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MAK M20, Operating Instructions Manual

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MAK M20 Operating Instructions Manual Download Page 293

Piston

Maintenance / Reassembly

 

A5.05. 

02.10.01.01

M20

en / 17.06.1998

IB004785

1/3

02

Ĺ

See also:

02.04.02.nn, 02.07.01.nn

Spare parts list:

B1.05.02.2.2601

Time requirement:

1 Pers./ 0,50 h

Personnel qualification: skilled engine hand

----------------------------------------------------------------------------------------------------------------------

Operating medium:

Heavy fuel and distillate fuel

Tools:

Mounting/extraction device for pistons

W1 

1.9080-012

Cylinder liner holder

W2

2.9217 A

Piston assembly ring

W3 

2.9220 B

Piston insertion device (sheet metal sleeve)

W4

259220 A

Auxiliary material:

Molykote paste "G-Rapid Plus“ **

** or a product of equal standard

Note:

The cylinder liner must always be secured by means of the cylinder liner holder (

fig. 3

/W2) 

to prevent the cylinder liner from coming loose when turning the engine (without 
dismantled cylinder head)!
Pay attention to the cylinder number mark on the bottom end.

Drive in the engine according to the driving-in regulation (

A3.10.01.nn

) after fitting a new 

piston/new piston rings!

Sequence of operations:

1.

Replace the piston rings as required.

2.

Fit the new piston rings with the ring joints in a longitudinal direction to the engine 
alternately arranged opposite each other! Lubricate the piston rings and pistons well on 
the outside.  

Summary of Contents for M20

Page 1: ...General Engine operating instructions Type M20 General Engine operating instructions A0 M20 en 31 10 2001 AA021665 1 1...

Page 2: ...Records A1 10 Operating instructions A3 Table of contents A3 01 Introduction A3 02 Safety instructions A3 03 Instructions for heavy fuel operation A3 04 Initial operation A3 05 Operational supervisio...

Page 3: ...chapters the technical personnel is able to maintain the engine in such a manner that regarding its output reliability economy and service life optimum operating results can be achieved If you need f...

Page 4: ...ird parties all safety regulations which are marked with the symbol have to be observed in all cases Technical instructions and or operations to be strictly observed are marked in the documents with a...

Page 5: ...Technical engine data A1 M20 M601C en 31 10 2001 AA000103 1 1 Technical engine data...

Page 6: ...Governor data A1 04 en 18 02 2000 AA000097 1 1 Governor data not installed on CD Rom...

Page 7: ...4 5 bar at rated engine speed Cooling water min feed head at pump inlet 4 m water gauge 2 5 5 0 bar Fuel at injection pump inlet Distillate fuel 3 0 5 0 bar Heavy fuel 4 0 5 0 bar Injection nozzle op...

Page 8: ...Fuel before injection pumps see diagram 1 Permissible injection viscosity must be set on the viscothermic device to enable a kinematic viscosity of 10 12 mm2 s cSt to be reached before the injection p...

Page 9: ...Torsional vibration calculation A1 09 en 16 11 1999 AA020354 1 1 Torsional vibration calculation not installed on CD Rom...

Page 10: ...Acceptance Test Records A1 10 en 16 11 1999 AA000095 1 1 Acceptance test records not installed on CD Rom...

Page 11: ...Operating instructions A3 M20 M601C en 31 10 2001 AA000108 1 1 Operating instructions...

Page 12: ...05 07 00 Initial operation Lubricating oil system A3 05 08 00 Initial operation Cooling water system A3 05 09 00 Initial operation Starting air system A3 05 11 00 Initial operation General performance...

Page 13: ...ice stopping A3 07 18 01 Decommissioning Decommissioning Stopping A3 07 18 02 Danger of frost Engine A3 08 00 Danger of frost Antifreeze protection A3 08 01 00 Preservation Engine A3 09 00 00 Preserva...

Page 14: ...A020023 3 3 Emergency operation With a defective turbocharger A3 12 01 02 Emergency operation With a defective turbocharger A3 12 01 02 Emergency operation Operational misfire A3 12 02 00 Emergency op...

Page 15: ...a restrictor on the injection pump racks Unless otherwise indicated our information always refers to the maximum continuous power and if this is unknown to the operator he should make inquiries to th...

Page 16: ...e from the operating instructions and explanations should be noted down in the instructions After commissioning the engine all important data and work should be recorded in either the engine log book...

Page 17: ...evention of accident regulations of the particular employee s liability insurance association or equivalent institution are to be observed for example Observe all fire warning and fire fighting proced...

Page 18: ...ection guards must be in operation position and operative Hearing protection must be worn Before putting the engine into operation ensure that there is no danger to persons by the starting engine plan...

Page 19: ...stated below are to be stringently observed as the readiness for service and operational reliability of the engine system during high extremes of use requires perfect fuel and depends upon optimal con...

Page 20: ...er increased The distinguishing properties of such residual oils are their high viscosity and their density as well as the increased portion of chemical compounds with sulphur vanadium sodium and cat...

Page 21: ...tank DT2 Diesel oil intermediate tank HF1 Fuel fine filter duplex filter HF2 Fuel primary filter duplex filter HF3 Fuel coarse filter HF4 Self cleaning fuel filter HH1 Heavy fuel final preheater HH3 H...

Page 22: ...vided for HFO operation and each one has been designed for a full load operation of 24 hours Connect the tanks alternately irrespective of the fuel consumed so as to obtain the best settling effect po...

Page 23: ...is in order it will always be filled to the overflow level No formation of water condensation Daily de sludging is important A temperature level between 80 95 C should be maintained 6 Fuel pressure pu...

Page 24: ...t the steam outlet to ensure sufficient heating is possible Attention Fuel temperature before engine intake 150 C 11 Fine filter HF1 The fine filter protects the fuel injection system and removes soli...

Page 25: ...selection of the suitable lube oil and the limit values are observed according to the operating media A4 05 08 nn The lube oil has important functions in engine operation as e g Replace metallic fric...

Page 26: ...5 C The maximum utilization of the separator is to be 20 of the rated capacity see the rating plate of the separator or pump 2 Oil level control Check the oil level daily Top up with fresh oil if 20 o...

Page 27: ...015 2 4 Principal diagrammatic view of the lubricating oil circulatory system LF1 Duplex lube oil filter LF2 Lube oil automatic filter LF4 Suction strainer LH1 Lube oil cooler LH2 Lube oil preheater L...

Page 28: ...iner clogged is the flushing quantity of the automatic filter too large 3 3 Lube oil Automatic filter LF2 flushing with oil or compressed air The flushing frequency results from the quantity of dirt p...

Page 29: ...for damage If the filter has various cartridges one damaged cartridge means a malfunction of the entire filter Renew damaged cartridges See the servicing instructions in the documents from the manufac...

Page 30: ...Initial operation Engine A3 05 00 en 14 02 2001 BA000022 1 1 Initial operation...

Page 31: ...2 01 nn Ensure that all cocks and valves are in the correct position Vent the fuel system Use auxilary fuel pump In case the day tank is at a higher level and the pump has a bypass line open the stop...

Page 32: ...the standby or pre lubricating pump and Vent the entire lubricating oil system Check all flanges and threaded connections in the system for tight connection Check the lubrication of the following poi...

Page 33: ...be cooled Unless connected to a permanent venting arrangement all components and pipes belonging to the system must be consecutively vented The vent pipe from the engine to the header tank generally...

Page 34: ...crankcase oil mist detector When the shut off valve is closed the air supply of the emergency stop cylinders at the injection pumps and at the crankcase oil mist detector are shut off in addition to...

Page 35: ...t the charge air manifold for free passage When the engine is cold a small amount of water may come out as a result of condensation Note If the amount of water is large the cause must be traced Do not...

Page 36: ...nality of the total system If alarm and safety devices as well as the switch device for the speed are disconnected all functions which are normally recorded automatically must be checked or performed...

Page 37: ...001 BA000636 2 3 H11 Wrong start H12 Start locking H13 Run from remote control R1 Speed adjustment S11 H9 Start S12 H10 Stop S13 Change over switch 1 Engine 2 Remote control S14 Lamps test S15 Change...

Page 38: ...fore starting the engine For operating pressure see A1 05 Adjust speed slightly higher than nmin at the speed switch R1 Start engine manually at the start solenoid or main start up valve 20 Keep the s...

Page 39: ...so revolution counters are switched off normally all functions are automatically monitored manually checked or executed Starting operating panel in the gauge board Switch position selector in the boar...

Page 40: ...starting the cold engine with heavy fuel are very restricted A more viscous fuel will make ignition more difficult in addition to the above thermal influences Incomplete combustion heavy deposits in t...

Page 41: ...ter a correspondingly shorter period The engine is started at a nominal speed When working temperature has been reached load may be added as described in operating media increasing the load of a warme...

Page 42: ...d by DIN ISO is possible The diagram shows guide values for load stages in engine rating depending on the mean effective piston pressure of rated output on the example of a 6 M20 engine with a full lo...

Page 43: ...ng to the duty required and its frequency The engine should always reach working temperature after every start particularly in short test runs Running the engine for a short time only will produce sul...

Page 44: ...Operational supervision Engine A3 06 00 en 15 02 2001 BA000058 1 1 Operational supervision...

Page 45: ...low 10 C as otherwise the permissible nominal ignition pressure is exceeded It can be run at full power if the intake air is pre warmed or mixed with machine air so that the temperature at the compres...

Page 46: ...The result of such a measurement has therefore only a restricted meaning which can lead to false conclusions For this reason in order to attain the same temperature readings it is not permissible by a...

Page 47: ...possible to assess the the operational behaviour sufficiently and reliably and a reliable indication if any shortcomings is ensured The exhaust gas temperatures after the turbocharger are used for th...

Page 48: ...gressively lessen the performance of the compressor For cleaning the compressor see book C Daily cleaning of the compressor end For periodic washing of the turbine end see maintenance A5 05 06 Charge...

Page 49: ...ween the pump foot and the control edge of the pump element so that every pump can be used on every cylinder As the camshaft is assembled from individual sections per cylinder there are very small dif...

Page 50: ...ers are influenced to a varying degree by turbulence influences in the exhaust manifold Any deviations among the cylinders within the scope of the values given in the acceptance test certificate are p...

Page 51: ...ambient conditions type of fuel fouled charger etc Also refer to A3 11 18 nn Reduce the engine power if the maximum permissible temperature after the turbine is exceeded during operation with Heavy fu...

Page 52: ...he measuring device must be stored with care and the manufacturer s instructions observed Operating instructions for the indicator refer to manual C Draw indicator diagrams at full load if possible Bl...

Page 53: ...anent drain separators of the air charge manifold Note Manual correction of the air charge temperature control is only necessary in special cases If there is water in the air charge manifold raise the...

Page 54: ...hermometers are heavily influenced by the whirling effects in the exhaust collector pipe Any deviations among the cylinders within the scope of the values mentioned on the acceptance test re cords or...

Page 55: ...type of fuel fouled charger etc see A3 11 18 nn Reduce the engine output if the maximum permissible temperature after the turbine is exceeding in operation heavy fuel texh gas temp after turb max 400...

Page 56: ...commended to check the engine by indicator cards at regular intervals Only proper measuring instruments will make an exact measurement possible The indicator must therefore be carefully stored and the...

Page 57: ...anent drain of the charge air manifold Note A manual correction of the charge air temperature control is only necessary in speci al cases If there is water in the charge air manifold raise the charge...

Page 58: ...g on heavy fuel change over to distillate fuel in time See Changing the Type of Fuel A3 06 07 nn Changing over to distillate fuel may be necessary after lengthy service at partial load operation see P...

Page 59: ...hree way selector cock for heavy fuel distillate fuel The three way cock in the return line from the engine to the heavy fuel day tank and or to the mixing tank has to remain in its position so that t...

Page 60: ...en 16 12 1997 BA000078 1 1 Lubricating oil system Check daily the levels in the Lube oil sump tank Base frame Oil sump Monitor the lubricating oil pressure temperature For Pressure Temperature indicat...

