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MAK M43C Operating Instructions Manual
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MAK M43C Operating Instructions Manual

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M43C
Engine Operating Instructions
en / 26.05.2009
Engine Operating Instructions
Type
M43C
Engine No.:
68 280
68 281
AA000643
Record No.:
281717
A0
1/2

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Summary of Contents for MAK M43C

  • Page 1 Engine Operating Instructions M43C Engine Operating Instructions Type M43C Engine No.: Record No.: 68 280 281717 68 281 en / 26.05.2009 AA000643...
  • Page 2 Engine Operating Instructions M43C Please note the copyright notice pursuant to ISO 16016 "All documents such as drawings, data and programmes, etc. and models, templates etc. shall remain our exclusive property. They are only handed over to the agreed purpose and must not be used for any other purpose.

  • Page 3: Table Of Contents

    Total Index A0.01 Book A, B and C Engine Operating Instructions Total Index Book A, B and C A0.01 Introduction A0.02 Safety instructions A0.03 Emergency Stop Safety System A0.04 Technical Engine Data Governor Data A1.04 Working pressures of auxiliary equipment A1.05 Temperatures of operating media A1.06...

  • Page 4: Table Of Contents

    Total Index A0.01 Book A, B and C Spare Parts Catalogue Total Index Book A, B and C B0.01 Introduction B0.02 Spare Parts Table of contents B1.01 Safety instructions B1.03 Stand-by parts External Documentation Total Index Book A, B and C C0.01 Introduction Electrical Equipment C0.02...

  • Page 5: Introduction

    Since the type of fuel used considerably influences the service life of the components, the Caterpillar / MaK after-sales service has to be consulted when it is required to change from destillate fuel operation to heavy fuel oil operation, in order to ensure an expert retrofit of the engine plant and to exchange the necessary documentation.

  • Page 6: Safety Instructions

    Safety instructions A0.03 M20-M601C Personnel entrusted with work on the engine/plant must have read the operating instructions and in particular the pages on safety instructions which precede the chapters before beginning work. In order to eliminate danger which may constitute a risk of life and limb of the user or of third ~ ~ ~ ~ parties, all safety regulations which are marked with the symbol have...
  • Page 7 Safety instructions A0.03 M20-M601C Our engine is equipped with a monitoring system and an emergency stop system to prevent damage caused to the operators' health as well as damages to the engine. Within the scope of commissioning all mechanical, electric and pneumatic equipment and systems allowing the engine to be stopped for safety reasons will be demonstrated and explained by our commissioning personnel.
  • Page 8 Actions that must be performed after a safety/emergency stop* occurred: - Identify the reason for emergency stop based on the points listed below. - Work through list of corresponding sub-points. - Contact your Caterpillar/ MaK Service. Type of emergency stop: Overspeed condition...
  • Page 9 • Checking governor drive. • Verification of possible out of calibration of actuator (if fitted). Contact your Caterpillar/ MaK Service. Lube oil (lube oil pressure, lube oil temperature) Emergency stop due to lack of lube oil Checks: •...
  • Page 10 Pressurize each cylinder through opened indexing valves with shop air. If there is a rapid pressure drop or if no pressure builds up the cause must be investigated. Contact the Caterpillar/ MaK Service. Engine room monitoring Emergency Stop due to excessive oil mist concentration (refer to A3.11.18.01.nn).

  • Page 11: Exhaust Gas

    M20/M25/M32/M43 • Check fresh water cooler • Operational test of LT - Cooling water circuit with cooling water pump. Contact your Caterpillar/ MaK Service. Exhaust gas Emergency stop due to excessively high exhaust temperature Checks: • Check exhaust gas temperature sensors.

  • Page 12: Emergency Stop

    Terminal set X1 voltage failure 9717 * Terminal set X3 voltage failure * see also List of Measuring Points C5.05.02.01.nn.nn. Plant-specific fault messages: - Safety system failure - RPM switch unit failure (overspeed) Please contact the Caterpillar/ MaK Customer Service. en / 20.02.2008 AA033984...
  • Page 13 Technical Engine Data M20-M601C Technical Engine Data en / 26.05.2009 AA000103...
  • Page 14 Governor Data A1.04 Governor Data en / 20.02.2008 AA000097...
  • Page 15 Governor-data A1.04.30 en / 26.05.2009 AA045578...
  • Page 16 Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Motor-Type: Kostenträger-Nr.: Motor-Nr.: Engine type: Record No.: Engine No.: 9 M43 C 281717/1 68280 Motordaten / Engine Data Aussteller: Leistung: Regelbereich: Abteilung: 8100 300-500 Power: Control range: 1/min Vollastdrehzahl: Gesamt-Massenträgheitsmoment: Name: 7845,4 Full load speed: 1/min Total moment of inertia:...

  • Page 17: Governor Data

    Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Motor-Type: Kostenträger-Nr.: Motor-Nr.: Engine type: Record No.: Engine No.: 9 M43 C 281717/2 68281 Motordaten / Engine Data Aussteller: Leistung: Regelbereich: Abteilung: 8100 300-500 Power: Control range: 1/min Vollastdrehzahl: Gesamt-Massenträgheitsmoment: Name: 7845,4 Full load speed: 1/min Total moment of inertia:...

  • Page 18: Working Pressures Of Auxiliary Equipment

    Working pressures of auxiliary equipment A1.05 Lubricating oil at the last Camshaft bearing at rated engine speed 4,0 - 5,0 bar 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...

  • Page 19: Temperatures Of Operating Media

    9 - 11 mPa s (distillate fuel below 10 mm /s or 9 mPa s). The heavy fuel specifications defined by MaK (e.g. RHM 35 (~ IF 380) give the heavy fuel tempe- rature before engine starting.
  • Page 20 Torsional Vibration Calculation A1.09 Torsional Vibration Calculation en / 20.02.2008 AA020354...
  • Page 21 Torsional vibration calculation A1.09.12 en / 10.11.2008 AA043720 1/26...

  • Page 22: Torsional Vibration Calculation

    Bericht-Nr./ Drehschwingungsberechnung Drehschwingungsberech nung Drehschwingungsberech Drehschwingungsberech nung nung Report No. Torsional Vibration Calculation Torsional Vibration Calculation Torsional Vibration Calculation Torsional Vibration Calculation 08043087 Motor Motor- - - - Nr. / Engine No. Nr. / Engine No. Ktr. Ktr.- - - - Nr. / Record No. Nr.
  • Page 23 Bericht-Nr./ Ergebnis der Berechnung Ergebnis der Berechnung Ergebnis der Berechnung Ergebnis der Berechnung Report No. Result of Calculation Result of Calculation Result of Calculation Result of Calculation 08043087 1. 1. 1. 1. B B B B etriebseinschränkungen: etriebseinschränkungen: 1. 1. 1. 1. Operational restrictions: Operational restrictions: etriebseinschränkungen:...
  • Page 24 Bericht-Nr./ Ergebnis der Berechnung Ergebnis der Berechnung Ergebnis der Berechnung Ergebnis der Berechnung Report No. Result of Calculation Result of Calculation Result of Calculation Result of Calculation 08043087 1.2.2 Vollaussetzer: 1.2.2 Full failure: Keine Kompression, ausgebautes Triebwerk No compression, running gear dismantled Allgemeine Hinweise: General notes: Siehe Betriebsanleitung Notbetrieb...
  • Page 25 58.80 0.00.6-63.13.00-33 Innenteil / inner part 19.80 Kurbelwelle / crankshaft nach MaK-Zeichnung / acc. to MaK drawing: 4309.7-25.10.01-03 Abschnitt Dämpfer-letzter Zyl. / section damper-last cylinder 4.75 MT-Moment eines Zylinders / moment of inertia of a cylinder 132.60 Abschnitt zwischen zwei Zylindern / section between two cylinders 5.00...
  • Page 26 Bericht-Nr./ Berechnungsdaten Berechnungsdaten Berechnungsdaten Berechnungsdaten Report No. Calculation Data Calculation Data Calculation Data Calculation Data 08043087 Propellerwelle / propeller shaft: MAN B&W Diesel AS, Project P-20905-10 , Zeichnungs-Nr. / drawing no. 2130882-6, state 1 ½ Zwischenwelle / ½ intermediate shaft 4.37 Elastizität Zwischenwelle / flexibility intermediate shaft 590.00...
  • Page 27 Bericht-Nr./ Elastisches System Elastisches System Elastisches System Elastisches System Report No. Mass Elastic System Mass Elastic System Mass Elastic System Mass Elastic System 08043087 2.1 Propeller max. pitch, P=8100 kW 19,8 282,2 282,2 282,2 282,2 282,2 282,2 282,2 282,2 282,2 1571,2 207,3 14,5...
  • Page 28 Bericht-Nr./ Elastisches System Elastisches System Elastisches System Elastisches System Report No. Mass Elastic System Mass Elastic System Mass Elastic System Mass Elastic System 08043087 2.2 Propeller 0 pitch, P=3785 kW 19,8 282,2 282,2 282,2 282,2 282,2 282,2 282,2 282,2 282,2 1571,2 207,3 14,5...
  • Page 29 Bericht-Nr./ Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Report No. Speed Diagrams Speed Diagrams Speed Diagrams Speed Diagrams 08043087 2.1 Propeller , max. pitch, 8100 kW Belastung nach Propellerkurve / Load acc. To Propeller Law Gsl.-Dämpfer Systemstelle 1-2 Gsl.-Dämpfer Systemstelle 1-2 Gsl.-damper location 1-2 Gsl.-Damper Location 1-2 Moment / torque [kNm] Verlustleistung / power loss [kW]...
  • Page 30 Bericht-Nr./ Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Report No. Speed Diagrams Speed Diagrams Speed Diagrams Speed Diagrams 08043087 2.1 Propeller max. pitch, P=8100 kW Belastung nach Propellerkurve / Load acc. to Propeller Law Elast. Kupplung Systemstelle 12- 13 Elast. Kupplung Systemstelle 12- 13 Flex.
  • Page 31 Bericht-Nr./ Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Report No. Speed Diagrams Speed Diagrams Speed Diagrams Speed Diagrams 08043087 2.1 Propeller max. pitch, P=8100 kW Belastung nach Propellerkurve / Load acc. to Propeller Law Elast. Kupplung Systemstelle 16- 17 Elast. Kupplung Systemstelle 16- 17 Flex.
  • Page 32 Bericht-Nr./ Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Report No. Speed Diagrams Speed Diagrams Speed Diagrams Speed Diagrams 08043087 2.1 Propeller max. pitch, P=8100 kW Belastung nach Propellerkurve / Load acc. to Propeller Law Elast. Kupplung Systemstelle 12- 13 (Aussetzer Zyl. 9) Elast. Kupplung Systemstelle 12- 13 (Aussetzer Zyl. 9) Flex.
  • Page 33 Bericht-Nr./ Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Report No. Speed Diagrams Speed Diagrams Speed Diagrams Speed Diagrams 08043087 2.1 Propeller max. pitch, P=8100 kW Belastung nach Propellerkurve / Load acc. to Propeller Law Elast. Kupplung Systemstelle 16- 17 (Aussetzer Zyl. 9) Elast. Kupplung Systemstelle 16- 17 (Aussetzer Zyl. 9) Flex.
  • Page 34 Bericht-Nr./ Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Report No. Speed Diagrams Speed Diagrams Speed Diagrams Speed Diagrams 08043087 2.2 Propeller 0 pitch, P=3785 kW Belastung nach Propellerkurve / Load acc. to Propeller Law Elast. Kupplung Systemstelle 12- 13 Elast. Kupplung Systemstelle 12- 13 Flex.
  • Page 35 Bericht-Nr./ Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Report No. Speed Diagrams Speed Diagrams Speed Diagrams Speed Diagrams 08043087 2.2 Propeller 0 pitch, P=3785 kW Belastung nach Propellerkurve / Load acc. to Propeller Law Elast. Kupplung Systemstelle 16- 17 Elast. Kupplung Systemstelle 16- 17 Flex.
  • Page 36 Bericht-Nr./ Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Report No. Speed Diagrams Speed Diagrams Speed Diagrams Speed Diagrams 08043087 2.2 Propeller 0 pitch, P=3785 kW Belastung nach Propellerkurve / Load acc. to Propeller Law Elast. Kupplung Systemstelle 12- 13 (Aussetzer Zyl. 9) Elast. Kupplung Systemstelle 12- 13 (Aussetzer Zyl. 9) Flex.
  • Page 37 Bericht-Nr./ Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Drehzahldiagramme Report No. Speed Diagrams Speed Diagrams Speed Diagrams Speed Diagrams 08043087 2.2 Propeller 0 pitch, P=3785 kW Belastung nach Propellerkurve / Load acc. to Propeller Law Elast. Kupplung Systemstelle 15- 16 (Aussetzer Zyl. 9) Elast. Kupplung Systemstelle 15- 16 (Aussetzer Zyl. 9) Flex.
  • Page 38 Bericht-Nr./ Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Report No. Natural Frequencies Natural Frequencies Natural Frequencies Natural Frequencies 08043087 2.1 Propeller max. pitch, P=8100 kW 1.Grad / Node 163 1/min 10 11 21 22 2.Grad / Node 222 1/min 10 11 21 22 3.Grad / Node 563 1/min 10 11 21 22...
  • Page 39 Bericht-Nr./ Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Report No. Natural Frequencies Natural Frequencies Natural Frequencies Natural Frequencies 08043087 2.1 Propeller max. pitch, P=8100 kW 4.Grad / Node 1071 1/min 10 11 21 22 5.Grad / Node 1513 1/min 10 11 21 22 6.Grad / Node 2287 1/min 10 11 21 22...
  • Page 40 Bericht-Nr./ Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Report No. Natural Frequencies Natural Frequencies Natural Frequencies Natural Frequencies 08043087 2.1 Propeller max. pitch, P=8100 kW 7.Grad / Node 2315 1/min 10 11 21 22 8.Grad / Node 2377 1/min 10 11 21 22 9.Grad / Node 2549 1/min 10 11 21 22...
  • Page 41 Bericht-Nr./ Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Report No. Natural Frequencies Natural Frequencies Natural Frequencies Natural Frequencies 08043087 2.1 Propeller max. pitch, P=8100 kW 10.Grad / Node 4159 1/min 10 11 21 22 11.Grad / Node 4321 1/min 10 11 21 22 12.Grad / Node 6624 1/min 10 11 21 22...
  • Page 42 Bericht-Nr./ Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Report No. Natural Frequencies Natural Frequencies Natural Frequencies Natural Frequencies 08043087 2.2 Propeller 0 pitch, P=3785 kW 1.Grad / Node 174 1/min 10 11 21 22 2.Grad / Node 232 1/min 10 11 21 22 3.Grad / Node 566 1/min 10 11 21 22...
  • Page 43 Bericht-Nr./ Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Report No. Natural Frequencies Natural Frequencies Natural Frequencies Natural Frequencies 08043087 2.2 Propeller 0 pitch, P=3785 kW 4.Grad / Node 1071 1/min 10 11 21 22 5.Grad / Node 1513 1/min 10 11 21 22 6.Grad / Node 2287 1/min 10 11 21 22...
  • Page 44 Bericht-Nr./ Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Report No. Natural Frequencies Natural Frequencies Natural Frequencies Natural Frequencies 08043087 2.2 Propeller 0 pitch, P=3785 kW 7.Grad / Node 2315 1/min 10 11 21 22 8.Grad / Node 2377 1/min 10 11 21 22 9.Grad / Node 2550 1/min 10 11 21 22...
  • Page 45 Bericht-Nr./ Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Eigenfrequenzen Report No. Natural Frequencies Natural Frequencies Natural Frequencies Natural Frequencies 08043087 2.2 Propeller 0 pitch, P=3785 kW 10.Grad / Node 4159 1/min 10 11 21 22 11.Grad / Node 4321 1/min 10 11 21 22 12.Grad / Node 6624 1/min 10 11 21 22...
  • Page 46 Bericht-Nr./ Erläuterungen Erläuterungen Erläuterungen Erläuterungen Report No. Explanations Explanations Explanations Explanations 08043087 Verwendete Maßeinheiten: Units of measurement used: Alle in diesem Bericht genannten Zahlenwerte All figures mentioned in this report correspond entsprechen dem internationalen Maßsystem (SI- with the International System of Units (SI Units). System).

