipe section

Operating sequence 1 -- Checking

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Steps 1. Check valve clearance, screw connections and control lever

lubrication in the intervals specified in the maintenance schedule.
Whenever cylinder heads are removed and in the course of overhaul
work, check the individual parts for wear. In case the bearing
clearance is too large, renew the bearing bushes (11).
Blow the oil bores in the control levers (1, 4 and 8) and axles (13 and
15) through with compressed air.
Turn the engine by means of the turning gear, checking whether the
valves constantly follow the movements of the control levers or
whether they got stuck.

Operating sequence 2 -- Removing the rocker arm casing

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), lube oil pump (if available) turned off, cylinder head cover
opened.

Steps 1. Loosen pipe couplings (12) and shift them sideward onto the longer
end of the charge--air pipe sections, direction of dislocation (M--N).
See Figure 1 and 2 .
Important! When removing the rocker arm casing situated next to
the charge--air cooler (24), screw hexagon head bolts (28) out and
separate the axial compensator (27) from the charge--air pipe section
(26a). See Figure 1 .

6621 111.01--03 E 02.98 L 40/54 102/ 07

 2. Remove the lube oil supply pipe (14) and secure it against
penetration of dirt.
3. Fix the control levers (1 and 4) by means of the connecting links
(111.111). See Figure 4 .
4. Loosen six hexagon socket screws (9) and screw them out.
5. Close the cylinder head cover (6). Fasten the suspension device
(111.110) to the rocker arm casing (26) by means of four hexagon
head bolts (16 and 23) and suspend in lifting tackle using the rope
(33). See Figure 4 .
6. Screw pilot rod (034.006) into suspension device.
7. Carefully lift and remove the rocker arm casing, guiding it by means
of the pilot rod.
8. Close the air inlet in the cylinder head (7) by means of the sealing
cover (055.148) so that no foreign particle can fall into the inlet duct.
9. Put complete rocker arm casing down onto wooden support.

Operating sequence 3 -- Attaching the rocker arm casing

Starting condition Control lever fixed by means of connecting links, cylinder head cover
closed, suspension device fastened to rocker arm casing, pilot rod
screwed into suspension device.

Steps 1. Clean the sealing lips on the pipe couplings (12) and check them for
damage, renew pipe couplings if necessary.
2. Clean the contact faces on the cylinder head (7).
3. Suspend the attached suspension device (111.110) in the lifting tackle
by means of the rope (33).
4. Lift the rocker arm casing (26).
5. Clean the supporting face on the rocker arm casing.
Important! When attaching the rocker arm casing which is situated
next to the charge--air cooler (24), also clean the contact face between
charge--air pipe section (26a) and exhaust gas compensator (27).
6. Insert new O--ring seals (30 and 32), which have been lubricated with
acid--free grease, in the groove, taking note that they are not
distorted.
7. Run the rocker arm casing over the cylinder, remove the sealing
cover (055.148) and lower the rocker arm casing carefully onto the
cylinder head, paying attention to the two cylindrical pins (31) in the
cylinder head. See Figure 3 .
Important! When lowering the rocker arm casing, guide it by
means of the pilot rod.
8. Remove the suspension device.
9. Open the cylinder head cover (6).
10. Verify that the thrust pieces of the control levers (1 and 8) are seated
on the thrust cups of the push rods.
11. Remove the connecting links (111.111).
12. Apply MoS2 lubricant to the threads and contact faces of the hexagon
socket screws (9).
13. Screw six hexagon socket screws in, hand--tight, and tighten at the
specified torque (see work card 000.30).
14. Attach the lube oil supply pipe (14) to the rocker arm casing.
15. Slip the pipe coupling over the parting line, align pipe coupling, apply
MoS2 lubricant to the threads and contact faces of the hexagon
socket screws and tighten at the specified torque (see work card
000.30). See Figure 1 , 2 und 5 .
Important! When attaching the rocker arm casing positioned next
to the charge--air cooler, fasten axial compensator to charge--air pipe sec-

6621 111.01--03 E 02.98 L 40/54 103/ 07

 tion. For this purpose, insert hexagon head bolts (28) from the compensa-
tor side, screw them in and tighten them. See Figure 1 .
16. Check the valve clearance (A) on the inlet and exhaust valves, and
readjust it, if necessary -- see operating sequence 4.