Page 61: ...pressure temperature indications see A1 05 of the operation media for Temperatures of the Operating Media A1 06 as well as Acceptance Test Records A1 10 If for any reason whatsoever temperatures are t...

Page 62: ...piston and cylinder liner Restrictions for partial load operation on heavy fuel cannot be avoided for some special ships such as supply vessels diver base vessels etc and for generators if the low lo...

Page 63: ...entire operating range including partial load Differing rules may be applicable at partial load to protect the entire engine during for instance turbocharger failures See A3 12 00 If a new engine is f...

Page 64: ...Removal from operation Engine A3 07 00 en 16 02 2001 BA000094 1 1 Removal from operation...

Page 65: ...ed revolution head at the mechanic electric governor to nmin Stop the engine by manual operation of the starter magnetic valve Close the isolating valves on the starting air bottles and fuel day tank...

Page 66: ...ing pump If the engine is preheated by other engines in operation open the isolating valves In heavy fuel distillate fuel operation running of the fuel system must continue as when operating the engin...

Page 67: ...rcooling Direct operation at the main engine Disconnect engine from the mains Switch main power switch to Off Engine stop control panel in manometer board Switch change over switch S13 to 1 Engine Adj...

Page 68: ...00 BA000630 2 4 H11 Wrong start H12 Start locking H13 Run from remote control R1 Speed adjustment S11 H9 Start S12 H10 Stop S13 Change over switch 1 Engine 2 Remote control S14 Lamps test S15 Change o...

Page 69: ...circulations and keep the engine at operating temperature or preheating temperature see A3 05 18 nn according to the interruption period and type of fuel In heavy oil operation a change over to disti...

Page 70: ...ventilation for engine room only if required to make cooling off of the engine more difficult Before a long term operation stop e g down time up to 4 weeks heavy oil engines must be changed over to d...

Page 71: ...Danger of frost Engine A3 08 00 en 16 02 2001 BA000106 1 1 Danger of frost...

Page 72: ...solution with protection against corrosion see A4 05 09 nn Attention The concentration level of the antifreeze solution is to be choosen in such a way that a sufficient degree of protection is ensured...

Page 73: ...mble work is always to be carried out or monitored by by skilled mashine personnel Short term preservation A short tern preservation A3 09 01 nn is to be carried out for a shut down of the engine with...

Page 74: ...Ensure sufficient ventilation below the covering In Central Europe check tarpaulin and preservation regulary every 4 weeks In case of bad climate conditions the measures of a long term preservation A...

Page 75: ...ndividual engine components are to be carried out according to the following sequence of operations 2 1 Fuel system In case of heavy fuel driven engine switch over to destilled fuel see A3 06 07 nn Cl...

Page 76: ...C and drain the cooling water Note The cooling water tracts are protected by the corrosion inhibiter in the cooling water see A4 05 09 02 Engines with caged exhaust valves fill the water spaces of th...

Page 77: ...Attention The engine finish may not be etched by cleaning and or washing agent Use only suitable washing agents Keep to the operation safety and sanitation instructions of the manufacturer Dry the cle...

Page 78: ...engine finish may not be etched by cleaning and or washing agent Use only suitable washing agents Keep to the operation safety and sanitation instructions of the manufacturer 2 Preservation measures e...

Page 79: ...out banjo plug of the starting air distributor Spray in preservation oil see 1 2 and refit banjo plug 2 3 Mechanic hydraulic governor Change the oil in case of due interval Fill governor according to...

Page 80: ...sufficient thickness 3 Preservation measures fittings and tools Thoroughly clean the small parts If necessary cover threads bores grooves and similar parts with self adhesive aluminium foil Then seal...

Page 81: ...y measures were taken remove the protective plugs covers blanking flanges or other sealant parts and any locking devices Reconnect the engine to the plant if it has been necessary to seperate it 2 2 F...

Page 82: ...endent lubrication If necessary clean the preserved parts according to instructions of the manufacturer Drain protective oil Assemble new bearings and fill up oil 2 7 External depreservation Remove co...

Page 83: ...Running in Engine A3 10 00 en 16 02 2001 BA000242 1 1 Running in...

Page 84: ...t at 20 rated power and then go to full power within the time provided for each type of engine M 20 M 282 M 332 C 6 h M 25 M 32 M 453 C 8 h M 552 C M 601 M 601 C 8 10 h M 43 10 h If a heavy fuel engin...

Page 85: ...Fault tracing Engine A3 11 00 en 19 02 2001 BA000130 1 1 Fault tracing...

Page 86: ...nature of the trouble will be the determining factor as to whether the power or speed have to be reduced for the duration it lasts If there is a failure in the measuring instruments or monitors that c...

Page 87: ...p see manufacturer s instructions in book C control shaft is defective Governor failures Faulty connection between governor Control shaft is jamming fuel feed pressure is terminal shaft and injection...

Page 88: ...ystem is defective Air in the fuel system Water in the fuel Fuel feed pump is defective Repair or replace pump see A5 05 07 13 01 nn Fuel filter is clogged Clean filter see A5 05 07 12 01 nn Pressure...

Page 89: ...___________________________ Opaque exhaust gas engine is emitting soot Possible cause Remedy Pressure of injection valve is too low Nozzles are fouled by carbon deposits Nozzle needle is jammed or noz...

Page 90: ...ce see A5 05 01 05 01 nn ______________________________________________________________________________________________ Exhaust gases are white Possible cause Remedy Exhaust gas condensation due to lo...

Page 91: ...Emergency operation Engine A3 12 00 en 19 02 2001 BA000142 1 1 Emergency operation...

Page 92: ...missing charge air pressure only permit a reduced bmep to protect the engine against thermal overload The fuel injection pump delivery must be reduced according to the bmep recommended below Determina...

Page 93: ...ld having no central bore hole Block all oil feeds and return lines All possible openings on the transitional air housing of the charger are to be opened KBB turbocharger shut down for this see KBB se...

Page 94: ...t casing of the turbocharger taken out of service with a blanking cover Start the engine and reduce the output If the installation is for heavy fuel we recommend the change to distillate fuel in emerg...

Page 95: ...efective Note If the charge air cooler has two stages the charge air temperature is raised at part load by isolating the low temperature circuit of the cooler which is controlled by charge air pressur...

Page 96: ...t casing of the turbocharger taken out of service with a blanking cover Start the engine and reduce the output If the installation is for heavy fuel we recommend the change to distillate fuel in emerg...

Page 97: ...efective Note If the charge air cooler has two stages the charge air temperature is raised at part load by isolating the low temperature circuit of the cooler which is controlled by charge air pressur...

Page 98: ...res A cylinder head valve or piston and connecting rod should only be removed if unavoidable If misfiring operation cannot be avoided it may be necessary to limit the power output of the whole plant i...

Page 99: ...occasionally check the flexible coupling visually and its temperature The defect should be repaired immediately Before returning to normal operation again the flexible coupling should be checked for d...

Page 100: ...not be repaired by means of on board tools we differentiate between the following extreme conditions depending on the severity of the troubles 1 Misfire Misfire means engine operation with interrupted...

Page 101: ...ine speed must not exceed 80 of the rated speed A1 10 This limit value applies to engines arranged rigidly as well as flexible The exhaust gas temperatures upstream turbocharger must not exceed the te...

Page 102: ...Operating media A4 en 31 10 2001 AA020105 1 1 Operating media...

Page 103: ...ns and care CCAI limit curves A4 05 07 03 01 Regulations and care Limit specification A4 05 07 04 Regulations and care Heavy fuel specification A4 05 07 05 Regulations and care Viscosity temperature s...

Page 104: ...stem For that the following notes and instructions must be observed Warranty When unsuitable operating media are used or are maintained insufficiently no warranty for trouble free operation can be gua...

Page 105: ...process materials During all work or contact with lube oil hydraulic fluid grease fuel distillate heavy oil water with anticorrosive antifreeze detergent solvent coolant CO2 N2 the safety instruction...

Page 106: ...Regulations and care Engine A4 05 00 en 21 02 2001 BA000158 1 1 Regulations and care...

Page 107: ...5 07 00 M20 M601C en 28 06 1996 BA000162 1 1 For the Caterpillar MaK engines used in shore based and ship based operation according to their equipment condition two product groups of fuels are allowed...

Page 108: ...d fuels which are known as marine Diesel oil MDO Diesel fuel oil marine Diesel fuel MDF etc These types of fuel differ from the former types in general by their higher viscosity specific gravity and i...

Page 109: ...ummer quality max 0 6 6 Carbon residue micro carbon m m ISO 10370 max 0 3 on 10 destillation bottoms Carbon residue micro carbon m m ISO 10370 max 0 3 2 50 Ash m m ISO 6245 max 0 01 0 01 0 05 Sediment...

Page 110: ...m the large international fuel suppliers Pre heating of the fuel can be dispensed with if the viscosity of the bunkered fuel at 40 C is below 7 mm2 s cSt If this value is exceeded and a pre heating fa...

Page 111: ...BFO Marine Fuel Oil MFO Bunker C Fuel Intermediate Fuel IF Light Fuel Oil LFO Thin Fuel Oil TFO Various organizations such as BSI British Standards Institution CIMAC Conseil International des Machine...

Page 112: ...wer density limits for the A10 D15 classes Introduction of minimum viscosity with CIMAC The CIMAC specification is the basis for the Caterpillar MaK heavy fuel specification A4 05 07 05 BSI Specificat...

Page 113: ...he type of engine and the condition of the fittings and included in A4 05 07 03 00 an A4 05 07 03 01 The three sub ranges which develop in this manner mean the following The diagrams permit the determ...

Page 114: ...reference should be given to heavy fuel with a low ash content Mixing of fuel components to obtain the desired viscosity should be done in suitable mixing appliances before bunkering A separate fillin...

Page 115: ...hich could not be separated in a simple separating process mixing proportions 1 3000 to 1 6000 Proven additives can be obtained from most oil or additive suppliers b Additives against high termperatur...

Page 116: ...601C en 28 05 1998 BA000178 1 1 CCAI limit curves CCAI 880 870 860 850 840 830 820 30 20 40 50 60 80 100 150 200 300 400 700 1 02 1 01 1 00 0 99 0 98 0 97 0 96 0 95 0 94 0 93 0 92 Density kg l15 C to...

Page 117: ...ble X admissible in connection with suitable treatment system only increased density limit Caution Observe CCAI limit curves A4 05 07 03 nn Limit M 20 M25 M32 M43 specification CIMAC A10 X X X X CIMAC...

Page 118: ...x 6 24 30 30 30 30 30 Carbon Residue Conradson Koksr ckstand m m max 12 6 14 14 15 20 18 22 22 22 Ash Asche m m max 0 10 0 10 0 10 0 15 0 15 0 15 7 0 15 7 0 15 7 Total sedim after ageing Totaler Sedim...

Page 119: ...t Viscosity 30 3000 2000 Temperatur Temperature L i m i t f o r p r e h e a t i n g G r e n z e f r V o r w r m u n g 1000 40 60 100 200 50 300 500 700 400 40 50 60 100 200 300 400 2000 3000 2 30 500...

Page 120: ...1 Base Oil The base oil should be a high quality solvent refined product from a source suitable for engine lub ricating oil and have a good oxidation stability as well as a good load carrying capacity...

Page 121: ...l when operating on heavy fuel the installation of an Automatic back flush filter in conjunction with a follo wing indicator filter as double filter is necessary See the details in the Instructions fo...

Page 122: ...EXXMAR CM X ESSOLUBE X 301 X FINA CAPRANO S 412 X STELLANO S 420 X CAPRANO TD X MOBIL MOBILGARD 412 X MOBILGARD ADL X MOBILGARD 430 1 X MOBILGARD 1 SHC 2 X SHELL GADINIA X SIRIUS FB X ARGINA S X ARGIN...