  • Page 47: Acceptance Test Records

    Acceptance Test Records A1.10 Acceptance Test Records en / 20.02.2008 AA000095...
  • Page 48 Technical Data A1.10.20.32.33 Acceptance test records en / 22.05.2009 AA045559...
  • Page 53 Operating Instructions M20-M601C Operating Instructions en / 26.05.2009 AA000108...
  • Page 54 Table of Contents A3.01 Operating Instructions Table of Contents A3.01 Introduction A3.02 Safety Instructions A3.03 Instructions for Heavy Fuel Operation A3.04 Instructions for Heavy Fuel Operation Fuel system A3.04.07.00 Instruction for heavy fuel operation Care and supervision / Engine fuel A3.04.07.01 Instructions for heavy fuel operation Lubricating oil system...
  • Page 55 Table of Contents A3.01 Operational supervision Adjustment Instructions A3.06.09.01 Operational supervision Starting system A3.06.10.00 Operational supervision Partial load operation A3.06.18.00 Removal from operation Engine A3.07.00 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 Preservation...
  • Page 56 Table of Contents A3.01 Emergency operation Operational misfire A3.12.02.01 en / 26.05.2009 AA020023...
  • Page 57 The alteration of the fuel rack position may only be carried out by personnel who have received permission to do this from Caterpillar / MaK ! en / 17.01.2006...
  • Page 58 MaK. The preparations for the first startup are made by the MaK service engineer, who will explain the plant to the engine room staff in detail. Detail questions are to be settled on site from the operating instructions and explanations should be noted down in the instructions.
  • Page 59 Introduction A3.02 M20-M601C Basic notes on engine operation relating to the service life of combustion chamber components Of vital importance to the service life of highly loaded combustion chamber components such as inlet and exhaust valves, piston, and liner are the operating conditions of the engine. These, however, can be influ- enced to a very large extent by the operator of the plant.
  • Page 60 Introduction A3.02 M20-M601C Lubricating oil As regards the lubricating oil treatment it is of particular importance to ensure correct separation and filtration and keep an eye on the operating values of the oil. To this end, we recommend to have the lubricating oil analyzed at regular intervals by a laboratory.
  • Page 61 Introduction A3.02 M20-M601C Problems in case of wrongly adjusted injection viscosity: Low viscosity: • Seizure of the injection pumps due to decreased lubrication of the pump plunger (especial- ly in case of gas oil operation), • Formation of steam bubbles due to excessive temperature and resulting excess consump- tion.
  • Page 62 An introduction to the system specifications, requirements/characteristics can be carried out in the training center of Caterpillar / MaK. For the operators of the system this is a necessary requirement to the order. General safety instructions...

  • Page 63: Proposition 65 Warning

    Safety Instructions A3.03 M20-M601C Remote control The engine remote control of seegoing ships and inland ships will be constructed according to the safety regulations of the classification society. Inland ships must also observe the relevant customary safety recommendations! Safety measures for local control of the engine Before the start: •...