Operating sequence 4 -- Adjusting of the valve clearance

Starting condition Engine is cold (all engine parts have the same temperature).

▲ Attention! In case engine has operating temperature, six hours

after shut- down at the earliest.

Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Steps 1. Loosen hexagon nut (2) and screw back valve adjusting screw (4).
2. Push setting gauge (113.130, exhaust valve) or a thickness gauge
from the set of feeler gauges (000.455, inlet valve) between valve
shaft and ball cup.

Valve clearance: Exhaust valve . . . 0.8 mm

Inlet valve . . . . . . 0.2 mm

3. Tighten valve adjusting screw until setting gauge or thickness gauge

fits snugly.
4. With the setting gauge or thickness gauge inserted, hold the valve
adjusting screw and tighten the hexagon nut.

Operating sequence 5 -- Shifting and fixation of the control levers (4) for removal of the exhaust valves

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Steps 1. Screw out the hexagon head bolts (29) and remove the plate (5).
2. Move the control lever (4) from position (B) to position (C), fold it
upwards and secure it against dropping back by means of the tommy
bar (000.264) which is passed through the bore in the control lever
and in the axle (15).

For shifting back, proceed in the reverse order. After shifting back,
tighten the hexagon head bolts (29) at the specified torque (see work
card 000.31). Check the valve clearance, readjust it, if necessary --
see operating sequence 4.

6621 111.01--03 E 02.98 L 40/54 104/ 07

 12 Pipe coupling 27 Axial compensator
24 Charge--air cooler 28 Hexagon head bolt
26 Rocker arm casing with integrated charge--air
pipe section M-N Displacement of the pipe coupling

Figure 1. Charge--air cooler and charge--air pipe

6621 111.01--03 E 02.98 L 40/54 105/ 07

 12 Pipe coupling
26 Rocker arm casing
with integrated
charge--air pipe section

M-N Displacement of the

pipe coupling

Figure 2. Pipe coupling between the charge--air pipe sections (sectional drawing)

1 Control lever
2 Hexagon nut
3 Valve adjusting screw
4 Control lever
5 Plate
6 Cylinder head cover
7 Cylinder head
8 Control lever
9 Hexagon socket screw
10 Spacer ring
11 Bearing bush
12 Pipe coupling
13 Axle
14 Lube oil supply pipe
15 Axle
26 Rocker arm casing
with integrated
charge--air pipe section
29 Hexagon head bolt
30 O--ring seal
31 Cylindrical pin
32 O--ring seal

A Valve clearance
B-C Possible displacement
of the control lever (4)
D Bore for fixation

Figure 3. Attached rocker arm casing with integrated charge--air pipe section and control levers

6621 111.01--03 E 02.98 L 40/54 106/ 07

 1 Control lever
4 Control lever
16 Hexagon head bolt
M16x160
17 Hexagon nut M24
23 Hexagon head bolt
M16x40
26 Rocker arm casing
with integrated
charge--air pipe section
33 Rope

Figure 4. Rocker arm casing with attached suspension device

12 Pipe coupling
26 Rocker arm casing
with integrated
charge--air pipe section

Figure 5. Position of screwed connection for pipe coupling

6621 111.01--03 E 02.98 L 40/54 107/ 07

Rocker arm casing with rocker arms
Valve clearance
Removing, attaching, checking 111.01

Purpose of jobs to be done

Impart the required knowledge,

ensure correct execution of work.
Carry out the work in time according to the maintenance schedule,
enable/support economic operation,
prevent operating problems/damage.

Brief description

Rocker arm casings are to be disassembled within the scope of

maintenance and repair work.
The work/steps include:
removal of components,
attachment of components,
checking/adjusting of valve clearance.