Page 123: ...HEVRON DELO 3000 MARINE OIL X DELO 3400 MARINE OIL X ELF AURELIA 4030 X AURELIA XT 4040 X ESSO EXXMAR 30 TP X EXXMAR 40 TP X EXXMAR 30 TP PLUS X EXXMAR 40 TP PLUS X FINA STELLANO S 430 X STELLANO S 44...

Page 124: ...ating oil consumption rates of 1 g kWh which in individual cases may even be significantly below this value Under such conditions and due to the low refilling requirement the usability limit can alrea...

Page 125: ...the engine is running on gas oil or MDO the total base number must not fall below 50 of the value of the new oil If the base number has reached the lower limit and the other analysis values show a sat...

Page 126: ...be noted Lubricating oil firm Lubricating oil brand AGIP OSO 68 OTE 68 DICREA SX 68 1 BP ENERGOL HLP 68 ENERGOL THB 68 ENERSYN TC S 68 1 CALTEX RANDO HD 68 REGAL R O 68 CASTROL PERFECTO T 68 HYSPIN AW...

Page 127: ...sistency number 2 also suitable for pneu matic control instruments Lubricating oil firm Brand name AGIP GR MU 2 BP ENEGREASE LS 2 CALTEX MULTIFAK EP 2 CASTROL SPHEEROL AP 2 GREASE CHEVRON DURA LITH GR...

Page 128: ...If the the preperation monitoring and maintenance work are not carried out properly even a short period of operation may result in damages due to corrosion Three decisive facts are to be considerd fo...

Page 129: ...is purpose if corrosion inhibiting oils are used Dosing For 1 dPH 21 4 mg Mg SO4 per ton of water are required German total Permanent hardness Carbonate hardness dGH dPH dKH Comparison with other valu...

Page 130: ...ems heating living quarters by engine cooling water or in case of shell cooling In this cases use only chemicals 1 1 Anti corrosion oil The fresh water is mixed outside the engine with anti corrosion...

Page 131: ...oisonous nature Using and checking procedures must be obtained from the manufacturers taking particular care not to use any poisonous substance it fresh water plants are connected into the cooling cir...

Page 132: ...higher than 1 5 test again with fresh sample water If the result is confirmed a correction of the emulsion is necessary Emulsion freshening in case of concentration too low Mix required amount of oil...

Page 133: ...he entire system Remove water inlets on the crankcase and flush out any sludge which may have formed Fill engine with an alkali solution e g P3T 308 from Messrs Henkel 0 5 solution and run it for appr...

Page 134: ...t with cooling water with chemical corrosion protection in order to guarantee adequate radiator performance at higher ambient temperatures 3 Cleaning the cooling water chambers Before badly scaled coo...

Page 135: ...oling system capacity 2300 l via the intersection of the 19 dGH line to the ordinate Amount used and read off the amount of water with 19 dGH which is to be used and which is to be mixed with the diff...

Page 136: ...0 2 3 4 5 6 8 10 20 30 40 7 9 0 4 0 2 0 1 0 amount of oil to be added in litres to obtain a 0 7 oil concentration measured oil concentration in vol amount of cooling water in circuit m 3 2 0 1 8 1 6 1...

Page 137: ...Maintenance A5 en 31 10 2001 AA000026 1 1 Maintenance...

Page 138: ...5 05 01 06 01 00 Nozzle Sleeve A5 05 01 06 50 00 Inlet and Exhaust Valves A5 05 01 07 01 00 Inlet and Exhaust Valve Cones A5 05 01 07 01 01 Valve Cones A5 05 01 08 01 00 Inlet Valve Cones A5 05 01 08...

Page 139: ...00 Zylinderbuchse A5 05 03 03 01 02 Cylinder Liner A5 05 03 04 01 00 Cylinder Liner A5 05 03 04 02 00 Engine Bolting and Unions A5 05 03 07 01 00 Engine control A5 05 04 Camshaft A5 05 04 04 01 00 Cam...

Page 140: ...3 Turbocharger A5 05 06 13 01 04 Turbocharger A5 05 06 13 01 05 Abgasturbolader A5 05 06 13 01 06 Abgasturbolader A5 05 06 13 01 07 Turbocharger A5 05 06 13 01 08 Engine fuel system A5 05 07 Injection...

Page 141: ...fugal Cooling Water Pump A5 05 09 07 01 00 Centrifugal Cooling Water Pump A5 05 09 07 01 01 Centrifugal Cooling Water Pump A5 05 09 07 01 02 Engine starting system A5 05 10 Engine control equipment A5...

Page 142: ...nance It is the purpose of the maintenance to replace parts subject to wear and tear or to repair these parts before they are damaged The Scheduled maintenance is thereby supported by inspections acco...

Page 143: ...erval schedule is subdivided into the following four areas Daily inspection and control work Initial inspection and maintenance work Work which has to be carried out after first commissioning or commi...

Page 144: ...Title of the job card Activity Maintenance work en 30 09 91 IB000003 1 1 Language Date of issue Registration number Page number of pages See also 01 01 01 nn 01 02 01 nn 01 08 01 nn Spare parts list B...

Page 145: ...is required The fourth pair of digits indicates the type of variant See job card Reference is made to other job cards required for maintenance work At this point the types of variants fourth pair of d...

Page 146: ...nance schedule Periodic maintenance work A large scale plan showing all maintenance work up to the largest maintenance interval clearly indicating all occurrences and the future work expenditure for t...

Page 147: ...uld be disposed of immediately and above all it should be taken care that this material is not overheated even by accident e g during combustion and welding operations If this should however has happe...

Page 148: ...or stand under suspended loads When carrying out overhead assembly work the specially designed or safety oriented climbing aids are to be used only Do not use engine plant parts for climbing on Keep a...

Page 149: ...maintenance work is being carried out have to be if prescribed shut off at the power supply and provided with the notice Do not switch on or the corresponding warning sign 1 4 Working with hydraulic d...

Page 150: ...5 C Observe instructions for use in accordance with DIN safety data sheet of the regulati ons for dangerous substances Observe the specialist disposal of all cleansing agents and chemicals in accordan...

Page 151: ...cooler downstream charge air cooler Temperature Charge air A1 10 Upstream charge air cooler downstream charge air cooler Temperature Exhaust gas A1 10 After cylinder downstream turbocharger Pressure...

Page 152: ...1 M20 en 31 10 2001 AA020780 2 8 Intervall Designation Doc Nr Work to be carried out Remarks Fuel Day tank A3 05 07 00 system Desludging of fuel level gauge Fuel Duplex fuel filter A5 05 07 12 01 00 s...

Page 153: ...05 07 12 01 00 Maintenance Cleaning at 50 differential pressure clean strainer 24 h Lubricating oil system A5 05 08 02 01 00 Maintenance Oil change 24 h Lubricating oil duplex filter A5 05 08 04 01 00...

Page 154: ...arger A5 05 06 05 00 01 Maintenance Cleaning see book C 300 h Turbocharger A5 05 06 13 01 00 Maintenance Cleaning see book C 750 h Cooling water system A4 05 09 01 Inspection Anti corrosion oil 750 h...

Page 155: ...of one cylinder unit 7 500 h Compressed air filter A5 05 05 09 06 00 Maintenance Cleaning 7 500 h Exhaust manifold A5 05 06 01 01 00 Maintenance Disassembly and reassembly 7 500 h Turbo Charger Sound...

Page 156: ...mp A5 05 09 07 01 00 Maintenance Disassembly and reassembly 30 000 h Valve rocker A5 05 01 02 02 00 Maintenance Disassembly and reassembly 30 000 h Valve guide Oil scraper ring A5 05 01 05 01 00 Inspe...

Page 157: ...ir Checking Cylinder head A5 05 01 11 01 00 Repair Reassembly Crank web deflection A5 05 02 02 01 00 Inspection Measuring Bearing shells A5 05 02 03 07 01 Inspection Evaluate Al grooved bearings A5 05...

Page 158: ...enance Disassembly and reassembly Fuel injector A5 05 07 07 01 00 Maintenance Disassembly and reassembly Fuel injector A5 05 07 08 01 00 Maintenance Adjust Duplex fuel filter A5 05 07 12 01 00 Mainten...

Page 159: ...air cooler Temperature Exhaust gas A1 10 After cylinder downstream turbocharger Pressure Lubricating oil A1 05 At the main bearing or at the camshaft bearing see also A1 10 Pressure Cooling water A1...

Page 160: ...5 05 07 12 01 00 Maintenance Cleaning at 50 differential pressure clean strainer 24 h Lubricating oil system A5 05 08 02 01 00 Maintenance Oil change 24 h Lubricating oil duplex filter A5 05 08 04 01...

Page 161: ...00 Maintenance Cleaning 750 h Cooling water system A4 05 09 01 Inspection Anti corrosion oil 750 h Duplex fuel prefilter A5 05 07 12 02 02 Maintenance Cleaning 750 h Oil mist detector A5 05 11 09 01...

Page 162: ...tenance Cleaning 7 500 h Exhaust manifold A5 05 06 01 01 00 Maintenance Disassembly and reassembly 7 500 h Injection valve A5 05 07 09 01 00 Repair Disassembly and reassembly 7 500 h RPM switch A5 05...

Page 163: ...ly 30 000 h Valve rocker A5 05 01 02 02 00 Maintenance Disassembly and reassembly 30 000 h Big end bearings A5 05 02 04 01 00 Inspection Disassembly exchange of all big endbearings 30 000 h Main beari...

Page 164: ...g shells A5 05 02 03 07 01 Inspection Evaluate Al grooved bearings A5 05 02 03 09 01 Inspection Evaluate Big end bearings A5 05 02 04 02 00 Inspection Reassembly Main bearings A5 05 02 05 02 00 Mainte...

Page 165: ...1 00 Maintenance Adjust Duplex fuel filter A5 05 07 12 01 00 Maintenance Cleaning Fuel Distributor Line Manifold Line A5 05 07 15 01 00 Repair Disassembly and reassembly Lubricating oil system A5 05 0...

Page 166: ...Periodical schedule Heavy fuel A5 04 02 M20 en 31 10 2001 AA021679 8 8...

Page 167: ...W1 2 9100 380 Feeler gauge W2 1 9075 3 not available as figure Note The valve clearance shall only be measured with warm engine i e 15 min after the engine is shut down Valve clearance Fig 1 S Inlet 0...

Page 168: ...e adjusting screw Fig 3 4 into the valve bridge until the valve bridge has contact at both valves Tighten counternut 3 Note During tightening of the counternut the adjusting screw 4 turns back so far...

Page 169: ...apid Plus or a product of equal standard Sequence of operations 1 Disassembly 1 1 Remove the cylinder head cover 1 2 Move the piston to firing TDC Inlet valves and exhaust valves are closed valve rock...

Page 170: ...2 01 2 4 Grease the thread and nut contact face with Molykote paste G Rapid Plus and tighten the nuts gradually 1 with a Torque of 120 Nm and nuts 2 with a Torque of 60 Nm 2 5 Set the valve clearance...

Page 171: ...g clearances 30 000 h Note The bushes must be lubricated with oil only Molykote paste must not be used even on assembly Sequence of operations 1 Disassembly 1 1 Disassemble valve rocker bracket 01 02...

Page 172: ...ing fluid nitrogen 4 Measure valve rocker bush Fig 2 13 and axle Fig 1 5 and renew bushes on attaining the limit clearance New clearance Limit clearance 0 015 0 14 0 2 5 Replace bearing bushes 5 1 Kno...

Page 173: ...e of burrs 6 1 Oil surfaces of the bushes of the inlet valve rocker Fig 1 3 and exhaust valve rocker 4 and rocker axle and carefully move the valve rocker onto the axle Do not tilt valve rocker 6 2 Fi...

Page 174: ...Use this rotational speed for reference later Sequence of operations 1 Check valve rotation 2 The valve rotator works properly if a uniform and engine speed dependent rotation can be detected 3 Lubri...