  • Page 64: Instructions For Heavy Fuel Operation

    Instructions for Heavy Fuel Operation A3.04 M20-M601C The instructions 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 concentrations and monitoring supervision.
  • Page 65 Instructions for Heavy Fuel Operation A3.04.07.00 Fuel system M20-M601C Fuel system The evermore intensive utilization of crude oils by modern processing is the reason the portion of the residual oils (heavy fuel) has become smaller and the portion of the in the residual oils remaining contaminating matter has, however, increased.
  • Page 66 Instruction for heavy fuel operation A3.04.07.01 Care and supervision / Engine fuel Care and supervision If you are uncertain of the bunker quality, a careful ascertation of the quality must take place. Basic schema of the heavy fuel system Diesel oil day tank Fuel pressure regulating valve Viscometer Fuel fine filter (duplex filter)
  • Page 67 Instruction for heavy fuel operation A3.04.07.01 Care and supervision / Engine fuel Note: The shown fuel circutory diagram is as well valid for operation with destillate fuel after periods of longer operation on low partial load and prior to planned service measures. For permanent opera- tion of the engine with destillate fuel, please refer to diagram A3.06.07.nn.
  • Page 68 Instruction for heavy fuel operation A3.04.07.01 Care and supervision / Engine fuel Day tank HT1 The day tank is designed to collect the treated fuel, for a minimum of 4 hours of full load operati- on. If the treatment plant is in order, it will always be filled to the overflow level. This prevents the formation of water condensation.
  • Page 69 Instruction for heavy fuel operation A3.04.07.01 Care and supervision / Engine fuel Circulating pump HP3, HP4 This pump is designed like a force pump. The pump relief valve has to be closed in operation. Final preheater HH1 The preheater is to lower the fuel viscosity to a level that is optimal for injection, 10 - 12 mm /s cSt;...
  • Page 70 Instructions for heavy fuel operation A3.04.08.00 Lubricating oil system M20-M601C Lubricating oil system The progressively declining quality of heavy fuel oils and the contamination contained therein can lead to engine troubles with increasing frequency if the lube oil is not cared for in an adequate manner. For this reason, the following instructions point out the importance of a careful lube oil treatment and supervision of the lube oil circuit so as to ensure a trouble-free and economical engine operation.
  • Page 71 Instructions for heavy fuel operation A3.04.08.01 Care and supervision / Lubricating Oil Care and supervision In heavy fuel operation, lube oil purification by separators is indispensible for a proper treatment. There are no other means to eliminate from the oil, the products resulting from cleaning and neutralisation (carbon and asphalt compounds) including water.
  • Page 72 Instructions for heavy fuel operation A3.04.08.01 Care and supervision / Lubricating Oil Basic schema of the lubricating oil system Precise schema see yard drawing Duplex lubeoil filter Lubeoil thermostat valve Lubeoil automatic filter Oil pressure regulaging valve Suction strainer Lubeoil separator Lubeoil cooler Lubeoil preheater Lubeoil sump tank...
  • Page 73 Instructions for heavy fuel operation A3.04.08.01 Care and supervision / Lubricating Oil 3.1. Prelubrication LP2 (standby or prelubrication pump) Only a sufficient prelubrication will produce the necessary oil filn on all bearings for engine star- ting. • Check the pressure build-up at the last main bearing (if there is no automatic engine locking). •...
  • Page 74 Instructions for heavy fuel operation A3.04.08.01 Care and supervision / Lubricating Oil • Check and clean the filter elements. See servicing instructions in the documents form the manufacturer, book C. • If the back-flushing filter flushes with oil, set the flushing flow (valve in the flushing line) so that there will be no drop in the working pressure, see A1.05.
  • Page 75 Initial Operation A3.05.00 Engine Initial Operation en / 20.02.2008 BA000022...
  • Page 76 Initial operation A3.05.07.01 Fuel system Fuel system After a long break from service and/or before the initial operation with heavy and destillated fuels we recommend: • Remove the fuel injectors according to A5.05.07.07.01.nn. • Check the nozzles and opening pressure according to A5.05.07.08.01.nn. •...
  • Page 77 Initial operation A3.05.08.00 Lubricating oil system M20-M601C Lubricating oil system The lubricating oil should be analyzed regularily during operation and after a longer period of engine down- time, see A4.05.08.nn. • Clean the lubricating oil duplex filter and the suction strainer, these both being situated in front of the lube oil force pump and the standby pump (see A5.05.08.02.01.nn, A5.05.08.04.01.nn) •...
  • Page 78 Initial operation A3.05.09.00 Cooling water system M20-M601C Cooling water system • Fill the cooling water system via the expansion tank. It is required that the cooling water has a level of corrosion protection (see A4.05.09.nn). • Set the correct position of the isolating and changeover cocks and/or valves on the cooling water system, see book C.
  • Page 79 Initial operation A3.05.11.00 Starting air system M20/M25/M32/M43/M282/M332C/M452/M453C/M551/M552C/M601/ M601C Do not close starting air shut-off valve during operation! • Apart from the starting system, the engine air system also supplies the emergency stop devices and the 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 the starting air.
  • Page 80 Where these devices are included in the scope of supply of the Caterpillar / MaK, a matching function diagram and a description has been created for this system, see Book C.
  • Page 81 Commissioning A3.05.18.00 Putting into operation/starting M20/M32/M43 Wrong start Start locking Run from remote control Speed adjustment S11 / H9 Start S12 / H10 Stop Change-over switch 1 = Engine 2 = Remote control Lamps test Change-over switch ahead / back en / 30.01.2001 BA000636...
  • Page 82 Commissioning A3.05.18.00 Putting into operation/starting M20/M32/M43 Emergency start • Switch change-over switch S13 to "1 = Engine". • Put emergency-off leaver (10) in operating position at the control station/regulation linkage. • Prelubricate engine. Switch on lubrication oil - lubrication - or backing pump approximately 5 minutes before starting the engine.
  • Page 83 3 - 4 min. Cold starting, below the above preheating temperature MaK generally advises against cold starting because of the higher wear and the high thermal loads on the parts forming the combustion chamber. Only the following brief instructions are therefore given: It is possible to start the cold engine on distillate fuel, however, this should only be done in exceptional cases and the engine should be warmed up very carefully.
  • Page 84 Operational Supervision A3.06.00 Engine Operational Supervision en / 20.02.2008 BA000058...
  • Page 85 Monitoring A3.06.05.00 Intake air temperature M20-M601C Operation in the case of low intake air temperatures The engine is only allowed to be operated at max. 90 % power if the air intake temperatures are below +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 compressor inlet is higher than +10 °C.
  • Page 86 Monitoring of operation A3.06.06.01 Exhaust system/Firing pressure M20/M25/M32/M43 The engine is designed so that an adjustment of delivery take-up as well as filling of the individual cylinders is no longer necessary. The individual erection heights of the injection pumps of the individual cylinders are secured by ground, cylinder-tied, firmly mounted plates.
  • Page 87 Operational supervision A3.06.06.04 Exhaust system/supercharging Waste gas temperatures 1.1 General A comparison of the waste gas temperatures with the values from the acceptance brake certificate and/or the records from the test/preliminary trial run is the best method of evaluating the thermodynamic behaviour of the engine and to additionally pinpoint any changes (supercharging, injection, combustion) from the new condition of the engine.
  • Page 88 Operational supervision A3.06.06.04 Exhaust system/supercharging 1.3 Permissible temperatures: The waste gas temperatures at 100% load should not exceed the following values according to the values specified in the acceptance brake certificates A1.10: Downstream of cylinder: + 70 ° ° ° ° C * Upstream of turbine: + 50 °...
  • Page 89 • Maximum permissible ignition pressure (pz) see acceptance brake certificate A1.10. • Permissible variation from cylinder to cylinder acc. to MaK ± 5 bar. • Variation/correction for cylinder pressure measurement: The pressure measured at the indicator valve is higher than in the combustion chamber...
  • Page 90 Operational supervision A3.06.06.04 Exhaust system/supercharging Indication Attention: Completely close the indicator valve after indication. If there is no longer any pressure at the indicator, release the connection. • Note down the following on the diagram: date, engine number, cylinder number, waste gas tempera- ture per cylinder, charge, speed, charge air pressure.
  • Page 91 Operational supervision A3.06.06.31 Exhaust system/supercharging M43/VM43 Turbocharger: Compressor side Preface How fast the compressor stage (compressor impeller and diffusor) will be contaminated depends on the cleanliness of the aspired air and the operating point. Dirt will be deposited in the air ducts in particular when oil or salt mists or various types of dust are aspired from the engine compartment or from outside.
  • Page 92 Operational supervision A3.06.06.31 Exhaust system/supercharging M43/VM43 Please see work card A5.05.06.05.00.nn for the operating procedure of the cleaning device. Note A thick layer of encrusted deposits can only be removed from the compressor after the latter has been removed from its location. That is why regular cleaning of the compressor during operation is recommended for machines with increased dust, oil, or salt mist exposure.
  • Page 93 Operational supervision A3.06.06.31 Exhaust system/supercharging M43/VM43 Turbocharger: Turbine side Preface The combustion of heavy oil in Diesel engines causes contamination of the turbine blades and nozzle rings of the turbochargers. The deposits on turbine components are caused by combustion products and include mostly soot, molten ash, slag, non-burned oil, fuel that was not burned completely and Sodium-Vanadyl Vanadate.
  • Page 94 Operational supervision A3.06.06.31 Exhaust system/supercharging M43/VM43 Turbine and Nozzle Ring Wet Cleaning Procedure There are two types of wet cleaning: - low load washing, (washing of turbine and nozzle ring at low exhaust gas temperature or low engine load **), - “thermo shock cleaning“...
  • Page 95 Operational supervision A3.06.06.31 Exhaust system/supercharging M43/VM43 Sequential or parallel cleaning? On “inline engines“, there is no difference. Compressor Cleaning (air-side) for “V-type engines“ : 3.2.1 During compressor cleaning, a certain amount of water is sprayed - sequentially - into each turbocharger; this procedure is called “sequential cleaning“. 3.2.2 The volume of the washing water container is designed for cleaning one turbocharger;...
  • Page 96 Operational supervision A3.06.06.31 Exhaust system/supercharging M43/VM43 Turbine-side Cleaning Parameters for : ABB turbochargers TPL 76 C < temperature before turbine intake: 430 ° C injection time: min. of 10 minutes water pressure before control valve : 2.0 bar ± 0.2 bar volume flow: (A5.05.06.13.01.nn) needle valve opening diameter:...
  • Page 97 Operational supervision A3.06.07.01 Changing the type of fuel M20-M601C Changing the type of fuel Changing over from distillate fuel to heavy fuel Prepare the system according to A3.05.07.nn. Changing over from heavy fuel to distillate fuel while the engine is running see diagram in A3.04.07.nn.
  • Page 98 Operational supervision A3.06.08.00 Lubricating oil system M20-M601C 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 indications see A1.05 and A1.06 and also Acceptance Test Records page A1.10. en / 16.12.1997 BA000078...
  • Page 99 Operational supervision A3.06.09.00 Cooling water system M20-M601C Cooling water system • Check the level in the fresh-water expansion tank. • Check the water pressure, temperatures and temperature rise. For 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.
  • Page 100 Operational supervision A3.06.09.01 Adjustment Instructions M20/M25/M32/M43 Adjustment Instructions for Cooling Water Pressure (Start of Standby Pump, Alarm, and Emergency Stop) There must be a minimum cooling water pressure of 2.5 bar at the engine in order to safely dissi- pate from the engine the amount of heat generated under full load operation. Terminal temperature difference Under full load operation the cooling water will be heated up by 7 to 10 K to a max.
  • Page 101 Operational supervision A3.06.09.01 Adjustment Instructions M20/M25/M32/M43 Minimum operating pressure (add static pressure) 3.5 bar Start of standby HT freshwater pump 3.3 bar Low HT freshwater pressure at engine inlet – Alarm 2102 3.1 bar Low HT freshwater pressure at engine inlet – Emergency stop 2103 2.9 bar For sensor equipment adjustment and test instructions please refer to the manual.
  • Page 102 Operational supervision A3.06.09.01 Adjustment Instructions M20/M25/M32/M43 Adjustment at 70 % nominal speed The engine is running at 70 % nominal speed and the electric standby pump is switched off. The pressure indicator for HT freshwater on the engine control stand displays an operating pressure of min.
  • Page 103 Operational supervision A3.06.09.01 Adjustment Instructions M20/M25/M32/M43 Adjustment at nominal speed: The engine is running at nominal speed and the electric standby pump is switched off. The pres- sure indicator for HT freshwater on the engine control stand displays an operating pressure of min.