Safety requirements

- Engine shut--down
- Engine secured against starting
- Operating media system closed/depressurised

Tools/appliances required

Quant Denomination No. Availability

1 Setting gauge 0.8 113.130 Standard
1 Connecting link 111.111 Standard
1 Suspension device 111.110 Standard
1 Sealing cover 055.148 Standard
1 Pilot rod 034.006 Standard
1 Torque wrench 008.029 Standard
1 Torque wrench 008.017 Standard
1 Adapter 12.5x20 001.927 Standard
1 Adapter 20x12.5 001.923 Standard
1 Adapter 12.5x10 001.922 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Cross handle 001.891 Standard
1 Screw driver insert 19x20 001.868 Standard
1 Screw driver insert 8x12.5 001.854 Standard
1 Ratchet 001.521 Standard
1 Set of feeler gauges 0.2 000.455 Standard

6621 111.01--04 E 05.98 L 40/54 101/ 07

 Quant Denomination No. Availability
1 Thickness gauges 0.05--1 000.451 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Grease (acid--free) -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.30

Technical details

Term Information
Rocker arm casing with cylinder head cover 485 kg
and charge air pipe section

Operating sequence 1 -- Checking

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Arbeitsschritte 1. Check valve clearance, screw connections and control lever lubrication
in the intervals specified in the maintenance schedule.
Whenever cylinder heads are removed and in the course of overhaul
work, check the individual parts for wear. In case the bearing clea-
rance is too large, renew the bearing bushes (11).
Blow the oil bores in the control levers (1, 4 and 8) and axles (13 and
15) through with compressed air.
Turn the engine by means of the turning gear, checking whether the
valves constantly follow the movements of the control levers or whether
they got stuck.

Operating sequence 2 -- Removing the rocker arm casing

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), lube oil pump (if available) turned off, cylinder head cover
opened.

Arbeitsschritte 1. Loosen pipe couplings (12) and shift them sideward onto the longer
end of the charge--air pipe sections, direction of dislocation (M--N).
See Figure 1 and 2 .
Important! When removing the rocker arm casing situated next to
the charge--air cooler (24), screw hexagon head bolts (28) out and
separate the axial compensator (27) from the charge--air pipe section
(26a). See Figure 1 .
2. Remove the lube oil supply pipe (14) and secure it against penetration
of dirt.

6621 111.01--04 E 05.98 L 40/54 102/ 07

 3. Fix the control levers (1 and 4) by means of the connecting links
(111.111). See Figure 4 .
4. Loosen six hexagon socket screws (9) and screw them out.
5. Close the cylinder head cover (6). Fasten the suspension device
(111.110) to the rocker arm casing (26) by means of four hexagon head
bolts (16 and 23) and suspend in lifting tackle using the rope (33). See
Figure 4 .
6. Screw pilot rod (034.006) into suspension device.
7. Carefully lift and remove the rocker arm casing, guiding it by means of
the pilot rod.
8. Close the air inlet in the cylinder head (7) by means of the sealing co-
ver (055.148) so that no foreign particle can fall into the inlet duct.
9. Put complete rocker arm casing down onto wooden support.

Operating sequence 3 -- Attaching the rocker arm casing

Starting condition Control lever fixed by means of connecting links, cylinder head cover
closed, suspension device fastened to rocker arm casing, pilot rod
screwed into suspension device.