Page 175: ...00 h Auxiliary material Molykote paste G Rapid Plus or a product of equal standard Sequence of operations 1 Replacement of the oil scraper rings O rings 1 1 Dismount valve face thoroughly clean stem 1...

Page 176: ...of the guide bush 2 2 Measure the inside diameter of the guide bush in traverse direction of the engine 2 3 Normal clearance mm Limit clearance mm Exhaust Inlet 0 10 0 17 0 4 3 Replacement of the valv...

Page 177: ...h Auxiliary material Molykote paste G Rapid Plus or a product of equal standard Sequence of operations 1 Replacement of the oil scraper rings O rings 1 1 Dismount valve face thoroughly clean stem 1 2...

Page 178: ...of the guide bush 2 2 Measure the inside diameter of the guide bush in traverse direction of the engine 2 3 Normal clearance mm Limit clearance mm Exhaust Inlet 0 10 0 17 0 4 3 Replacement of the valv...

Page 179: ...erating medium Heavy fuel and distillate fuel Safety note Depressurize system before commencing work Auxiliary material soft green soap or product of equal standard Sequence of operations 1 Disassembl...

Page 180: ...O rings fig 2 12 and if necessary insert new O rings untwisted in the grooves using soft soap 1 6 Remove seals 11 and clean sealing surfaces 2 Assembly 2 1 Mount sleeves fig 2 4 with flanges 3a and 3b...

Page 181: ...of fuel leakage monitor 3 1 Secure pipe Z 5 3 2 Disassemble pipe 5 with screwed socket 6 and sealing ring 7 3 3 Check that bore Fig 4 Y is free and clean if necessary 3 4 Assemble pipe Z 5 with screwe...

Page 182: ...able as figure Note When lifting the cylinder head or when turning afterwards the liner is always to be secured with the hold down in order to prevent the liner from becoming loose Attention Do not fa...

Page 183: ...during disassembly of the last cylinder head at counter coupling side 4 Loosen and remove block pieces and or end flange Cyl 1 of the medium guide of the cylinder head to be disassembled 5 Loosen pres...

Page 184: ...ift of 5 mm must not be exceeded 8 1 Screw spacer Fig 2 W7 on cylinder head screw 11 8 2 Place bearing ring W6 over round nut 12 thereby make surethe slots 13 are easily accessible 8 3 Screw hydraulic...

Page 185: ...nuts Fig 2 12 with pin W8 Note If the round nuts cannot be loosened the cylinder head screw can be further prestressed with approx 50 bar If the pressure is increased further there is a risk of the r...

Page 186: ...nch W3 1 9454 6 no illustration Auxiliary material Vaseline High temperature thread paste Dag S 5080 or product of equal standard Sequence of operations 1 Dismount the nozzle sleeve 1 1 1 Attach the p...

Page 187: ...g is not twisted 2 2 Apply a film of green soft soap to the new green O ring and insert it in the groove 3 Make sure the O ring is not twisted Attention Do not change the position of the O rings Obser...

Page 188: ...erhaul intervals of the valves depend on the fuel grade used the operating conditions of the plant and the quality of the reconditioned valves and seats They are therefore different for each plant For...

Page 189: ...are heavily worn in the clamping area and any clamping cone halves which have large burrs Remove projecting burrs before disassembling such valves Maintenance of valve cone valve seat 01 08 01 nn 01 0...

Page 190: ...rhaul intervals of the valves depend on the fuel grade used the operating conditions of the plant and the quality of the reconditioned valves and seats They are therefore different for each plant For...

Page 191: ...worn in the clamping area and any clamping cone halves which have large burrs Remove projecting burrs before disassembling such valves Maintenance of valve cone valve seat 01 08 01 nn 01 08 02 nn 2 R...

Page 192: ...with sequence of operations 4 Refinishing of the valve cones in accordance with sequence of operations 3 may be necessary in the following cases after extended operating periods in the case of negativ...

Page 193: ...the valve cone face is damaged cracks blowholes the wear caused by corrosive material is 2 of the valve head diameter comparison with new valve concave burns s caused by high temperature corrosion at...

Page 194: ...the valves should be given to a MaK workshop for regrinding 3 1 Regrind valve cone faces in accordance with prescribed angle Fig 3 Do not refinish existing concave fillet 3 2 The appropriate informat...

Page 195: ...the seat ring surface is to be sprayed with a thinner F25 belonging to the diamond paste for dilution and in order to increase of the grip 4 2 Insert the oiled valve stem into the guide bush Fasten t...

Page 196: ...refinished on a machine 4 4 Ensure that the components valve cone and seat ring refaced to one another remain together 5 Final inspection 5 1 Ensure that the the refinishing limit dimensions are main...

Page 197: ...h sequence of operations 4 Refinishing of the valve cones in accordance with sequence of operations 3 may be necessary in the following cases after extended operating periods in the case of negative r...

Page 198: ...hen the valve cone face is damaged cracks blowholes the wear caused by corrosive material is 2 of the valve head diameter comparison with new valve concave burns s caused by high temperature corrosion...

Page 199: ...ble the valves should be given to a MaK workshop for regrinding 3 1 Regrind valve cone faces in accordance with prescribed angle Fig 3 Do not refinish existing concave fillet 3 2 The appropriate infor...

Page 200: ...ter the seat ring surface is to be sprayed with a thinner F25 belonging to the diamond paste for dilution and in order to increase of the grip 4 2 Insert the oiled valve stem into the guide bush Faste...

Page 201: ...be refinished on a machine 4 4 Ensure that the components valve cone and seat ring refaced to one another remain together 5 Final inspection 5 1 Ensure that the the refinishing limit dimensions are m...

Page 202: ...ence of operations 4 Refinishing of the valve cones in accordance with sequence of operations 3 may be necessary in the following cases after extended operating periods in the case of negative result...

Page 203: ...when the valve cone face is damaged cracks blowholes the wear caused by corrosive material is 2 of the valve head diameter comparison with new valve concave burns s caused by high temperature corrosio...

Page 204: ...le the valves should be given to a MaK workshop for regrinding 3 1 Regrind valve cone faces in accordance with prescribed angle Fig 3 Do not refinish existing concave fillet 3 2 The appropriate inform...

Page 205: ...fter the seat ring surface is to be sprayed with a thinner F25 belonging to the diamond paste for dilution and in order to increase of the grip 4 2 Insert the oiled valve stem into the guide bush Fast...

Page 206: ...o be refinished on a machine 4 4 Ensure that the components valve cone and seat ring refaced to one another remain together 5 Final inspection 5 1 Ensure that the the refinishing limit dimensions are...

Page 207: ...ce of operations 4 Refinishing of the valve cones in accordance with sequence of operations 3 may be necessary in the following cases after extended operating periods in the case of negative result e...

Page 208: ...when the valve cone face is damaged cracks blowholes the wear caused by corrosive material is 2 of the valve head diameter comparison with new valve concave burns s caused by high temperature corrosio...

Page 209: ...le the valves should be given to a MaK workshop for regrinding 3 1 Regrind valve cone faces in accordance with prescribed angle Fig 3 Do not refinish existing concave fillet 3 2 The appropriate inform...

Page 210: ...fter the seat ring surface is to be sprayed with a thinner F25 belonging to the diamond paste for dilution and in order to increase of the grip 4 2 Insert the oiled valve stem into the guide bush Fast...

Page 211: ...o be refinished on a machine 4 4 Ensure that the components valve cone and seat ring refaced to one another remain together 5 Final inspection 5 1 Ensure that the the refinishing limit dimensions are...

Page 212: ...h sequence of operations 4 Refinishing of the valve cones in accordance with sequence of operations 3 may be necessary in the following cases after extended operating periods in the case of negative r...

Page 213: ...hen the valve cone face is damaged cracks blowholes the wear caused by corrosive material is 2 of the valve head diameter comparison with new valve concave burns s caused by high temperature corrosion...

Page 214: ...ble the valves should be given to a MaK workshop for regrinding 3 1 Regrind valve cone faces in accordance with prescribed angle Fig 3 Do not refinish existing concave fillet 3 2 The appropriate infor...

Page 215: ...ter the seat ring surface is to be sprayed with a thinner F25 belonging to the diamond paste for dilution and in order to increase of the grip 4 2 Insert the oiled valve stem into the guide bush Faste...

Page 216: ...be refinished on a machine 4 4 Ensure that the components valve cone and seat ring refaced to one another remain together 5 Final inspection 5 1 Ensure that the the refinishing limit dimensions are m...

Page 217: ...ying glass with light 8 fold magnification Diamond paste Dp 30 10 15 m Thinner DIAPLASTOL or a product of equal standard Note In case irregular contact reflections or pittings are indicated on the sea...

Page 218: ...erations 1 Check of valve condition The hardness of the valve seats is designed in such a manner that a certain adaptability is present with regard to the valve face Carbon deposits are therefore a no...

Page 219: ...ces 3 Maintenance refinishing the valve seat rings Note Refinishing is to be carried out with the MaK precision seat grinding machine W1 in a workmanlike manner Refer to special operating instructions...

Page 220: ...e Set the contact pressure by touch Attention The machine will rattle when the contact pressure is too low and or the cutting speed is too high 3 1 5 Prior to finishing the cutting process slowly unsc...

Page 221: ...device W1 01 08 01 nn to the valve head and grind the valve face and seat by hand applying a moderate pressure rotating the device The contact reflection a which is visible by the rough grinding proc...

Page 222: ...ying glass with light 8 fold magnification Diamond paste Dp 30 10 15 m Thinner DIAPLASTOL or a product of equal standard Note In case irregular contact reflections or pittings are indicated on the sea...

Page 223: ...erations 1 Check of valve condition The hardness of the valve seats is designed in such a manner that a certain adaptability is present with regard to the valve face Carbon deposits are therefore a no...

Page 224: ...ces 3 Maintenance refinishing the valve seat rings Note Refinishing is to be carried out with the MaK precision seat grinding machine W1 in a workmanlike manner Refer to special operating instructions...

Page 225: ...e Set the contact pressure by touch Attention The machine will rattle when the contact pressure is too low and or the cutting speed is too high 3 1 5 Prior to finishing the cutting process slowly unsc...

Page 226: ...device W1 01 08 01 nn to the valve head and grind the valve face and seat by hand applying a moderate pressure rotating the device The contact reflection a which is visible by the rough grinding proc...

Page 227: ...cording to prescriptions 01 11 01 nn If no tightness is obtained remove the cylinder head clean and check the sealing faces and refit with a new gasket according to prescriptions 01 11 01 nn 2 Check c...

Page 228: ...disassembled inlet exhaust injection valve valve rocker brackets 1 Wash cylinder head with cold cleaner 2 Remove carbon deposits from inlet and exhaust ducts and cylinder head bottom do not clean the...

Page 229: ...assembled inlet exhaust injection valve valve rocker brackets 1 Wash cylinder head with cold cleaner 2 Remove carbon deposits from inlet and exhaust ducts and cylinder head bottom do not clean the val...

Page 230: ...sheet 01 06 01 nn Auxiliary material High temperature thread paste Dag S 5080 Molykote paste G Rapid Plus Vaseline or a product of equal standard Note When lifting the cylinder head or when turning a...

Page 231: ...aces and contact surfaces of cylinder head and liner thoroughly and check for damage Insert new sealing ring Fig 1 1 into cylinder liner collar 3 Renew the following O rings Top O ring at the cylinder...

Page 232: ...ing pin in the cooling water distributor ring 5 Insert new seal Fig 1 7 for exhaust flange and align cylinder head Lubricate screws for exhaust pipe with Dag S 5080 high temperature thread paste and s...

Page 233: ...Fig 3 Z open at the high pressure pump W1 6 6 Close valve Fig 3 Z at high pressure pump W1 and simultaneously extend all 4 cylinder head screws steadily with a hydraulic pressure of p 600 bar Attentio...

Page 234: ...l pin 9 Connect lube oil line and transverse thrust pieces of the respective injection pump in reverse order to the disassembly instructions 01 06 01 nn The mounting instructions of 07 07 01 nn sequen...