  • Page 104: Air Starting System

    Operational supervision A3.06.10.00 Starting system M25-M601C Air starting system • Check the pressure in the air bottles. • Drain the water daily from the air bottles, compressed air filter, water traps and fittings. • Secure the compressed air supply for the emergency stop facility! •...
  • Page 105 Operational supervision A3.06.18.00 Partial load operation M20-M601C Partial load operation with heavy fuel In order to prevent increased wear and tear, pollution of air and exhaust systems and an increased contamination of the lube oil, the partial load operation has to be carried out with distillate fuel only. The distillate fuel provides for an unlimited partial load operation.
  • Page 106 Operational supervision A3.06.18.00 Partial load operation M20-M601C Note: If neither a changing-over to destillate fuel nor to high-load operation is possible, an increased contamination of the lubricating oil is to be expected! Notes: • The permissible exhaust gas temperature after the turbine (see A3.06.06.nn) must not be exceeded over the entire operating range, including partial load.
  • Page 107 Removal from operation A3.07.00 Engine Removal from Operation en / 21.02.2008 BA000094...
  • Page 108 Within the framework of this decommissioning, only the stoppage of the engine at the main engine is discussed. The functions of the remote control are documented with a function diagram and its description if it is included in the scope of supply of the Caterpillar / MaK, see Book C. Attention:...
  • Page 109 Decommissioning A3.07.18.02 Decommissioning/Stopping M20/M25/M32/M43 Wrong start Start locking Run from remote control Speed adjustment S11 / H9 Start S12 / H10 Stop Change-over switch 1 = Engine 2 = Remote control Lamps test Change-over switch ahead / back en / 11.05.2000 BA000630...
  • Page 110 Decommissioning A3.07.18.02 Decommissioning/Stopping M20/M25/M32/M43 Note: The push-button switch "Reset" located at the safety system must be activated after an activation of the external emergency stop device! Aftercooling If the engine is stopped under load, it must be aftercooled for approximately 5 min. to prevent steam bubble formation.
  • Page 111 Decommissioning A3.07.18.02 Decommissioning/Stopping M20/M25/M32/M43 • Keep lubrication oil system warm by means of permanent separation to prevent an accumulation of condensation products and sludge. • Switch off ventilation for engine room only if required to make cooling-off of the engine more difficult. Before a long term operation stop (e.g.
  • Page 112 Danger of Frost A3.08.00 Engine Danger of Frost en / 20.02.2008 BA000106...
  • Page 113 Danger of frost A3.08.01.00 Antifreeze protection M20-M601C Antifreeze protection If the engine is repeatetely taken out of service for only short periods (without a device in the system to keep it warm), during times when the temperature can fall under freezing point, it will be necessary to protect the system by the use of an antifreeze solution with protection against corrosion (see A4.05.09.nn).
  • Page 114 (under deck) of seagoing ships into similar international areas! Attention: The measures for preservation for subtropical or tropical areas are to be coordinated with Caterpillar / MaK according to the destination and storage location and the intended period of storage! en / 16.12.1997 BA000114...
  • Page 115 Preservation A3.09.00.00 Engine M20-M601C Package/Storage: The measures for storage and package depend on period of storage and storage location. The short term preservation provides sufficient protection when stored and placed in well ventilated machine rooms/halls and when transported on road under European climate conditions. In case of storage in the open the engine is to be carefully protected against atmospheric influences with a water restistent tarpaulin or a plastic foil.
  • Page 116 Preservation A3.09.01.00 Short term preservation M20-M601C Light preservation (short term preservation) Required tools, preservation, cleaning and auxiliary means spray gun, injection pipe, brush preserving oil that can be sprayed and does not dry (e.g. Aral Konit SAE 30) a viscous, sticking and drying preservative (e.g. Valvoline Tectyl 506) corrosion-inhibiting oil (e.g.
  • Page 117 Preservation A3.09.01.00 Short term preservation M20-M601C Lubricating oil system • Cleaning the lubricating oil duplex filters, see A5.05.08.04.01.nn. Note: The lubricating oil remains in the circuit if the values required for engine operation are in order (see A4.05.08.nn). Recommendation: Pump fresh lubricating oil through the engine circuit, until clean oil drips out of the last small end bearing.
  • Page 118 Preservation A3.09.01.00 Short term preservation M20-M601C External preservation • Clean or wash all unpainted bright parts of the engine. 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! •...
  • Page 119 Preservation A3.09.02.00 Long term preservation M20-M601C Heavy preservation (long term preservation) Required tools, preservation, cleaning and auxiliary means spray gun, injection pipe, brush, cloth preserving oil that can be sprayed and does not dry (e.g. Aral Konit SAE 30) a viscous, sticking and drying preservative (e.g. Valvoline Tectyl 506) non-drying corrosion-inhibiting grease (e.g.
  • Page 120 Preservation A3.09.02.00 Long term preservation M20-M601C Starting system and starting air distributor • Remove the sealing flange from the starting air distributor. • Slacken the drain plug at the staring valve as well as the banjo plugs of the air feed lines at the starting valves of all cylinders.
  • Page 121 Preservation A3.09.02.00 Long term preservation M20-M601C External preservation • Close the crancase ventilation with protective plug so that it is air tight (see 1.8). • Clean or wash all unpainted bright parts of the engine. 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! •...
  • Page 122 Preservation A3.09.03.00 Depreservation M20-M601C Depreservation Required cleaning and auxiliary means Clean turbine or hydraulic oil (A4.05.08.nn) Solvent-free washing and/or cleaning agent Attention: The engine finish may not be etched by the cleaning and/or washing agent! Use only correspondingly suitable washing agents! Keep to operation, safety and sanitation instructions of the manufacturer! Depreservation measures The following measures are to be implemented after a light or heavy preservation.
  • Page 123 Preservation A3.09.03.00 Depreservation M20-M601C Governor (mechanical-hydraulic regulator) • Re-establish the correct oil level in the governor. • Dial governors: remove any excess preserving grease from the gear wheels behind the governor dial. Turbocharger (with independent lubrication) • If necessary, clean the preserved parts according to instructions of the manufacturer. •...
  • Page 124 Running-in A3.10.00 Engine Running-in en / 16.02.2001 BA000242...
  • Page 125 Running-in A3.10.01.00 Engine M20-M601C Running-in All engines leaving our works have been fully run in, thus no further running in instructions are required. In the case of certain repairs however, such as reconditioning work on pistons (A5.05.02.10.01.nn), piston rings (A5.05.02.07.01.nn) and cylinder liners (A5.05.03.04.02.nn), as is pointed out on the job card in question, the following instructions must be observed: •...
  • Page 126 Fault Tracing A3.11.00 Engine Fault Tracing en / 20.02.2008 BA000130...
  • Page 127 Fault tracing A3.11.18.00 Introduction M20-M601C Fault tracing In the event of any irregularity in the machinery the characteristic of the trouble should be ascertained, the fault traced and the cause found. Remedial actions must be initiated immediately. Attention: In case of discernible faults stop the motor timely to avoid the risk of greater damages. Minor troubles, whose cause is not obvious or whose influence on operation seems to be less important for the present, must never be ignored.
  • Page 128 After standstill of an engine that has run hot, wait 10 to 15 minutes before opening the crankcase doors in order to prevent a possible explosion by air supply from outside. If ne- cessary, contact the Caterpillar/ MaK-Customer Service! Checks after an engine stop due to oil mist alarm:...
  • Page 129 Fault tracing A3.11.18.01.01 Oil mist detector M25-M601C Extended checks: Check of the main running gear: • Remove all crankcase doors. • Check the main running gear for ease of movement by turning the crankshaft. • Visually inspect the main running gear (bearings, piston skirts, liners, etc.) for discoloration and traces of seizing.
  • Page 130 The engine must not be restarted until the disturbance or damage has been eliminated. Contact the Caterpillar / MaK Customer Service! Note: The indicated checks are intended to assist in troubleshooting and will allow to identify the main causes of an oil mist alarm.
  • Page 131 Fault tracing A3.11.18.02 Remedial measures M20-M601C Engine starts poorly or does not start at all Possible cause: Remedy: • Air pressure in the starting air bottle is too See A1.05 for required bottle pressure • Solenoid valve to the air starter is defective •...
  • Page 132 Fault tracing A3.11.18.02 Remedial measures M20-M601C Filter differential pressure is too high during starting/pre-lubrication Possible cause: Remedy: • Fuel filter is dirty Clean filter; see A5.05.07.12.01.nn • Differential pressure gauge is defective • Oil is too cold • Water in the oil causes greasy emulsion and oil thickening •...
  • Page 133 Fault tracing A3.11.18.02 Remedial measures M20-M601C Engine speed is not steady Possible cause: Remedy: • Too much clearance in the linkage between governor and injection pump • Fuel line is sluggish • Friction in the injection pumps caused by excessive fuel feed pressure •...
  • Page 134 Fault tracing A3.11.18.02 Remedial measures M20-M601C Exhaust gases are blue Possible cause: Remedy: Oil in the combustion chamber • Piston rings are sticking For servicing the pistons and rings see, A5.05.02.07.01.nn • Severe wear and tear of cylinder liner: For checking the cylinder liners see scoring, ovality A5.05.03.03.01.nn •...
  • Page 135 Emergency Operation A3.12.00 Engine Emergency Operation en / 20.02.2008 BA000142...
  • Page 136 Emergency operation A3.12.01.00 With a defective turbocharger M20-M601C Defective turbocharger For supercharged marine diesel engines, it may occur that they have to continue their operation as a naturally aspirated engine with a reduced output, when the turbocharger has failed. As the valve timing of the engine has been adjusted to full load, the engine will exhaust part of the combustion gases into the induction manifold and take them in again when the turbocharger is inoperative (and also normally in the lower partial load range).
  • Page 137 Emergency operation A3.12.01.02 With a defective turbocharger M20-M601C Emergency operation of the main engine • Stop the engine • Remove the air filter silencer • Shut down the turbocharger (block the rotor), see manufacturer´s instructions book C. Note: If blocking is not possible: disassemble the rotor.
  • Page 138 Emergency operation A3.12.01.02 With a defective turbocharger M20-M601C Monitoring the engine while the turbocharger is defective Change the fuel rack position gradually until the exhaust gas temperature after the turbine is a maximum 500 ° ° ° ° C Carefully monitor the exhaust gas temperatures during emergency operation, especially if exhaust gas alarms have been cut out.
  • Page 139 Emergency operation A3.12.01.03 With a defective turbocharger Defective turbocharger Under ship service conditions the turbocharged diesel engine may have to continue to operate in spite of a turbocharger failure as naturally aspirated engine with reduced output. As the valve timing of the engine has essentially been adjusted to operation with turbocharger, the engine will exhaust part of the combustion gases into the charge air manifold and take them in again in the event of a turbocharger failure (and also in the lower part load range).
  • Page 140 Emergency operation A3.12.01.03 With a defective turbocharger • Remove the cover from the free end of the charge air duct (B1.05.06.437240) • Always remove the expansion joint between air inlet casing and turbocharger (B1.05.06.437250) • Put the engine into operation with reduced output. •...
  • Page 141 Emergency operation A3.12.01.03 With a defective turbocharger Multi-engine plants with one propeller The propellers are normally of the controllable pitch type. Declutch the engine with the defective turbochar- ger. Set the propeller pitch so that the engine remaining in service can be run at rated speed and conti- nuous power.
  • Page 142 Emergency operation A3.12.02.00 Operational misfire M20-M601C Operational misfire - protection of the flexible coupling The following instructions and restrictions refer only to engines with flexible couplings. Attention: If one cylinder fails partially or completely, this will always increase the stresses in the flexible coupling.
  • Page 143 Emergency operation A3.12.02.00 Operational misfire M20-M601C The permissible surface temperature in misfiring operation is approx. 60 C. If heating is only moderate, the power output can be increased in steps up to max. 80 % of the rated power, which should not be exceeded for thermal reasons. •...
  • Page 144 Emergency operation A3.12.02.01 Operational misfire M20/M25/M32/M43 Operational misfire In general, „operational misfire“ means that the engine is operated with non-uniformly loaded cy- linders. This will cause additional loads which are the higher the more the march of the gas pressure of a defective cylinder deviates from the remaining cylinders.
  • Page 145 The engine output possible under these conditions is approx. 35 % of the rated output. In case of doubt please contact Caterpillar / MaK . Twin engine systems / generator systems The damaged engine should not be restarted.

  • Page 146: Operating Media

    Operating Media Operating Media en / 26.05.2009 AA020105...