Arbeitsschritte 1. Clean the sealing lips on the pipe couplings (12) and check them for
damage, renew pipe couplings if necessary.
2. Clean the contact faces on the cylinder head (7).
3. Suspend the attached suspension device (111.110) in the lifting tackle
by means of the rope (33).
4. Lift the rocker arm casing (26).
5. Clean the supporting face on the rocker arm casing.
Important! When attaching the rocker arm casing which is situated
next to the charge--air cooler (24), also clean the contact face between
charge--air pipe section (26a) and exhaust gas compensator (27).
6. Insert new O--ring seals (30 and 32), which have been lubricated with
acid--free grease, in the groove, taking note that they are not distorted.
7. Run the rocker arm casing over the cylinder, remove the sealing cover
(055.148) and lower the rocker arm casing carefully onto the cylinder
head, paying attention to the two cylindrical pins (31) in the cylinder
head. See Figure 3 .
Important! When lowering the rocker arm casing, guide it by
means of the pilot rod.
8. Remove the suspension device.
9. Open the cylinder head cover (6).
10.Verify that the thrust pieces of the control levers (1 and 8) are seated
on the thrust cups of the push rods.
11. Remove the connecting links (111.111).
12.Apply MoS2 lubricant to the threads and contact faces of the hexagon
socket screws (9).
13.Screw six hexagon socket screws in, hand--tight, and tighten at the
specified torque (see work card 000.30).
14.Attach the lube oil supply pipe (14) to the rocker arm casing.
15.Slip the pipe coupling over the parting line, align pipe coupling, apply
MoS2 lubricant to the threads and contact faces of the hexagon socket
screws and tighten at the specified torque (see work card 000.30). See
Figure 1 , 2 und 5 .
Important! When attaching the rocker arm casing positioned next
to the charge--air cooler, fasten axial compensator to charge--air pipe sec-
tion. For this purpose, insert hexagon head bolts (28) from the compensa-
tor side, screw them in and tighten them. See Figure 1 .
16.Check the valve clearance (A) on the inlet and exhaust valves, and re-
adjust it, if necessary -- see operating sequence 4.

6621 111.01--04 E 05.98 L 40/54 103/ 07

Operating sequence 4 -- Adjusting of the valve clearance

Starting condition Engine is cold (all engine parts have the same temperature).

▲ Attention! In case engine has operating temperature, six hours

after shut- down at the earliest.

Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Arbeitsschritte 1. Loosen hexagon nut (2) and screw back valve adjusting screw (4).
2. Push setting gauge (113.130, exhaust valve) or a thickness gauge from
the set of feeler gauges (000.455, inlet valve) between valve shaft and
ball cup.

Valve clearance: Exhaust valve .... 0.8 mm

Inlet valve ........... 0.2 mm

3. Tighten valve adjusting screw until setting gauge or thickness gauge

fits snugly.
4. With the setting gauge or thickness gauge inserted, hold the valve ad-
justing screw and tighten the hexagon nut.

6621 111.01--04 E 05.98 L 40/54 104/ 07

 12 Pipe coupling 27 Axial compensator
24 Charge--air cooler 28 Hexagon head bolt
26 Rocker arm casing with integrated charge--air
pipe section M-N Displacement of the pipe coupling

Bild 1. Charge--air cooler and charge--air pipe

6621 111.01--04 E 05.98 L 40/54 105/ 07

 12 Pipe coupling
26 Rocker arm casing
with integrated
charge--air pipe section

M-N Displacement of the

pipe coupling

Bild 2. Pipe coupling between the charge--air pipe sections (sectional drawing)

1 Control lever
2 Hexagon nut
3 Valve adjusting screw
4 Control lever
6 Cylinder head cover
7 Cylinder head
8 Control lever
9 Hexagon socket screw
10 Spacer ring
11 Bearing bush
12 Pipe coupling
13 Axle
14 Lube oil supply pipe
15 Axle
26 Rocker arm casing
with integrated
charge--air pipe section
30 O--ring seal
31 Cylindrical pin
32 O--ring seal

A Valve clearance

Bild 3. Attached rocker arm casing with integrated charge--air pipe section and control levers

6621 111.01--04 E 05.98 L 40/54 106/ 07

 1 Control lever
4 Control lever
16 Hexagon head bolt
M16x160
17 Hexagon nut M24
23 Hexagon head bolt
M16x40
26 Rocker arm casing
with integrated
charge--air pipe section
33 Rope

Bild 4. Rocker arm casing with attached suspension device

12 Pipe coupling
26 Rocker arm casing
with integrated
charge--air pipe section

Bild 5. Position of screwed connection for pipe coupling

6621 111.01--04 E 05.98 L 40/54 107/ 07