Page 235: ...bearings to see whether they are of uniform and normal temperature 4 Check tight fit of the bolts and nuts 5 Check the degree of fouling in the crankcase sludge corrosion bearing metal deposits disin...

Page 236: ...g one rotation of the crankshaft Fig 1 Depending on the location of the engine the rigidity of the foundation and of the vessel different values will be contained when the vessel is loaded the values...

Page 237: ...dicate the space in which to use the measuring tips 2 Adjust the value of scale 20 to the pointer 1st measuring point initial point 3 Bar the crankshaft so that the crank pin turns in direction of the...

Page 238: ...n bearings This means that the admissible deflection is determined by the engine load A high load admits less deflection than a low one The values below must be observed if it is impossible to obtain...

Page 239: ...Engine cold Shut down for Preheated down up hours press C Indication of Dial Gauge Operating hours Engine Type Vessel Engine no Date Engineer Service Station Draft forward Draft aft Measuring point ma...

Page 240: ...abrasion and fatigue the bearing shells Refitting Criteria catalogue Fig 1 The contact reflection is uniformly formed on the entire bearing width This bearing shell can be reused Fig 2 The contact ref...

Page 241: ...of damage with various degrees of scratching This bearing shell is not reusable The cause for this slide bearing damage has to be determined and eliminated Further bearing shells are to be inspected...

Page 242: ...Bearing Shells Inspection Evaluate A5 05 02 03 07 01 M20 en 13 06 1997 IB001449 3 4 02 1 2 3...

Page 243: ...Bearing Shells Inspection Evaluate A5 05 02 03 07 01 M20 en 13 06 1997 IB001449 4 4 02 4 5 6...

Page 244: ...glass minimum magnification 5x is necessary Under the magnifying glass the overlay appears as a dark area and the aluminium alloy ridge as a light area The most important criteria for assessing the d...

Page 245: ...s intact The dark points are predominantly embedded oil coke particles Fig 2 Assessment The ratio between the overlay and the aluminium alloy ridges is 75 25 Reuse possible Condition The overlay in th...

Page 246: ...e No significant alteration of the aluminium allow ridges Fig 4 Assessment Reuse of the bearing shell is possible since foreign particles are embedded in the grooves Condition The overlay has been loc...

Page 247: ...1 The width of the bearing metal ridges has increased from 25 when new to 50 Some overlay still exists in the grooves Fig 6 Wear limits a max 30 of circumference b max 70 of width c max 50 of circumfe...

Page 248: ...case Condition Bearing metal ridges are worn locally Wear limits a max 20 of width b max 5 of circumference c max 10 of width d max 35 of circumference e max 10 of width f lock of chamber Assessment...

Page 249: ...e grooves as a result of overloading at certain points Wear limits a max 25 of circumference b max 70 of width c max 50 of circumference d max 35 of width Assessment Bearing is operative Should a cond...

Page 250: ...areas empty grooves are visible after washing out the ruptured overlay Wear limits a max 40 of width b max 10 of circumferende c max 30 of width d max 40 of circumference e max 15 of width Assessment...

Page 251: ...60 420 Nm 3 4 W2 1 9454 060 Tightening angle gage big end bolts W3 2 9180 A Turning rod W4 2 9100 380 not available as figure Auxiliary material Molykote paste G Rapid Plus or a product of equal stan...

Page 252: ...m corresponding to a minimum tightening angle of bolts 1 and 2 of min 13 16 3 and 4 of min 17 19 Achtung the minimum tightening angle is to be kept 1 7 Measure dimension x2 between the bore holes on t...

Page 253: ...3 Lift bearing cap out of the crankcase 2 4 Check the toothing in the joint faces of connecting rod big end bearing cap and thread for damage 3 Removing the bearing shells 3 1 Move piston to TDC posit...

Page 254: ...60 420 Nm 3 4 W2 1 9454 060 Tightening angle gage big end bolts W3 2 9180 A Turning rod W4 2 9100 380 not available as figure Auxiliary material Molykote paste G Rapid Plus or a product of equal stan...

Page 255: ...m corresponding to a minimum tightening angle of bolts 1 and 2 of min 13 16 3 and 4 of min 17 19 Achtung the minimum tightening angle is to be kept 1 7 Measure dimension x2 between the bore holes on t...

Page 256: ...3 Lift bearing cap out of the crankcase 2 4 Check the toothing in the joint faces of connecting rod big end bearing cap and thread for damage 3 Removing the bearing shells 3 1 Move piston to TDC posit...

Page 257: ...420 Nm 3 4 W2 1 9454 060 Tightening angle gage big end bolts W3 2 9180 A Turning rod W4 2 9100 380 not available as figure Auxiliary material Molykote paste G Rapid Plus or a product of equal standar...

Page 258: ...m corresponding to a minimum tightening angle of bolts 1 and 2 of min 13 16 3 and 4 of min 17 19 Achtung the minimum tightening angle is to be kept 1 7 Measure dimension x2 between the bore holes on t...

Page 259: ...3 Lift bearing cap out of the crankcase 2 4 Check the toothing in the joint faces of connecting rod big end bearing cap and thread for damage 3 Removing the bearing shells 3 1 Move piston to TDC posit...

Page 260: ...uxiliary material Molykote paste G Rapid Plus or a product of equal standard Note The bearing caps shells and bolts have been marked according to their cylinder numbers and must not be interchanged Ne...

Page 261: ...g Fig 2 2 of the clamp engages in the groove of the joint face for centrical guide of the bearing shells of big end bearing 4 1 5 Turn the bearing shells with the handle of the clamp so that the dowel...

Page 262: ...king the tightening operation place the angle gages Fig 3 W3 over the bolt head collars according to the marking and pull the pointer against the stop Check the set collars of the gage for freedom Mar...

Page 263: ...ing without gage the bolts must have turned through an angle of 13 16 3 7 2 Lower bolts 3 and 4 The maximum pointer must have passed the angle marking or the bolts must have turned through 17 19 Note...

Page 264: ...exchange all crankshaft bearings every 30 000 h Tools Hydraulic equipment set consisting of Bearing ring W1 0 9203 109 Hydr tensioning element W2 0 9213 A High pressure pump W3 0 9204 D High pressure...

Page 265: ...mshaft and exhaust side and turn crankshaft into favorable position for removing 1 2 Measure axial play s by the locating bearing Fig 1 1 2 1 Place gage with magnetic holder on flywheel set and align...

Page 266: ...hat the slots 14 are easily accessible 1 3 3 Link hydraulic tensioning element W2 with high pressure pump W3 via high pressure hose W4 and press onto block length Valve Z open at the high pressure pum...

Page 267: ...rting faces of the bearing shells just come into contact with each other 1 4 5 Measure clearance K between cylinder block and crankcase and bearing cap on exhaust and camshaft side with feeler gage an...

Page 268: ...riteria 02 03 09 nn 1 10 In the case of 2 material bearings check wearing of the wall thickness in the main load region at check points Fig 7 X with micrometer caliper Wear new dimension actual dimens...

Page 269: ...hange all crankshaft bearings every 30 000 h Tools Hydraulic equipment set consisting of Bearing ring W1 0 9203 109 Hydr tensioning element W2 0 9213 A High pressure pump W3 0 9204 D High pressure hos...

Page 270: ...mshaft and exhaust side and turn crankshaft into favorable position for removing 1 2 Measure axial play s by the locating bearing Fig 1 1 2 1 Place gage with magnetic holder on flywheel set and align...

Page 271: ...hat the slots 14 are easily accessible 1 3 3 Link hydraulic tensioning element W2 with high pressure pump W3 via high pressure hose W4 and press onto block length Valve Z open at the high pressure pum...

Page 272: ...rting faces of the bearing shells just come into contact with each other 1 4 5 Measure clearance K between cylinder block and crankcase and bearing cap on exhaust and camshaft side with feeler gage an...

Page 273: ...riteria 02 03 09 nn 1 10 In the case of 2 material bearings check wearing of the wall thickness in the main load region at check points Fig 7 X with micrometer caliper Wear new dimension actual dimens...

Page 274: ...hould be over the equipment which is under pressure Attention Do not fall below minimum bending radius r 120 mm of the high pressure hoses Only use hydraulic oil as an operating material Note Bearing...

Page 275: ...working face of the lower bearing shell wipe bearing back dry and insert into bearing cap Attention The bearing guide groove for the lower shell is on the camshaft side Observe fixing pin on the exha...

Page 276: ...ten in 2 steps with the following torques 1st stage M 100 Nm 1st stage M 280 Nm After that the lateral bolts are to be tightened with an angle of 30 1 2 hexagon X Place hydraulic tightening equipment...

Page 277: ...if the pump is not activated Otherwise tightening errors occur 2 4 Firmly tighten round nuts 1 uniformly with pin W5 3 Inspection Lower pressure by 50 bar Round nuts 1 should no longer be able to be...

Page 278: ...ing rod W3 2 9100 380 no illustration Auxiliary material Rust removal spray Caramba or product of equal standard Note The cylinder liner is to be secured with the liner supports W1 1 to prevent loo se...

Page 279: ...5 slightly beat it with a copper hammer until you can turn the guide of the calibrating ring by hand 12 Turn piston 3 with turning rod W3 approx 50 to TDC 13 Insert thrust ring W1 2 and compressed sn...

Page 280: ...1998 IB004750 3 3 02 19 Screw the ring bolt Fig 2 W2 into the piston 20 Mount the crane to the ring bolt W2 21 Slowly pull out the piston carefully in sert con rod foot into the liner and re move big...

Page 281: ...sonnel qualification skilled engine hand Operating medium Heavy fuel and distillate fuel Tools Sleeve support W1 2 9216 103 Eye screw M12 W2 1 9080 012 Turning rod W3 2 9100 380 Disassembly unit W4 2...

Page 282: ...etween the top section of the 1st piston ring and the lower edge of the calibration ring 5 and remove so that the shoulder of the calibration ring can be clearly felt all round Note Take care not to d...

Page 283: ...that the calibration ring is drawn out smoothly when removing the piston If the calibration ring becomes tilted lower the piston and align the calibration ring The connecting rod must not strike the...

Page 284: ...and no heavy wear can be detected the inspection of the others pistons can be postponed to a later date but not beyond a maximum of 30 000 operating hours During the inspection pay special attention t...

Page 285: ...ome layer is no longer visible If the chrome layer of one piston ring has been worn check the rings of all pistons 1 7 Clean the piston ring grooves and oil return holes for the scraper scraper ring 1...

Page 286: ...0 000 h 2 1 Draw all pistons 02 06 01 nn 2 2 Check the state of lubrication and appearance of the running surface of the piston and clean it 2 3 Remove the piston rings with piston ring expander Fig 1...

Page 287: ...e and no heavy wear can be detected the inspection of the others pistons can be postponed to a later date but not beyond a maximum of 30 000 operating hours During the inspection pay special attention...

Page 288: ...ome layer is no longer visible If the chrome layer of one piston ring has been worn check the rings of all pistons 1 7 Clean the piston ring grooves and oil return holes for the scraper scraper ring 1...

Page 289: ...0 000 h 2 1 Draw all pistons 02 06 01 nn 2 2 Check the state of lubrication and appearance of the running surface of the piston and clean it 2 3 Remove the piston rings with piston ring expander Fig 1...

Page 290: ...and no heavy wear can be detected the inspection of the others pistons can be postponed to a later date but not beyond a maximum of 30 000 operating hours During the inspection pay special attention t...

Page 291: ...ome layer is no longer visible If the chrome layer of one piston ring has been worn check the rings of all pistons 1 7 Clean the piston ring grooves and oil return holes for the scraper scraper ring 1...

Page 292: ...0 000 h 2 1 Draw all pistons 02 06 01 nn 2 2 Check the state of lubrication and appearance of the running surface of the piston and clean it 2 3 Remove the piston rings with piston ring expander Fig 1...