  • Page 147: Regulations And Recommendations Engine

    Table of Contents A4.01 Operating Media Table of Contents A4.01 Introduction A4.02 Safety instructions A4.03 Regulations and Recommendations Engine A4.05.00 Regulations and care Engine fuel A4.05.07.00 Regulations and care Heavy fuels A4.05.07.02 Regulations and care CCAI-limit curves A4.05.07.03.01 Regulations and care Limit specification A4.05.07.04 Regulations and care...
  • Page 148 Introduction A4.02 M20-M601C The use of suitable and unobjectionable operating media is an assumption for working readiness and relia- bility of surface of the engine system. 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 guaranteed.
  • Page 149 Safety instructions A4.03 M20-M601C Safety instructions • No open fire during work at the fuel system! • No smoking! • Lube oil and fuel vapours may ignite on contact with ignition sources! • Caution! Burning and scalding hazard when handling hot process materials! During all work or contact with: •...
  • Page 150 Regulations and Recommendations A4.05.00 Engine Regulations and Recommendations en / 20.02.2008 BA000158...
  • Page 151 Regulations and care A4.05.07.00 Engine fuel M20-M601C For the Caterpillar / MaK-engines used in shore-based and ship-based operation according to their equip- ment condition two product groups of fuels are allowed, these are: • Destillate fuel • Heavy oil en / 28.06.1996...
  • Page 152 Regulations and care A4.05.07.02 Heavy fuels M20-M601C Heavy fuels (Viscosity in mm /s (cSt) at 100 °C for CIMAC, at 50 °C for ISO) All fuels are called heavy fuels that consits in the main of residual oils from oil refining. General Requirements: The fuel must represent a homogenous mixture of hydro-carbon coming from the mineral oil processing.
  • Page 153 – Introduction of minimum viscosity with CIMAC. The CIMAC-specification is the basis for the Caterpillar / MaK heavy fuel specification (A4.05.07.05). BSI-Specification The BS MA 100 which came into force in 1982 was with drawn in September 1989. Since then the contents of BS MA 100 conforms with ISO 8217.
  • Page 154 50 °C, 80 °C and Redw. I sec. The heavy fuel grades permitted for Caterpillar / MaK engines can be found in the table “Permissible limits for heavy fuels to be burnt in Caterpillar / MaK engines” (A4.05.07.04).
  • Page 155 Caribbean area. It will frequently happen in the near future that the limits of the Caterpillar / MaK heavy fuel specifica- tion are reached owing to a general change on the fuel market. If it is intended to take such fuels for a lengthy period of time and the owners have no experience with this, we recommend to contact Caterpillar / MaK first.
  • Page 156 High-temperature corrosion can occur on exhaust valves and turbine blades when burning heavy fuel containing vanadium and sodium. Caterpillar / MaK does not require additives against high-temperature corrosion. Should they be used, however, it must at least be ensured that they are not sensitive to water, compatible with the fuel in any case and no cause of troubles, in the fuel filters, for instance.
  • Page 157 Regulations and care A4.05.07.03.01 CCAI-limit curves M20-M601C CCAI-limit curves Density (kg/l 15 C) to be avoided * limited approved * permissible Viscosity (cSt 50 C) en / 28.05.1998 BA000178...
  • Page 158 Regulations and care A4.05.07.04 Limit specification M20/M25/M32/M43 Admissible limit specification for the operation with heavy fuel in Caterpillar/MaK engines Engine series Limit M 20 specification CIMAC A10 CIMAC B10 CIMAC C10 CIMAC D15 CIMAC E25 CIMAC F25 CIMAC G35 CIMAC H35...
  • Page 159 Regulations and care A4.05.07.05 Heavy fuel specification M20-M601C en / 27.11.2006 BA000186...
  • Page 160 Regulations and care A4.05.07.06 Viscosity temperature sheet M20-M601C en / 28.06.1996 BA000190...
  • Page 161 This is usually given as the Base Number (BN), or as Alka- linity Value (AV) and recorded in mgKOH/g. For Caterpillar/MaK engines operating on heavy fuel this value should be between 30 and 40 mg KOH/g for fresh oils.
  • Page 162 Cater- pillar/MaK. Furthermore no guarantee can be given for poor quality engine and lubricating oil care nor for the use of non-approved fuels. Proof that a defect has not been brought about by the lubricating oil must be provided by the user.
  • Page 163 DISOLA M 4015 AURELIA XL 4030 AURELIA TI 4030 Proven in use I I Permitted for controlled use.When these lubricating oils are used, Caterpillar/MaK must be informed Caterpillar/MaK because at the moment there is insufficient experience available in engines. Otherwise the warranty cover is invalid.
  • Page 164 AURELIA TI 4030 AURELIA TI 4040 Proven in use I I Permitted for controlled use.When these lubricating oils are used, Caterpillar/MaK must be informed because at the moment there is insufficient experience available in Caterpillar/MaK engines. Otherwise the warranty cover is invalid.
  • Page 165 20 % of the amount in circulation has been used. Note: Modern MaK engines are characterized by low lubricating oil consumption rates of < 1 g/kWh, which in individual cases may even be significantly below this value.
  • Page 166 1.6.4 Contamination When Caterpillar/MaK engines are running on heavy fuel, separators are specified to keep the oil clean. In this way the content of insolubles can usually be kept well below 1 % by weight. If the content increases beyond 1 % weight, the oil must be separated more intensively.
  • Page 167 Regulations and care A4.05.08.00 Lubricating Oil M20-M601C Lubricating oil for exhaust turbocharger, hydraulic governor and reversing controls A turbine or hydraulic oil with very good anti-oxidation properties and a viscosity between 68 and 90 mm (cSt) at 40 °C should be selected. For highly loaded ABB-turbochargers fully synthetic special oils (see footnote) are recommended.
  • Page 168 Regulations and care A4.05.08.00 Lubricating Oil M20-M601C Multi-purpose grease – lithium saponified – consistency number 2 (also suitable for pneu- matic control instruments) Lubricating oil firm Brand name AGIP GR MU 2 ENERGREASE MP-MG 2 CALTEX MULTIFAK EP 2 CASTROL SPHEEROL SX 2 CHEVRON DURA-LITH GREASE EP 2...
  • Page 169 Regulations and care A4.05.09.00 Cooling Water M20-M601C Recirculating Cooling Water The cooling system consists of a closed cooling water circuit with a cooling water volume which must be kept constant by topping up, depending on the evaporation loss. The checking of the recirculating cooling water level has to occur at the expansion tank.
  • Page 170 Regulations and care A4.05.09.00 Cooling Water M20-M601C *) Water hardness: Water which does not fulfil the above requirements must be hardened or softened. Water with a hardness of > 12° (10°) dGH must be brought within the specified range by mixing with condensate or fully de-ionized water (by ion exchange), see Diagram I (A4.05.09.03).
  • Page 171 Association for Internal Combustion Engines Inc). MaK/CAT will issue a recommendation on the basis of the results of the test. No liability for the anticorrosive agent used will be accepted because MaK/CAT is unable to control the recipe and treatment.
  • Page 172 Attention: It is important to avoid too low concentration, because this may result in crevice corrosion! As far as we know, the following materials are being used in MaK/CAT Diesel engines at the moment: Manufacturer Additive...
  • Page 173 Regulations and care A4.05.09.01 Treatment of cooling water M20-M601C Note: A chemical anticorrosive agent is added to the delivery scope (fittings) of some stationary engines. In any case, a filling with this chemical is to be implemented prior to commisioning. Checking and care of the treated water Anti-corrosion oil A daily check of the coolant level in the sight glass on the expansion tank is just as important as...
  • Page 174 Regulations and care A4.05.09.02 Changing the cooling water M20-M601C Changing the cooling water Anti-corrosion oil emulsion The anti-corrosion emulsion must be changed at the latest every 7500 operating hours, at least annually if the 7500 operating hours are spread over a period of more than one year due to long breaks in operation.
  • Page 175 When an anti-freeze agent is used, a reduction in cooling efficiency must be expected. In cases of doubt MaK should be contacted. For summer operation, it is advisable to drain off the cooling water with anti-freeze in it and replace it with cooling water with chemical corrosion protection in order to guarantee adequate radiator performance at higher ambient temperatures.
  • Page 176 Regulations and careÿ A4.05.09.03 Diagram I M20-M601C Diagram I Determining the cooling water mixture for 10 dGH Cooling system capacity (litres) Example: Cooling system capacity: 2300 l Hardness of available fresh water: 19 dGH To determine the fresh water mixture, proceed from the abscissa “Cooling system capacity” (2300 l) via the intersection of the 19 dGH line to the ordinate “Amount used”...
  • Page 177 Regulations and care A4.05.09.04 Diagram II + III M20-M601C Diagram II Emulsion freshening for weak concentration measured oil concentration in vol. % amount of oil to be added in litres to obtain a 0.7 % oil concentration Diagram III Emulsion freshening for excessive concentration measured oil concentration in vol.
  • Page 178 Maintenance Maintenance en / 26.05.2009 AA000026...
  • Page 179 Table of Contents A5.01 Maintenance Table of Contents A5.01 Introduction A5.02 Safety instructions A5.03 Periodical schedule Heavy fuel A5.04.02 Engine, cylinder head A5.05.01 Valve clearance A5.05.01.01.01.00 Valve Rocker Brackets A5.05.01.02.01.30 Valve Rockers A5.05.01.02.02.00 Valve Rocker Bush A5.05.01.02.03.00 Valve Rotor A5.05.01.03.01.00 Valve guide/Oil scraper ring A5.05.01.05.01.01 Media guiding system...
  • Page 180 Table of Contents A5.01 Engine, gear A5.05.02 Running Gear / Engine Timing A5.05.02.01.01.00 Crank Web Deflection A5.05.02.02.01.00 Bearing Shells and Bearing Bushes A5.05.02.03.03.01 Bearing Shells A5.05.02.03.07.01 Big End Bearings A5.05.02.04.01.30 Big End Bearings A5.05.02.04.02.30 Hydraulic Jack A5.05.02.04.51.00 Main Bearings A5.05.02.05.01.30 Main Bearings A5.05.02.05.02.30 Main Thrust Bearings...
  • Page 181 Table of Contents A5.01 Engine, regulation A5.05.05 Control Shaft Bearings A5.05.05.01.02.00 Starting Valve A5.05.05.02.01.02 Control Rod A5.05.05.08.01.00 Compressed-Air Filter A5.05.05.09.06.00 Compressed-Air Filter A5.05.05.09.06.01 Engine, exhaust gas system/supercharging A5.05.06 Exhaust Line A5.05.06.01.01.17 Exhaust Line A5.05.06.01.01.18 Charge Air Cooler A5.05.06.04.02.30 Exhaust gas turbocharger A5.05.06.05.00.30 Exhaust gas turbocharger A5.05.06.13.01.30...
  • Page 182 Table of Contents A5.01 Engine, starting system A5.05.10 Stop Piston A5.05.10.03.01.00 Engine control equipment A5.05.11 Pressure Switches A5.05.11.01.02.01 RPM Switch A5.05.11.05.01.02 Lubricating Oil/Cooling Water Thermostat A5.05.11.06.01.01 Pressure Switch A5.05.11.06.05.02 Pressure Switch A5.05.11.06.06.02 Crankcase Monitoring Device A5.05.11.09.01.03 Engine auxiliary units A5.05.12 Vibration Damper A5.05.12.04.01.02 Vibration Damper...
  • Page 183 The explanations are used to make the user of this engine plant familiar with the existing mainte- nance system of MaK and to interest and deepen the understanding of the user for the problems and importance of the “Scheduled maintenance”.
  • Page 184 Maintenance work to be carried out independent of deadlines List of work which may be required in the scope of scheduled work which cannot be allocated to a deadline. * will be handed over by the MaK service department for commissioning of the engine en / 27.02.2008 AA000021...
  • Page 185 Introduction A5.02 M20-M601C 2.2.2 Job cards The job cards are instructions for inspection, maintenance, repair and safety check. ¬ Title of the job card Activity Maintenance work Discharge valve A5.05.01.04.01.03 Inspection / Dismounting and mounting Operating hours/maintenance deadline M 551 / M 552 6,000 / 12,000 Engine type Register...
  • Page 186 Introduction A5.02 M20-M601C The job card number consists of the index breakdown (A5.05) and the maintenance number (bold) subdivided into four pairs of digits. • The first pair of digits indicates the engine main maintenance group: Cylinder head Lube oil system Driving mechanism Cooling water system Engine housing...
  • Page 187 Typical consumption parts which are replaced routinely or any time mounting is carried out (O- ring seals, O-rings etc.) are not considered defective parts. * The map will be handed over by the MaK service department for commissioning of the engine en / 27.02.2008...

  • Page 188: General Safety Instructions

    Safety instructions A5.03 M20-M601C Safety instructions Work safety symbol All texts marked with this symbol in the maintenance sheets are safety instructions which have to be observed in all cases in order to eliminate danger to life and limb of the user or of third parties! General safety instructions The provisions of the relevant accident prevention regulations of the appropriate employer's liability insurance association are to be observed any time operation and...
  • Page 189 Safety instructions A5.03 M20-M601C • When work is being carried out on engines and systems, the switch-on devices have to be switched off and protected. In order to prevent reconnection, the engines and systems have to be marked with a plate “Do not switch” or an appropriate pictogram plate! •...
  • Page 190 Safety instructions A5.03 M20-M601C Working on electrical equipment • Work on the electrical equipment of the engine/plant must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician in accordance with the electrical engineering rules and regulations! •...
  • Page 191 Safety instructions A5.03 M20-M601C Handling of liquid nitrogen or carbon dioxide snow • When handling liquid nitrogen or carbon dioxide snow, safety shoes, safety gloves and safety glasses are to be worn in order to avoid injuries. Observe protection against cold! •...
  • Page 192 Periodical schedule A5.04.02 Heavy fuel M43/VM43 Intervall Designation / Doc-Nr. Work to be carried out Remarks Daily inspection and monitoring procedures (if it is not automated) -------------------------------------------------------------------------------------------------------------------------------- General Engine operating data A1.10 Compare with acceptance test records: Speed, rating Temperature Lubricating oil A1.06 Engine inlet;...
  • Page 193 Periodical schedule A5.04.02 Heavy fuel M43/VM43 Intervall Designation / Doc-Nr. Work to be carried out Remarks Fuel system Fuel duplex filter A5.05.07.12.01.08 Maintenance/Cleaning at 50 % differential pressure Pressure Air bottles A3.06.10.00 Drain en / 26.05.2009 AA000649 2/10...
  • Page 194 Periodical schedule A5.04.02 Heavy fuel M43/VM43 Intervall Designation / Doc-Nr. Work to be carried out Remarks First inspection and maintenance procedures Work to be carried out after the first commissioning or after major repairs. -------------------------------------------------------------------------------------------------------------------------------- 24 h Duplex fuel filter A5.05.07.12.01.08 Maintenance/Cleaning Strainer...
  • Page 195 Periodical schedule A5.04.02 Heavy fuel M43/VM43 Intervall Designation / Doc-Nr. Work to be carried out Remarks Periodical maintenance procedures -------------------------------------------------------------------------------------------------------------------------------- 24 h Compressed air strainer A5.05.05.09.06.nn Maintenance/Cleaning 24 h Exhaust gas turbocharger A5.05.06.05.00.30 Maintenance/Cleaning see book C 150 h Valve rotor A5.05.01.03.01.00 Inspection/Evaluate 150 h...
  • Page 196 Periodical schedule A5.04.02 Heavy fuel M43/VM43 Intervall Designation / Doc-Nr. Work to be carried out Remarks 3.750 h Starting valve A5.05.01.09.01.00 Inspection/Checking 3,750 h Governor Oil change see book C 3,750 h Monitors Checking of alarm and safety system see book C 3,750 h Running gear/engine timing A5.05.02.01.01.00...
  • Page 197 Periodical schedule A5.04.02 Heavy fuel M43/VM43 Intervall Designation / Doc-Nr. Work to be carried out Remarks 7,500 h Injection valve A5.05.07.09.01.30 Repair/Disassembly and reassembly 7,500 h RPM-switch A5.05.11.05.01.02 Inspection/Adjust 7,500 h Lubricating oil/Cooling water thermostat A5.05.11.06.01.01 Maintenance/Checking 7,500 h Oil mist detector A5.05.11.09.01.03 Inspection/Checking 12,000 h...
  • Page 198 Periodical schedule A5.04.02 Heavy fuel M43/VM43 Intervall Designation / Doc-Nr. Work to be carried out Remarks 15,000 h Timing gear train A5.05.04.08.01.02 Inspection/Checking 15,000 h Governor drive A5.05.04.08.03.02 Inspection/Disassembly and reassembly 15,000 h Exhaust gas turbocharger Maintenance/Cleaning resp. revision of turbocharger see book C 15,000 h Injection pump...
  • Page 199 Periodical schedule A5.04.02 Heavy fuel M43/VM43 Intervall Designation / Doc-Nr. Work to be carried out Remarks 30,000 h Cylinder liner A5.05.03.03.01.01 Inspection/Measuring at all cylinder units 30,000 h Cylinder Liner A5.05.03.04.01.00 Maintenance/Disassembly 30,000 h Camshaft bearings A5.05.04.01.01.00 Inspection/Checking at all bearings 30,000 h Camshaft bearings A5.05.04.01.02.00...
  • Page 200 Periodical schedule A5.04.02 Heavy fuel M43/VM43 Intervall Designation / Doc-Nr. Work to be carried out Remarks Non-interval dependent maintenance procedures -------------------------------------------------------------------------------------------------------------------------------- Valve rocker brackets A5.05.01.02.01.30 Maintenance/Disassembly and reassembly Valve rocker bush A5.05.01.02.03.00 Inspection/Replace Media guiding system A5.05.01.05.50.01 Maintenance/Disassembly and reassembly Cylinder head A5.05.01.06.01.30 Maintenance/Disassembly...
  • Page 201 Periodical schedule A5.04.02 Heavy fuel M43/VM43 Intervall Designation / Doc-Nr. Work to be carried out Remarks Piston A5.05.02.10.01.30 Maintenance/Reassembly Cooling water distributor housing A5.05.03.02.00.00 Maintenance/Disassembly and reassembly Cylinder liner A5.05.03.04.02.00 Maintenance/Reassembly Camshaft A5.05.04.04.01.06 Repair/Disassembly and reassembly Timing Gear Train A5.05.04.08.02.02 Maintenance/Disassembly and reassembly Charge air cooler A5.05.06.04.02.30...