Page 293: ...e paste G Rapid Plus or a product of equal standard Note The cylinder liner must always be secured by means of the cylinder liner holder fig 3 W2 to prevent the cylinder liner from coming loose when t...

Page 294: ...tion device slightly 6 Check the floating position of the rings by turning the piston insertion device W4 7 Mount the piston assembly ring fig 2 W3 8 Mount the piston mounting extraction device fig 3...

Page 295: ...as the piston mounting extraction device fig 3 W1 14 Clean the contact surface on the cylinder liner collar Attention Insert the calibrating ring 1 only after the piston has been mounted 15 Insert a...

Page 296: ...ions 1 Check the relief valve 2 from the inside of the crankcase door 1 for freedom of movement by actuating it by hand 2 If the valve ist not free on the guide bolt 3 disassemble the valve 3 Check th...

Page 297: ...5 300 not illustrated special tool Sequence of operation 1 Check the cylinder liner Note Extreme wear can occur on the cylinder liners which has to be evaluated and measured depending on the operating...

Page 298: ...ed Reconditioning of the cylinder liners is only possible by Caterpillar MaK Cylinder liner wear chart Evaluation criteria Wear limit Explanation mm Nominal new Radius r 3mm 200 46 in circumferencial...

Page 299: ...1 with threaded rod and eye bolt on liner collar 2 Mount lower crosshead half 1 and tighten both crosshead halves firmly with each other with nuts 2 Attention The cylinder liner holding device must be...

Page 300: ...dard Note After fitting a new cylinder liner the engine must be driven in according to the driving in regulation A3 10 01 nn Sequence of operations 1 Clean cooling water distributor housing before ins...

Page 301: ...the fitting of the cylinder block and crankcase Fig 1 5 through its own weight Note Insert the cylinder liner in such a way that the markings 11 Fig 2 X top view liner collar point in longitudinal dir...

Page 302: ...r major repairs the engine unions and screwed connections have to be inspected for good fitting and leaks Sequence of operations 1 Check the flanged connections filter thermostats and pipe clamps of t...

Page 303: ...socket wrench 10 mm W4 1 9039 10 Turning rod W5 2 9100 380 not available as figure Auxiliary material Sliding coating Metaflux Molykote paste G Rapid Plus or a product of equal standard Sequence of op...

Page 304: ...mshaft camshaft mounting device piece at cylinder unit cylinder No 1 3 6 2 4 6 3 5 6 4 6 5 6 For removing the camshaft piece of cylinder unit 6 or cylinder unit 5 lift the camshaft piece of cylinder u...

Page 305: ...index 33 see table Camshaft Flange piece index cylinder No 1 4 2 2 3 3 4 4 5 5 6 6 2 1 Position the camshaft pieces in reverse disassembly order 2 2 Grease the threads and contact surfaces of the flan...

Page 306: ...socket wrench 10 mm W4 1 9039 10 Turning rod W5 2 9100 380 not available as figure Auxiliary material Sliding coating Metaflux Molykote paste G Rapid Plus or a product of equal standard Sequence of op...

Page 307: ...amshaft mounting device piece at cylinder unit cylinder No 1 3 7 2 4 8 3 5 8 4 6 9 5 7 9 6 8 7 9 8 9 For removing the camshaft piece of cylinder unit 9 or cylinder unit 8 lift the camshaft piece of cy...

Page 308: ...33 see table Camshaft Flange piece index cylinder No 1 1 2 1 3 2 4 3 5 4 6 4 7 3 8 2 9 1 2 1 Position the camshaft pieces in reverse disassembly order 2 2 Grease the threads and contact surfaces of th...

Page 309: ...socket wrench 10 mm W4 1 9039 10 Turning rod W5 2 9100 380 not available as figure Auxiliary material Sliding coating Metaflux Molykote paste G Rapid Plus or a product of equal standard Sequence of op...

Page 310: ...camshaft mounting device piece at cylinder unit cylinder No 1 3 7 2 4 7 3 5 8 4 6 8 5 7 8 6 8 7 8 For removing the camshaft piece of cylinder unit 8 or cylinder unit 7 lift the camshaft piece of cyli...

Page 311: ...x 33 see table Camshaft Flange piece index cylinder No 1 5 2 2 3 3 4 4 5 5 6 6 7 7 8 8 2 1 Position the camshaft pieces in reverse disassembly order 2 2 Grease the threads and contact surfaces of the...

Page 312: ...ooth surfaces of the camshaft gear Fig 1 1 intermediate wheel 2 and crankshaft gear 3 pitting cross bearing disintegrations etc 1 2 Check the function of the oil nozzles 4 5 and 6 1 3 Fit the covers a...

Page 313: ...ls Torque wrench 40 180 Nm 1 2 W1 1 9454 40 not available as figure Auxiliary material Molykote paste G Rapid Plus Silicon sealing compound Dirco Gray or a product of equal standard Sequence of operat...

Page 314: ...ey 19 1 8 Check the tooth surfaces of the helical gear wheels 13 and 18 for wear pitting cross bearing disintegrations 1 9 Lift the governor drive shaft 17 out of the cylinder block and crankcase and...

Page 315: ...aces of the hexagon screws with Molykote paste G Rapid Plus and tighten crosswise with a torque of M 60 Nm 2 5 Put the governor housing Fig 1 3 on the cylinder block and crankcase taking care of the d...

Page 316: ...ote paste or product of equal quality Note The torsional vibration dampers must be replaced after 15 000 operating hours Sequence of operations 1 Disassembly 1 1 Support the damper 1 loosen cheese hea...

Page 317: ...ote paste or product of equal quality Note The torsional vibration dampers must be replaced after 15 000 operating hours Sequence of operations 1 Disassembly 1 1 Loosen the cheese head screws 5 lift o...

Page 318: ...wrench 20 90 Nm 1 2 W1 1 9454 020 Hex cap screw drive A F12 W2 1 9039 012 no illustration Auxiliary material Molykote paste G Rapid or a product of equivalent standard Note After 15 000 operating hou...

Page 319: ...ct face of cylinder head screws 3 and 7 with Molykote paste G Rapid 2 4 Mount cover disk 6 2 5 Tighten cylinder head screws 7 with a torque of M 60 Nm 2 6 Slip on damper 1 as shown in the illustration...

Page 320: ...uence of operations 1 Remove control shaft injection pumps and control station covers 2 Check control shaft and spindle to emergency off lever and oil bearing areas slightly with lubricating oil Atten...

Page 321: ...The fuel limiter is only installed on reversible engines and is operable from a lubricating oil pressure of 0 8 bar If the oil is contaminated this may disturb operation A defective fuel limiter can...

Page 322: ...ton operation is not satisfactory Piston travel 26 mm 3 3 If the exhaust gas becomes black turn adjusting screw 2 1 to 1 5 turns clockwise to increase the spring load 3 4 Speed the engine up again and...

Page 323: ...ion depending on the carge air pressure so as to avoid a smoky exhaust The exhaust can become black in the event of a rapid speeding up or a brisk load increase Sequence of operations 1 Check all bolt...

Page 324: ...limiter if piston operation is not satisfactory Piston travel 26 mm 3 3 If the exhaust gas becomes black turn adjusting screw 2 1 to 1 5 turns clockwise to increase the spring load 3 4 Speed the engi...

Page 325: ...ust not be removed when there is pressure on the lubricating oil system A defective fuel limiter can be cut out during engine operation by turning the set screw in 11 Sequence of operations Fig 1 1 Di...

Page 326: ...l standard Attention Note The fuel limiter must not be removed when there is pressure on the lubricating oil system Sequence of operations 1 Disconnect the lubricating oil feed and outlet and the char...

Page 327: ...section A4 and it is not necessary to renew this for several years Only this grease must be used for repairs Proper operation of all parts will no longer be ensured when other lubricants are used Saf...

Page 328: ...Fill oil in as far as 7 mm below the housing top edge SAE 20 2 4 Insert the piston Drive the air out by screwing the plug in 2 5 Proceed according to 2 3 and 2 4 until no air escapes any more Unscrew...

Page 329: ...ttle screw 10 apply a pressure of approxi mately 0 7 bar to connection A 4 2 3 Fill oil SAE 20 in as far as 7 mm below the housing top edge at connection B 4 2 4 Tighten the throttle screw 10 and sock...

Page 330: ...ntrol or inspection depending on the type and function of the individual control units Regulating elements pressure reducers must be checked in their circuit after maintenance work for their setting v...

Page 331: ...ce cleaning Drain compressed air filter every 24 h Disassemble and clean compressed air filter initially 150 h Disassemble and clean compressed air filter every 7 500 h Auxiliary material Nitro Solven...

Page 332: ...tely 2 2 Close compressed air feed line and secure 2 3 Relieve compressed air filter via drain plug 2 4 Loosen housing cap 5 and remove check O ring 1 and replace if necessa ry 2 5 Loosen Phillips scr...

Page 333: ...doing the work on the exhaust manifold If excessive vibrations and noises occur in the exhaust gas turbine the flanged connection on the exhaust pipe behind the turbine must be unscrewed and examined...

Page 334: ...nsion joints and pipes 2 2 Remove the exhaust manifold 2 2 1 Loosen the flanged connections first at the expansion joint Fig 1 1 then at the cylinder head 2 and remove the pipe 2 3 Clean the inside of...

Page 335: ...tificate A1 10 Tools Torque wrench 40 180 Nm 1 2 W1 1 9454 40 not available as figure Auxiliary material Cleansing agent according to recommendations of the manufacturer e g of Vecom GmbH Hamburg Drew...

Page 336: ...ing agent to be used protect skin against contact with cleansing agent wear safety glasses Ensure good ventilation 2 Reassembly 2 1 Carry out reassembly in reverse order to disassembly Note Ensure pro...

Page 337: ...tificate A1 10 Tools Torque wrench 40 180 Nm 1 2 W1 1 9454 40 not available as figure Auxiliary material Cleansing agent according to recommendations of the manufacturer e g of Vecom GmbH Hamburg Drew...

Page 338: ...ing agent to be used protect skin against contact with cleansing agent wear safety glasses Ensure good ventilation 2 Reassembly 2 1 Carry out reassembly in reverse order to disassembly Note Ensure pro...

Page 339: ...nce test record A1 10 Tools Torque wrench 40 180 Nm 1 2 W1 1 9454 40 no illustration Auxiliary material Cleaning agent acc to recommendation of manufacturer e g Fa Vecom GmbH Hamburg Fa Drew Ameroid G...

Page 340: ...agon screws 1 2 and 3 with Molykote paste G Rapid Plus 2 3 Secure charge air cooler on hoist and push cooler into casing Strictly observe the tightening instructions for hexagon screws 1 2 and 3 2 4 M...

Page 341: ...nce test record A1 10 Tools Torque wrench 40 180 Nm 1 2 W1 1 9454 40 no illustration Auxiliary material Cleaning agent acc to recommendation of manufacturer e g Fa Vecom GmbH Hamburg Fa Drew Ameroid G...

Page 342: ...agon screws 1 2 and 3 with Molykote paste G Rapid Plus 2 3 Secure charge air cooler on hoist and push cooler into casing Strictly observe the tightening instructions for hexagon screws 1 2 and 3 2 4 M...

Page 343: ...a list of the maintenance operations which have to be carried out within the scope of the work schedule in accordance with the operation instructions in book C after the specified hours of operation...

Page 344: ...skilled engine hand Operating medium Distillate fuel Maintenance The maintenance of the turbocharger is always to be carried out according to the maintenance repair and spare part documents enclosed i...

Page 345: ...ed detergent Note Only perform the cleaning when the engine is stopped Observe the product manufacturer s safety regulations Auxiliary material Detergent Tankclean according to the manufacturer s reco...

Page 346: ...freshwater without addition of detergents or solvents The washing intervals depend on the fuel quality and the operating conditions and they can only be fixed by experience in operation It must always...

Page 347: ...1 4 Close stop valves and corner valves and remove hose clip Fig 1 1 1 5 Run the turbocharger dry with a written engine load approx 30 min then increase engine load slowly Note Repeat washing procedu...

Page 348: ...y injecting freshwater without addition of detergents or solvents The washing intervals depend on the fuel quality and the operating conditions and they can only be fixed by experience in operation It...

Page 349: ...06 1 4 Close stop valves and corner valves and remove hose clip 1 1 5 Run the turbocharger dry with a written engine load approx 30 min then increase engine load slowly Note Repeat washing procedure...

Page 350: ...cting freshwater without addition of detergents or solvents The washing intervals depend on the fuel quality and the operating conditions and they can only be fixed by experience in operation It must...

Page 351: ...06 1 4 Close stop valves and corner valves and remove hose clip 1 1 5 Run the turbocharger dry with a written engine load approx 30 min then increase engine load slowly Note Repeat washing procedure...

Page 352: ...ecting freshwater without addition of detergents or solvents The washing intervals depend on the fuel quality and the operating conditions and they can only be fixed by experience in operation It must...

Page 353: ...06 1 4 Close stop valves and corner valves and remove hose clip 1 1 5 Run the turbocharger dry with a written engine load approx 30 min then increase engine load slowly Note Repeat washing procedure...

Page 354: ...ting freshwater without addition of detergents or solvents The washing intervals depend on the fuel quality and the operating conditions and they can only be fixed by experience in operation It must a...

Page 355: ...06 1 4 Close stop valves and corner valves and remove hose clip 1 1 5 Run the turbocharger dry with a written engine load approx 30 min then increase engine load slowly Note Repeat washing procedure...

Page 356: ...ting freshwater without addition of detergents or solvents The washing intervals depend on the fuel quality and the operating conditions and they can only be fixed by experience in operation It must a...

Page 357: ...06 1 4 Close stop valves and corner valves and remove hose clip 1 1 5 Run the turbocharger dry with a written engine load approx 30 min then increase engine load slowly Note Repeat washing procedure...

Page 358: ...ecting fresh water without addition of detergents or solvents The washing intervals depend on the fuel quality and the operating conditions and they can only be fixed by experience in operation It mus...

Page 359: ...sits involves the risk that water runs bakc into the engine through the ex haust gas pipe In case of clogging pierce the drain val ve with a wire 1 5 Close stop Fig 1 3 and corner valves 4 and remove...

Page 360: ...ecting fresh water without addition of detergents or solvents The washing intervals depend on the fuel quality and the operating conditions and they can only be fixed by experience in operation It mus...

Page 361: ...sits involves the risk that water runs bakc into the engine through the ex haust gas pipe In case of clogging pierce the drain val ve with a wire 1 5 Close stop Fig 1 3 and corner valves 4 and remove...

Page 362: ...ecting fresh water without addition of detergents or solvents The washing intervals depend on the fuel quality and the operating conditions and they can only be fixed by experience in operation It mus...

Page 363: ...ts involves the risk that water runs bakc into the engine through the ex haust gas pipe In case of clogging pierce the drain val ve with a wire 1 5 Close stop Fig 1 3 and corner valves 4 and remove ho...

Page 364: ...led engine hand Operating medium Heavy fuel and distillate fuel Tools Torque wrench 40 180 Nm W1 1 9454 40 not available as figure Auxiliary material Molykote paste G Rapid Plus or a product of equal...

Page 365: ...pump Slide sleeve 13 to the left into the cylinder head 1 6 Disconnect distributor housing of the fuel collecting pipe at the injection pump 1 7 Loosen nuts 14 of the fastening screws at the injection...

Page 366: ...n pump 2 4 Tighten nuts 14 with a torque of M 50 Nm 2 5 Connect lube oil lines Fig 1 1 to the injection pump and screw on holder for stop cylinder 3 2 6 Link regulating shaft with control rack 2 of th...

Page 367: ...killed engine hand Operating medium Heavy fuel and distillate fuel Tools Torque wrench 40 180 Nm W1 1 9454 40 not available as figure Auxiliary material soft green soap Molykote paste G Rapid Plus or...

Page 368: ...d the injection pump Slide sleeve 13 to the left into the cylinder head 1 6 Loosen the fuel manifold and collector 07 15 01 nn 1 7 Loosen nuts 14 of the fastening screws at the injection pump uniforml...

Page 369: ...uts 14 with a torque of M 50 Nm 2 6 Connect lube oil lines Fig 1 1 to the injection pump and screw on holder for stop cylinder 3 2 7 Link regulating shaft with control rack 2 of the injection pump Obs...

Page 370: ...tion pump are manufactured with utmost precision in special workshops This is the only guarantee for proper function When repairing a pump it is to be ensured that the various components of the pump e...

Page 371: ...p plunger 14 1 6 Unscrew guide screw 15 pull control rod 16 out of injection pump housing 6 and check toothing 1 7 Clamp injection pump housing 6 with valve support pointing upwards 17 Unscrew locking...

Page 372: ...e guide fuel supply and discharge bores in the connecting flange cavitation erosion 2 Reassembly 2 1 The reassembly is carried out in reverse order to the disassembly procedure Attention During reasse...

Page 373: ...tion pump are manufactured with utmost precision in special workshops This is the only guarantee for proper function When repairing a pump it is to be ensured that the various components of the pump e...

Page 374: ...p plunger 14 1 6 Unscrew guide screw 15 pull control rod 16 out of injection pump housing 6 and check toothing 1 7 Clamp injection pump housing 6 with valve support pointing upwards 17 Unscrew locking...

Page 375: ...and needle guide fuel supply and discharge bores in the connecting flange cavitation erosion 2 Reassembly 2 1 The reassembly is carried out in reverse order to the disassembly procedure Attention Duri...

Page 376: ...jection pump are manufactured with utmost precision in special workshops This is the only guarantee for proper function When repairing a pump it is to be ensured that the various components of the pum...

Page 377: ...distance plate 9 slot washer 10 a unit pump spring 11 spring seat 12 control sleeve 13 pump plunger 14 1 6 Unscrew guide screw 15 pull control rod 16 out of injection pump housing 6 and check toothing...

Page 378: ...wisted into slots do not pull across sharp ed ges of the components During visual inspection pay special at tention to the following wear phenome na plunger scores marks on the run ning surface Contro...

Page 379: ...eeve plunger coincide 2 2 Grease contact surfaces between constant pressure release Fig 1 24 and barrel 23 thinly with absolutely clean Molykote paste G Rapid Plus 2 3 Coat threads and contact surface...

Page 380: ...rking on the injection system it is recommended to change to distillate fuel in the case of heavy oil operation in order to rinse the fuel injector thoroughly Sequence of operations 1 Disassembly 1 1...

Page 381: ...sealing ring 17 and all of the O rings 18 Attention Only use original MaK spare parts 2 Reassembly 2 1 Apply a thin film of Molykote paste on the threads of gudgeons Fig 2 11 O rings Excessive paste h...

Page 382: ...3 3 07 2 6 Tighteen the thrust bolts 1 and 2 manually in alternating order becauce of tapered seat of the transverse thrust piece 3 on the injection pump 2 7 First tighten thrust bolt 2 and then thru...

Page 383: ...ck and erosion however are the consequence if the nozzle temperature is too low The charge air temperature may also be too low or water in the charge air The perfect functioning of the injection nozzl...

Page 384: ...ges ovalization corrosion and damage 3 Place the injector with adapter Fig 1 W2 in the nozzle tester W1 and con nect the pressure pipe W3 4 Increase the pressure gradually via the pump until the nozzl...

Page 385: ...assembled if the inspection 07 08 01 nn yields deficiencies e g leaking too low opening pressure poor atomization All parts of the injection system are produced with utmost precision in special worksh...

Page 386: ...il 1 6 Insert nozzle needle with gas oil into the nozzle element and check whether the nozzle needle falls onto the seat through its own weight If the needle hangs or sticks replace it together with t...

Page 387: ...njector valve should only be disassembled if the inspection 07 08 01 nn yields deficiencies e g leaking too low opening pressure poor atomization All parts of the injection system are produced with ut...

Page 388: ...gas oil 1 6 Insert nozzle needle with gas oil into the nozzle element and check whether the nozzle needle falls onto the seat through its own weight If the needle hangs or sticks replace it together w...

Page 389: ...ever let the filter cool down in a filled state The cleaning intervals of the filter mostly depend on the engine operating conditions the fuel quality and the grade of the fuel purifying and thus diff...

Page 390: ...n case of stubborn dirt paint spots incrustation fibers chips place the strainers in a container with cleaning fluid and allow them to soak for max 4 h in accordance with the regulation of the cleansi...

Page 391: ...re connected in parallel and damage on only one filter element means malfunction of the entire element 2 12 Put a strong light behind the gauze and check success of the cleaning operation Repeat if ne...

Page 392: ...tenance of the filter have to be carried out with utmost care to avoid troubles in the fuel system The cleaning intervals of the filter mostly depend on the engine operation conditions and the fuel qu...

Page 393: ...of an element make sure that the gauze is not damaged Inspect all strainers on the inside and outside because the individual strainers are connec ted in parallel and damage on only one strainer means...

Page 394: ...e filter every 750 h Auxiliary material Cleaner Filterclean of Vecom or a product of equal standard Note Operation and maintenance of the filter have to be carried out with utmost care to avoid troubl...

Page 395: ...n basket 7 1 7 Put the screen basket 7 into a solvent An application time of 8 hours must not be exceeded 1 8 After taking the screen basket 7 out of the solvent carefully blow it out with compressed...

Page 396: ...aling compound Dirco Gray or a product of equal standard Note If the fuel feed pump cannot be used due to natural wear and tear it should be replaced The installation of spare parts cannot reproduce t...

Page 397: ...place if required Remove circlips 16 and 17 in order to pull off the deep groove ball bearings 2 Reassembly 2 1 Heat up coupling half 11 to 160 C and shrinkwrap on the shaft journal of the drive shaft...

Page 398: ...al surfaces of the cones free from grease and dry and immediately lubricate thread and contact surface of the hexagon screw 4 and washer with Molykote paste G Rapid Plus and tighten with a torque of M...

Page 399: ...te fuel Tools Torque wrench 20 90 Nm W1 1 9454 20 not available as figure Auxiliary material Molykote paste G Rapid Plus or a product of equal standard Sequence of operations 1 Disassembly 1 1 Drain f...

Page 400: ...ibutor housing 3 2 2 Insert new O rings 5 2 3 Check bore 6 in equalizer for passage 2 4 Insert and reassemble equalizer 4 in distributor housing 3 2 5 Insert screws 1 with Molykote paste G Rapid Plus...

Page 401: ...perating medium Heavy fuel and distillate fuel Helpful resource Green soft soap or a similar quality product Sequence of work 1 Disassembly 1 1 Empty fuel and fuel collector rail 2 Drainage tap on ant...

Page 402: ...7 IB003978 2 2 07 2 Assembly 2 1 Insert new O rings 4 with green soft soap in both injection pumps 2 2 Push fuel pipe ends into the fuel pump without retaining rings until they stop 2 3 Assemble fuel...

Page 403: ...ting conditions Lubricating oil consumption Lubricating oil filtering and centrifugal purifying Quantity of lubricating oil in the system The oil change interval can be extended if allowed by the resu...

Page 404: ...Oil change A5 05 08 02 01 00 M20 en 20 09 1995 IB001483 2 2 08 7 Refill new lubricating oil up to the respective mark on the sump tank lubricating oil quality see A4 05 08 nn 8 Refill lubricating oil...

Page 405: ...uence of operations 1 Screw off valve cover Fig 1 1 and mark set position of the valve spindle 2 Safety note Observe spring tension 2 Unscrew valve spindle 2 and take valve cone 3 with valve spring 4...

Page 406: ...nce of operations 1 Disassembly 1 1 Empty the lube oil system 1 2 Disconnect the suction pipe and delivery pipe 1 3 Loosen the pump flange from the pump carrier plate and pull the lube oil pump Fig 1...