  • Page 202: Valve Clearance

    Valve clearance A5.05. 01.01.01.00 Inspection / Adjust M43/VM43 1500 See also: 02.01.01.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Inspection: The valve clearance must be checked every 1,500 operating hours and adjusted if necessary.
  • Page 203 Valve clearance A5.05. 01.01.01.00 Inspection / Adjust M43/VM43 1500 Release valve bridge of rocker arm (Fig. 1/1). Enlarge clearance „S“ and/or flap back rocker arm (1). Release locknut (Fig. 2/3) and unsrew set- ting bolt (4) until a contact in „X” without clearance is reached.
  • Page 204 Valve Rocker Brackets A5.05. 01.02.01.30 Maintenance / Disassembly and reassembly M43/VM43 See also: 01.01.01.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Store hydraulic device kit consisting of clamping cylinder W1.1...
  • Page 205 Valve Rocker Brackets A5.05. 01.02.01.30 Maintenance / Disassembly and reassembly M43/VM43 Remove the four rocker arm nuts with the hydraulic clamping unit. 1.5.1 Place the hydraulic clamping elements (W1.1) on the round nuts (1), unscrew threaded bush up to the limit stop and pull. Ensure that the slits are easily accessible. 1.5.2 Connect the clamping elements with the high pressure pump by means of the high pressure lines (W1.2, W1.3).
  • Page 206 Valve Rocker Brackets A5.05. 01.02.01.30 Maintenance / Disassembly and reassembly M43/VM43 Note: If the round nuts cannot be removed, the pressure on the nuts can be increased by ca. 50 bar more. If the round nuts are subject to higher pressure, the pin threading may stretch, which can cause the round nuts to lock into place.
  • Page 207 Valve Rocker Brackets A5.05. 01.02.01.30 Maintenance / Disassembly and reassembly M43/VM43 2.5.6 Check to ensure that the round nut is seated properly. • Reduce pressure by 50 bar. • The round nuts must be tight enough that they cannot be loosened with the pin. 2.5.7 Depressurize the clamping elements, dismantle the clamping unit.
  • Page 208 Valve Rockers A5.05. 01.02.02.00 Maintenance / Disassembly and reassembly M43/VM43 30000 See also: 01.02.01.nn, 01.02.03.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Maintenance: Disassemble intake and exhaust rocker arms and check bearing clearance every 30,000 h Note:...
  • Page 209 Valve Rockers A5.05. 01.02.02.00 Maintenance / Disassembly and reassembly M43/VM43 30000 Check the bearing surfaces of the ball pin (Fig. 2/10) and the adjusting screw (12) for wear and damage. Replace parts as ne- cessary. Cool ball pins to -195 °C with liquid nitrogen and slide into place.
  • Page 210 Valve Rocker Bush A5.05. 01.02.03.00 Inspection / Replace M43/VM43 See also: 01.02.01.nn, 01.02.02.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 0,40 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Copper punch W1 * * no picture Note: The liners may only be lubricated with oil.
  • Page 211 Valve Rotor A5.05. 01.03.01.00 Inspection / Evaluate M43/VM43 See also: 01.07.01.nn, 01.10.00.nn Spare parts list: B1.05.01.432107, B1.05.01.432225 Time requirement: 1 Pers./ 0,10 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Inspection: of the valve rotor and the free-wheels every 150 h Note: The valve rotational speed in relation to the engine speed must be measured and documented...
  • Page 212 Valve Rotor A5.05. 01.03.01.00 Inspection / Evaluate M43/VM43 The valve rotor or free-wheel is functioning correctly when the valves rotate evenly in relation to the engine speed. The valve rotor and free-wheel must be lubricated with a few drops of oil-gas oil mixture (mixture ratio 1:1) if the rotational speed is noticeably slower than the speed indicated for new valves.
  • Page 213 Valve guide/Oil scraper ring A5.05. 01.05.01.01 Inspection / Replace M43/VM43 15000 See also: 01.01.01.nn, 01.02.01.nn, 01.06.01.nn, 01.07.01.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------- Inspection: of the valve guide clearance of the intake and exhaust valves after 15,000 h Auxiliary materials: Molykote Paste “G-Rapid Plus”...
  • Page 214 Intake Valve guide replacement Note: The valve guides should be replaced by a certified MaK workshop within the scope of a cylinder cover overhaul if possible. The cylinder cover may be damaged when removing the old valve guides. en / 05.06.2003...
  • Page 215 Media guiding system A5.05. 01.05.50.01 Maintenance / Disassembly and reassembly See also: 01.06.01.nn, 01.11.01.nn Spare parts list: B1.05.01.432144 Time requirement: 1 Pers./ 0,25 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Auxiliary material: Vaseline * * or a product of equal standard Sequence of operations: Disassembly...
  • Page 216 Media guiding system A5.05. 01.05.50.01 Maintenance / Disassembly and reassembly Pull the sleeves (fig. 2/9) out of the connecting flanges (1, 2). Check the O-rings (14). Replace faulty O-rings (14). Insert the O-rings in the grooves using vaseline and making sure that they are not twisted! Remove hexagon screws (Fig.
  • Page 217 Media guiding system A5.05. 01.05.50.01 Maintenance / Disassembly and reassembly Remove the cheese head screws (Fig. 3/22) with connecting flange (8). Pull the sleeves (10) out of the media block (6). Check the O-rings (15). Replace faulty O-rings (15). Remove lubricating oil pipe (4). 1.10 Remove hexagon screws (20, 23) with media block (6).
  • Page 218 Media guiding system A5.05. 01.05.50.01 Maintenance / Disassembly and reassembly Reassembly Mount the connecting flanges (fig. 2/1 and 2) with inserted sleeves (9). Replace faulty gaskets (13) beforehand. Mount the media block (fig. 3/6). Insert sleeves (10) with new O-rings (15). Mount lubricating oil pipe (4).
  • Page 219 Cylinder Head A5.05. 01.06.01.30 Maintenance / Disassembly See also: 01.02.01.nn, 02.06.01.nn, 03.04.01.nn, 06.01.01.nn, 07.05.01.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Tools: Store hydraulic device kit consisting of clamping cylinder W1.1...
  • Page 220 Cylinder Head A5.05. 01.06.01.30 Maintenance / Disassembly Disconnect and remove connecting flange of the media conduit for the cylinder head to be re- moved (01.05.50.nn). Remove rocker arm bracket (01.02.01.nn). Note To prevent damage and ensure trouble-free assembly and disassembly, the complete rocker arm bracket must be removed! Remove injection pressure pipe (07.05.01.nn).
  • Page 221 Cylinder Head A5.05. 01.06.01.30 Maintenance / Disassembly Loosen the six cylinder head screws using the hydraulic torque device. 10.1 Store hydraulic traction elements (Fig. 3/ W1.1) onto round nuts and tighten. Ensure good acces- sibility of the slots (3). Store hydraulic hydraulic traction elements by a 1 1/3 turn. 10.2 Store hydraulic traction elements via high pressure hoses (W1.2) to each other.
  • Page 222 Cylinder Head A5.05. 01.06.01.30 Maintenance / Disassembly Screw ring screws (Fig. 4/W3) into cylinder head. Fit cylinder head lifting device (W2). Lift cylin- der head with hoist. Watch for push rod bushing! Attention: Risk of damage for conduit connection, cylinder head screws, push rods, fuel pressure pipe and charged air inlet connection.
  • Page 223 Nozzle sleeve A5.05. 01.06.50.03 Maintenance / Disassembly and reassembly VM43 15000 See also: 01.06.01.nn, 07.07.01.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenace: Replacement of O-rings every 15.000 h Tools:...
  • Page 224 Nozzle sleeve A5.05. 01.06.50.03 Maintenance / Disassembly and reassembly VM43 15000 Attention: The threads of the nozzle sleeve and the cylinder head may no longer mesh. Remove flange (3). Use a brass mandrel (W3) and carefully drive out the nozzle sleeve. Remove the O-rings (4 and 5).
  • Page 225 Relief Valve A5.05. 01.06.70.01 Maintenance / Replace M43/VM43 30000 See also: 01.06.01.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Replacement of relief valve every 30,000 h Tools:...
  • Page 226 Relief Valve A5.05. 01.06.70.01 Maintenance / Replace M43/VM43 30000 Slacken relief valve (3) by means of a wrench and remove it. Lubricate the thread of the new relief valve with high-temperature thread paste “Dag 5420 A“ . Mount new relief valve (3) with new joint ring (4). Firmly tighten the relief valve by means of a wrench.
  • Page 227 Inlet and Exhaust Valve Cone A5.05. 01.07.01.03 Inspection / Disassembly and reassembly M43/VM43 15000, 7500 See also: 01.02.01.nn, 01.05.01.nn, 01.06.01.nn, 01.08.01.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Inspection: check the wear pattern of the intake and exhaust valve cone...
  • Page 228 Inlet and Exhaust Valve Cone A5.05. 01.07.01.03 Inspection / Disassembly and reassembly M43/VM43 15000, 7500 Sequence of operations: Disassembly Disassemble the cylinder head (01.06.01.nn). Disassemble the rocker arms (01.02.01.nn) and take off valve bridge. Put the valve spring compressor unit (W1) onto valve spring retainer (2).
  • Page 229 Inlet and Exhaust Valve Cone A5.05. 01.07.01.03 Inspection / Disassembly and reassembly M43/VM43 15000, 7500 Pull the valve cone out of the cylinder head. Note: Valve cones which display a large degree of wear in the clamping area and clamping piece haves with excessive burring must be replaced with new parts.
  • Page 230 Inlet and Exhaust Valve Cones A5.05. 01.08.01.00 Repair / Checking M43/VM43 See also: 01.07.01.nn, 01.08.02.nn Spare parts list: B1.05.01.432107 Time requirement: 0 Pers./ 0,00 h Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Tools: Valve seat grinding unit...
  • Page 231 Inlet and Exhaust Valve Cones A5.05. 01.08.01.00 Repair / Checking M43/VM43 • there is HT corrosion as shown below, i. e. no deep craters over the entire area of the bottom side of the valve heads. • the straightness deviation does not exceed the following values (Fig. 1) Span “s“...
  • Page 232 Inlet and Exhaust Valve Cones A5.05. 01.08.01.00 Repair / Checking M43/VM43 Valves may not be re-used for another in- terval when • the valve cone surface is damaged (cracks, blow-by) • there is burnout “s“ caused by high temperature corrosion on the underside of the valve head >...
  • Page 233 Inlet and Exhaust Valve Cones A5.05. 01.08.01.00 Repair / Checking M43/VM43 Repair (reworking the sealing surface) Note: The rework must be completed properly on precision spindle grinding machines. If such a machi- ne is not available, the valve cone should be sent to a CAT workshop for regrinding. Regrind the sealing surface in accordance with the indicated angle (Fig.
  • Page 234 Inlet and Exhaust Valve Cones A5.05. 01.08.01.00 Repair / Checking M43/VM43 Slide the oiled valve stem into the guide. Attach the rig (Fig. 5/W1) to the valve head and grind the cone and seat surface together briefly by turning the valve head with moderate pressure by hand.
  • Page 235 Valve Seat Ring A5.05. 01.08.02.00 Repair / Checking M43/VM43 See also: 01.07.01.nn, 01.08.01.nn Spare parts list: B1.05.01.432107 Time requirement: 0 Pers./ 0,00 h Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Tools: Precision seat grinding machine W1 * 1.9224 M...
  • Page 236 Valve Seat Ring A5.05. 01.08.02.00 Repair / Checking M43/VM43 Procedure: Inspection The grade (hardness) of the valve seat is designed to allow the seat to adapt to the valve cone to a certain extent. Carbon deposits are therefore normal and pose no danger with adequate cooling (Fig.
  • Page 237 (W1). Consult the special operating manual before beginning work. The seat rings can also be reworked with an MaK valve seat milling unit (Fig. 6/ W2). Avoid removing too much material, only the carbon deposits in the contact area should be removed.
  • Page 238 Valve Seat Ring A5.05. 01.08.02.00 Repair / Checking M43/VM43 3.1.2 Insert the centering disk (4) with the guide punch (5) and tighten with a star handle (6). Attention: Handle the cutting head (Fig. 6/2) carefully, milling blades can be damaged easily by im- pact and hard or sudden contact can damage the valve seat surface.
  • Page 239 Valve Seat Ring A5.05. 01.08.02.00 Repair / Checking M43/VM43 Contact surface check / grinding Apply small dots of diamond paste DP 30/10 - 15 µm to the new or reworked vale shaft with a small syringe and spread evenly. Next, spray the entire seat ring surface with thinner (DIAPLASTOL).
  • Page 240 Valve Seat Ring (Intake/Exhaust) A5.05. 01.08.03.00 Repair / Replace M43/VM43 See also: 01.06.01.nn, 01.07.01.nn, 01.08.02.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Tools: Press 439222 C Auxiliary materials: Diamond paste Dp 30/10 - 15 µm *...
  • Page 241 Valve Seat Ring (Intake/Exhaust) A5.05. 01.08.03.00 Repair / Replace M43/VM43 Install new seat ring. Cool seat ring to at least -20 °C, heat cylin- der head to 130 °C. Tap the seat ring completely into the bore with the help of a hammer and valve cone (strike lightly).
  • Page 242 Starting Valve A5.05. 01.09.01.00 Inspection / Checking M43/VM43 3750 See also: 01.02.01.nn, 01.09.02.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 0,40 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Checking: Check starting valve of one cylinder for easy movement 3.750 h For V-engines only on cyl.
  • Page 243 Starting Valve A5.05. 01.09.01.00 Inspection / Checking M43/VM43 3750 Ensure that the piston (5) and spindle (9) return to the original position quickly and easily. Note: Do not move spindle (9) by turning locknut (3). If the parts do not move freely, lubricate the piston (5) and guide in the cylinder head with engine oil.
  • Page 244 Starter Valve A5.05. 01.09.02.03 Maintenance / Disassembly and reassembly M43/VM43 15000 See also: 01.06.01.nn, 01.11.01.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel ------------------------------------------------------------------------------------------------------------------------------- Maintenance: Remove starter valve, disassemble and rework if necessary every 15,000 h Tools: Insertion ring for starting valve piston...
  • Page 245 Starter Valve A5.05. 01.09.02.03 Maintenance / Disassembly and reassembly M43/VM43 15000 Rework starting valve seat with reseating tool (W2). 1.9.1 Carefully clean valve seat and guide of valve spindle. 1.9.2 Loosen adjusting screw (20) on reseating tool (W2). Lightly oil valve canon. Insert reseating tool in valve guide and fix with spanner (21).
  • Page 246 Starter Valve A5.05. 01.09.02.03 Maintenance / Disassembly and reassembly M43/VM43 15000 Assembly Apply thin coat of Molykote paste “G-Rapid” to piston (5), distribute ring joints evenly around peri- phery. Insert piston using insertion ring (W1). Installation is completed in the reverse order as disassembly. Replace O-ring (2).
  • Page 247 Cylinder Head A5.05. 01.10.00.00 Inspection / Checking M43/VM43 See also: 01.03.01.nn, 01.06.01.nn, 01.11.01.nn, 07.07.01.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Inspection: inspect the cylinder head every 150 h Procedure: Check gasket between cylinder head, cylinder liner and coolant distributor housing for combusti-...
  • Page 248 Cylinder Head A5.05. 01.10.00.00 Inspection / Checking M43/VM43 Check the outside of the cylinder head for leaks. If oil leaks are found, check the valve cover bolts to ensure that they are tight and check the rub- ber profile for damage. If leaks are found at the media supply connecting flanges, check all bolts to ensure that they are tight.
  • Page 249 Cylinder Head A5.05. 01.10.01.01 Maintenance / Cleaning M43/VM43 15000 See also: 01.02.01.nn, 01.06.01.nn, 01.07.01.nn, 01.09.02.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel ---------------------------------------------------------------------------------------------------------------------------------- Note: The cylinder head may only be placed on the bench upright on a wood block. Procedure: The following parts must be dismantled: Intake, exhaust, injector valve, starter valve and rocker arm bracket.
  • Page 250 Cylinder Head A5.05. 01.11.01.30 Repair / Reassembly See also: 01.06.01.nn, 03.04.01.nn, 06.01.01.nn, 07.05.01.nn Spare parts list: B1.05.01.432107 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Tools: See maintenance sheet 01.06.01.nn. Ancillary materials: High temperature threading paste “Dag S-5080“...
  • Page 251 Cylinder Head A5.05. 01.11.01.30 Repair / Reassembly Procedure: Turn pistons to ignition TDC. Thoroughly clean sealing and bearing surfaces of cylinder head and cylinder bushing and check for damage. Insert new sealing ring (Fig. 1/1) into cylinder bushing collar. Check and clean sealing surface at exhaust pipe (06.01.01.nn). Replace the following O rings: Top O ring at cylinder bushing collar (2), at cylinder head (3), at the push rod bushing (4), at the cooling water conduit, at the starting air inlet, at the control air inlet and at the charger air inlet connection.
  • Page 252 Cylinder Head A5.05. 01.11.01.30 Repair / Reassembly Note: Insert all O rings with Vaseline or green lubricating sopa into the grooves without twisting. Align conduits for cooling water and starting air in cooling water manifold housing vertically and check for completeness. Carefully place cylinder head with cylinder head lifting device and hoist onto cooling water manifold housing.
  • Page 253 Cylinder Head A5.05. 01.11.01.30 Repair / Reassembly Store hydraulic traction elements (Fig. 2/ W1.1) onto round nuts and tighten. Ensure good acces- sibility of the slots (3). Store hydraulic traction elements via high pressure hoses (W1.2) to each other. Connect element 1 to pump.
  • Page 254 Running Gear / Engine Timing A5.05. 02.01.01.00 Inspection / Checking M43/VM43 3750 See also: 03.01.01.nn, 04.08.01.nn, 01.01.01.nn Spare parts list: B1.05.03.431112 Time requirement: 1 Pers./ 0,50 h Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Note: The temperature check for the bearings must be carried out with the engine at operating...
  • Page 255 Crank Web Deflection A5.05. 02.02.01.00 Inspection / Measuring See also: Spare parts list: B1.05.02.432520, B1.05.03.431110 Time requirement: 2 Pers./ 1,00 h Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Inspection: Measurements must be made in the following cases: If there may be a foundation deformation, e.g.: •...
  • Page 256 Crank Web Deflection A5.05. 02.02.01.00 Inspection / Measuring Procedure: Turn the crankshaft journal to the exhaust side so that the dial gauge is spread apart as far as possible between the crankshaft webs and the connecting rod just passes the dial gauge (Fig.
  • Page 257 The values indicated here may not be exceeded if permissible web deflection tolerance for the re- spective system cannot be obtained from MaK. Only web deflection values measured on an engine at operating temperature may be used for evaluation.
  • Page 258 Crank Web Deflection A5.05. 02.02.01.00 Inspection / Measuring en / 24.04.2006 IB020114...
  • Page 259 Bearing Shells and Bearing Bushes A5.05. 02.03.03.01 Inspection / Evaluate M43/VM43 See also: 02.03.07.nn, 02.04.01.nn, 02.05.01.nn, 02.09.01.nn Spare parts list: B1.05.02.432601, B1.05.03.431110 Time requirement: 0 Pers./ 0,00 h Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Note: Oil contamination, foreign objects, water and faulty tools cause...
  • Page 260 Bearing Shells and Bearing Bushes A5.05. 02.03.03.01 Inspection / Evaluate M43/VM43 The corrosion-resistant flash on the bearing (ca. 3 µm) is worn through after a short operating period. The bearing need only be replaced after heavy scoring, a clearance limit has been exceeded or in accordance with the applicable evaluation criteria (02.03.07.nn).