Page 407: ...icker end 2 3 Heat up the gear wheel Fig 1 2 to approx 150 C in the oil bath and shrink it on the driving wheel shaft 4 The conical surfaces are free from grease and dry 2 4 Grease the thread and cont...

Page 408: ...on part load operation with heavy fuel poor combustion poor centrifugal purifying or a defective automatic backflushing filter When starting up a new plant after major repairs or work on the lubricat...

Page 409: ...ge the working pressure 6 max 10 bar 2 2 4 Shift the spouting guard 13 to the stop at the pistol nozzle put it into the cartridge opening and hold it tight Pull the trigger of the cleaning pistol and...

Page 410: ...the filter element in the chamber fit the cover and renew the gasket if necessary 2 3 9 Fill the filter chamber and vent it see the plate on the filter cover 2 4 Cleaning the filter candles in the ca...

Page 411: ...to hold the nozzle too close to the gauze in order to avoid damage and or displacement of the gauze wires 2 4 8 Rinse the filter candles in clean cleansing liquid blow through with air and allow them...

Page 412: ...days Prelubrication alone is no guarantee that damage caused by vibration is prevented since the components which run on sliding bearings are not able to float in the bearing because of the prelubrica...

Page 413: ...1 1 Empty the cooling water system in the cooling water reservoir 1 2 Remove pipes from the cooling water pump 1 3 Disconnect pump flange from the pump carrier plate and remove the cooling water pump...

Page 414: ...eller 13 visually and renew it in the case of heavy cavitation 2 2 Check the ball bearings for freedom of movement wear corrosion ball disintegrations and renew them if necessary 2 3 Check the pressur...

Page 415: ...to the stop on the shaft cone 3 6 Grease the thread and contact surface of the hexagon screw 3 and the washer 4 with Molykote paste G Rapid Plus and tighten it with a torque of M 60 Nm 3 7 Insert the...

Page 416: ...1 1 Empty the cooling water system in the cooling water reservoir 1 2 Remove pipes from the cooling water pump 1 3 Disconnect pump flange from the pump carrier plate and remove the cooling water pump...

Page 417: ...the grooved ball bearing 23 1 15 Force the shaft with grooved ball bearing 22 out in Y direction and take out of bearing support 19 1 16 Pull the grooved ball bearing 22 off the shaft 2 Inspection 2 1...

Page 418: ...Grease the thread and contact surface of the hexagon screw 3 and the washer 4 with Molykote paste G Rapid Plus and tighten it with a torque of M 60 Nm 3 7 Insert the cooling water pump 1 with the gea...

Page 419: ...kt der Auslieferung war dieses Dokument leider nicht verf gbar bzw in der geforderten Sprache nicht lieferbar Sie bekommen das entsprechende Dokument in K rze nachgeliefert Dear customers At the time...

Page 420: ...nt instruction is valid for the following types Pressure range 0 2 2 5 bar mechanical switching differential 0 15 bar Pressure range 0 6 bar mechanical switching differential 0 2 bar Pressure range 1...

Page 421: ...ia the adjustment device Attention For setting the differential pressure switch the adjusting device must be equipped with two text connections pressure difference refer to view X 2 2 Inspect the pres...

Page 422: ...3 Loosen the stop screw A 3 4 Remove the cover aside by loosening the locking screw B 3 5 Set the upper or lower switching point differential pressure switch by means of the range spindle C The lower...

Page 423: ...operating values of the pressure switch every 3 750 operation hours Note These testing and adjusting instructions apply to the following types Pressure range 0 6 bar Switching difference 0 2 bar Pres...

Page 424: ...ic connection Fig 3 Connect terminals 1 2 3 in the appliance plug 2 Inspection 2 1 Vent pressure switch via adjusting device 2 2 Check switching point via the precision manometer of the setting equipm...

Page 425: ...s set in the case of falling pressure 3 1 Remove the lead seal 3 2 Disconnect housing cover Fig 4 20 of the pressure switch 3 3 Set switching point with hexagon wrench SW5 to the required value accord...

Page 426: ...card must switch and the luminous diode 3 on the dial will go out Fig 1 2 Turn the pointer carefully to the left towards 0 rpm When reaching the engine speed the output relay will switch and the diod...

Page 427: ...4 2 2 11 5 2 PICK UP IMPULSE dependent upon engine speed up to 1500 Hz at contact b14 and d14 If nothing could be detected whilst checking points 4 6 renew the plug in card Attention Carry out the rpm...

Page 428: ...ntrolling the thermostatic elements in case of failure is enabled by a manual control facility Hereto slacken counter nut 1 and turn set nut 2 clockwisely in order to get a lower temperature After set...

Page 429: ...sion 2 Functional Check of the Thermostatic Element 2 1 Put thermostatic element 1 into a water bath of a termpature of approx 10 K above the mean temperature specified on the insert XX specification...

Page 430: ...ts in case of failure is enabled by a manual control facility Hereto slacken counter nut 3 and turn set screw 4 clockwisely in order to get a lower temperature After setting counter again The cooling...

Page 431: ...static element Fig 1 5 into a water bath of temperature of approx 15 K above the temperature specified on the strap XX specification in degree C 2 2 The thermostatic element 5 must open steadiliy 3 As...

Page 432: ...nd distillate fuel Maintenance a Check the underpressure in the measuring chamber every 750 h b Clean the infrared filter and replace the sintered bronze filter in the measuring attachment every 1 500...

Page 433: ...the engine Free passage of oil bores 2 must be ensured for the proper functioning of the damper If running of the engine becomes unbalanced at certain speeds the cause can be a defecti ve damper In o...

Page 434: ...flywheel rim 7 and the carrier 8 in the marked position apply a thin film of Molykote paste G Rapid Plus to the springs and insert them into the damper For this purpose slightly squeeze spring assemb...

Page 435: ...Table of contents A6 01 en 31 10 2001 AA020050 1 1 Tools A6 Table of contents A6 01...

Page 436: ...M 20 Werkzeug Zusammenstellung Summary of tools Sommaira d outillage Somario de las herramientas Lista de ferramentas Verktory oversikt...

Page 437: ...er head Description Figur Benennung Bild Werkzeug Nr Tool No St ck Qty Aufbewahrungskasten 1 2 9101 A Tool case Hochdruckpumpe 1 0 9204D High pressurepump Steckschl ssel 1 1 9100 060 Socket wrench Hoc...

Page 438: ...inder head Description Figur Benennung Bild Werkzeug Nr Tool No St ck Qty Hydr Zugelement 4 0 9213 A Hydraulic jack Verteiler 1 0 9203 008 Distributor St tzring 4 0 9203 108 Supportingsleeve Hochdruck...

Page 439: ...opf Cylinder head Benennung Bild Werkzeug Nr St ck Qty Description Figur Tool No Stift 1 0 9203 110 Pin Profilring Dichtsatz 2 0 9213 051 Set of seal rings St tzring 2 0 9203 109 Supportingsleeve Zwis...

Page 440: ...St ck Qty Description Figur Tool No Ventilfederspannvorrichtung 1 2 9222 A Valve spring compressor Ventilschleifvorrichtung 1 2 9224 A Valve grinding device Hebevorrichtungf rZylinderkopf 1 2 9221 A L...

Page 441: ...01 M20 en 05 00 WB000001 5 A6 05 01 Zylinderkopf Cylinder head Benennung Bild Werkzeug Nr St ck Qty Description Figur Tool No Ventilsitzfr svorrichtung 1 2 9224 B Valve reseating tool Z...

Page 442: ...Figur Tool No Triebwerk Kolbenfangvorrichtung 1 2 9226 A Piston suspesion device Montageb gelf rPleuellager 1 2 9125 B Clamp for big end bearing shells Drehmomentschl ssel60 420Nm 1 1 9454 060 Torquew...

Page 443: ...ld Werkzeug Nr St ck Qty Description Figur Tool No Triebwerk Kolbenringzange 1 2 9227 A Piston ring expander T rnkn ppel 1 2 9100 380 Barringrod Kolbenringmanschette 1 2 9220 A Piston ring cuff Kolben...

Page 444: ...6 05 02 Running gear Benennung Bild Werkzeug Nr St ck Qty Description Figur Tool No Triebwerk Kurbelwangenme ger t 1 1 9425 300 Crank web deflection dial gauge Ausbauvorrichtungf rKolben 1 259223A Rem...

Page 445: ...orgeh use Laufbuchsenst tze 2 2 9216 103 Cylinderlinersupport Ausbauvorrichtung Kalibrierring 1 2 9216C Dismounting device for bushing Zylinderbuchsen Haltevorrichtung 2 2 9217 A Cylinderlinerhold dow...

Page 446: ...tion Figur Tool No Motor casing Motorgeh use 1x 2 9216 002 2x 2 9216 001 1x 2 9214 011 1x 2 9214 022 Absenkvorrichtungf rLagerdeckel 1 2 9214 B Device for lowering Ein undAusbauvorrichtung 1 2 9216 A...

Page 447: ...nnung Bild Werkzeug Nr St ck Description Qty Tool No Figur en 05 00 WB000001 1 Abgasanlage Aufladung Exhaust system supercharging Jumbo Autogenschlauch 1 1 9041 001 Rubberhose Oelspritze 1 1 9490 011...

Page 448: ...Description Figur Tool No Kraftstoffsystem Adapterf rD senhalter 1 2 9208 A Adapter for injector Ausbauwerkzeugf rD senhalter 1 2 9122 A Extractor for injector 1x 2 9208 001 1x 2 9208 002 Steckschl s...

Page 449: ...y Description Figur Tool No Kraftstoffsystem Ausbauwerkzeugf D senh lse 1 2 9122C Extractor for injector Einsatz SW 30 1 1 9450 030 Socket wrench SW 30 Reinigungspistole 1 1 9100 110 Cleaninggun Sprit...

Page 450: ...Werkzeug Nr St ck Qty Description Figur Tool No Kraftstoffsystem Zapfenschl ssel f r D senh lse 1 2 9122 B Pin socket wrench for nozzle cover D senpr fvorrichtung 1 1 9470 E Nozzle tester 1x 1 9470 0...

Page 451: ...A6 05 08 Benennung Bild Werkzeug Nr St ck Qty Description Figur Tool No Lubricating oil system Schmier lsystem Ausdr ckwerkzeug f r Siebkerzen 1 1 9100 120 Filtre cartridge extractor Bandschl ssel 1 1...

Page 452: ...Description Figur Tool No Additional installation Zusatzinstallation Diamantpaste 5 g 1 1 9493 002 Diamond paste 5 g Werkzeugkoffer 1 1 9498 001 Tool box Plastik ler 500 cm 1 1 9490 001 Oil can 500cm...

Page 453: ...13 Benennung Bild Werkzeug Nr St ck Qty Description Figur Tool No Additional installation Zusatzinstallation Drehmomentschl ssel40 180Nm 1 1 9454 040 Torquewrench40 180Nm Hakenschl ssel A 45 50 1 1 9...

Page 454: ...pen jaw wrenches 6 32 12 pcs SatzDoppelringschl ssel 1 1 9456 B SW 6 32 12 St ck Set of double ended ring wrenches 6 32 12 pcs Werkzeugkasten mit Steckschl sseleins 1 1 9457 A SW 10 32 Tool kit for So...

Page 455: ...m 1 1 9039 008 10 mm 1 1 9039 010 12 mm 1 1 9039 012 14 mm 1 1 9039 014 17 mm 1 1 9039 017 19 mm 1 1 9039 019 22 mm 1 1 9039 022 24 mm 1 1 9039 024 27 mm 1 1 9039 027 32 mm 1 1 9039 032 Schraubendrehe...

Page 456: ...ng Bild Werkzeug Nr St ck DIN Werkzeuge Zange f r Sicherungsringe Circlip pliers C 19 1 1 9067 419 C 40 1 1 9067 440 C 85 1 1 9067 485 Drehstift Tommy bar A 12 1 1 9090 112 A 16 1 1 9090 116 DIN Stand...

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