  • Page 261: Bearing Shells

    Bearing Shells A5.05. 02.03.07.01 Inspection / Evaluate M43/VM43 See also: 02.03.03.nn, 02.05.01.nn, 02.05.05.nn Spare parts list: B1.05.03.431110 Time requirement: 0 Pers./ 0,00 h Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Note: The following evaluation catalog contains different wear stages caused by mechanical wear and overloading the bearing shells.
  • Page 262 Bearing Shells A5.05. 02.03.07.01 Inspection / Evaluate M43/VM43 Criteria for replacement Fig. 4 -The wear pattern includes severe scoring and the aluminum alloy sliding layer is fretted. This bearing shell can not be used again, both bearing shells must be replaced. Find and eliminate the cause for the increased scoring.
  • Page 263 Bearing Shells A5.05. 02.03.07.01 Inspection / Evaluate M43/VM43 en / 05.06.2003 IB020121...
  • Page 264 Bearing Shells A5.05. 02.03.07.01 Inspection / Evaluate M43/VM43 en / 05.06.2003 IB020121...
  • Page 265 Big End Bearings A5.05. 02.04.01.30 Inspection / Disassembly 30000, 15000 See also: 02.03.03.nn, 02.03.07.nn, 02.06.01.nn Spare parts list: B1.05.02.432601 Time requirement: 2 Pers./ 0,50 h Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Inspection: one big end bearing every...
  • Page 266 Big End Bearings A5.05. 02.04.01.30 Inspection / Disassembly 30000, 15000 Procedure: Remove piston (02.06.01.nn). Turn the engine so that the connecting rod is horizontal. Both round nuts (2) must be accessible. Loosen the round nuts (2) with the hydraulic rig. Place and tighten the hydraulic clamping elements (W4) over the round nuts (2).
  • Page 267 Big End Bearings A5.05. 02.04.01.30 Inspection / Disassembly 30000, 15000 Note: If the round nuts cannot be removed, the pressure on the nuts can be increased by p = 50 bar more. If the pressure is increased further, the connecting rod bolt threading may stretch, which can cau- se the round nuts to lock into place.
  • Page 268 Big End Bearings A5.05. 02.04.01.30 Inspection / Disassembly 30000, 15000 Tighten hexagon nuts (12). Mount guide rail extension (13) with carriage (14) on camshaft side. en / 03.05.2004 IB024444...
  • Page 269 Big End Bearings A5.05. 02.04.01.30 Inspection / Disassembly 30000, 15000 Screw suspension (18) at big end bearing cap. Connect suspension (18) with carriage (14). Unscrew round nuts (2). Drive big end bearing cap (15) to the camshaft side out of the crankcase. Remove bearing shell (19).
  • Page 270 Big End Bearings A5.05. 02.04.01.30 Inspection / Disassembly 30000, 15000 Turn connecting rod (17) downward by 180° ° ° ° so that the connecting rod shank division shows to the camshaft side. Mount suspension (16) for connecting rod (17) and connect with carriage. Dismount connecting rod holder at the counterweight (02.06.01.nn).
  • Page 271 Big End Bearings A5.05. 02.04.02.30 Inspection / Reassembly See also: 02.04.01.nn, 02.03.03.nn, 02.03.07.nn Spare parts list: B1.05.02.432601 Time requirement: 2 Pers./ 0,50 h Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Tools: Tools W1 - W6 see 02.04.01.nn Note: Bearing caps, bearing shells, connecting rod eyes and connecting rods are labeled according to...
  • Page 272 Big End Bearings A5.05. 02.04.02.30 Inspection / Reassembly Mount suspension (16) at dismounted connecting rod. Fasten suspension (16) with suspended connecting rod (17) at the crane and lift. Mount connec- tion to the carriage (14). Remove sling. Push connecting rod (17) towards the crank pin up to approx. 20 mm. Put upper bearing shell (without holes) on the crank pin and turn below the connecting rod by 180°.
  • Page 273 Big End Bearings A5.05. 02.04.02.30 Inspection / Reassembly Mount connecting rod holder at counterweight n (02.06.01.nn). Secure connecting additionally with screw (20) at connecting rod holder. 1.10 Dismount suspension (16). 1.11 Turn connecting rod (17) downward by 180° ° ° ° so that the connecting rod shank division shows to the exhaust side.
  • Page 274 Big End Bearings A5.05. 02.04.02.30 Inspection / Reassembly 1.13 Fasten big end bearing cap (15) at crane and connect suspension (18) with carriage (14) at guide rail extension (13). 1.14 Remove sling. 1.15 Push big end bearing cap (15) towards the crank pin up to approx. 160 mm. Attention: Pay attention to the appropriate bores (50 / connecting rod) and clamping pin (51 / big end bearing cap)!
  • Page 275 Big End Bearings A5.05. 02.04.02.30 Inspection / Reassembly 1.16 Push big end bearing cap (15) forward towards the crank pin up to approx. 100 mm and insert, align and press lower bearing shell (19) into the big end bearing bore. 1.17 Push big end bearing cap (15) carefully against bearing shell (19) and bottom end of connecting rod.
  • Page 276 Big End Bearings A5.05. 02.04.02.30 Inspection / Reassembly 1.18 Insert big-end bolts (3) with washer (4). Assemble washer (4) with chamfer pointing towards bottom end of connecting rod. 1.19 Install round nuts (5) and tighten by hand. 1.20 Remove installation / disassembly unit (W6). 1.21 Check bearing shell pairs for axial misalignment on the exhaust side.
  • Page 277 Big End Bearings A5.05. 02.04.02.30 Inspection / Reassembly Tighten the round nuts (5) with the hydraulic rig. Turn the connecting rod with the connec- ting rod shank joint by about 15-30° down- wards, see indicated position (Fig. 11). Both round nuts (5) must be ea- sily accessible.
  • Page 278 Big End Bearings A5.05. 02.04.02.30 Inspection / Reassembly 2.11 Firmly tighten the round nuts (5) with a pin (W5). While doing so the nuts must turn smoothly. Visual check of angle of rotation 180° ° ° ° ± 22° ° ° ° 2.12 Check to ensure that the round nut is seated properly •...
  • Page 279 Hydraulic Jack A5.05. 02.04.51.00 Maintenance / Replace M43/VM43 See also: 02.04.01.nn, 02.05.01.nn, 02.05.05.nn Spare parts list: B1.05.02.432601, B1.05.03.431110 Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Exchange of all seals Tools: Fork wrench W1 *...
  • Page 280 Hydraulic Jack A5.05. 02.04.51.00 Maintenance / Replace M43/VM43 Insert new seals in consideration of the order: Order: At first rubber rings (4 and 5) and then joint rings (6 and 7). Attention: Do not press joint rings in too much. Press piston (3) into the cylinder.
  • Page 281 Main Bearings A5.05. 02.05.01.30 Inspection / Disassembly 30000, 15000 See also: 02.03.03.nn, 02.03.07.nn Spare parts list: B1.05.03.431110 Time requirement: 2 Pers./ 2,00 h Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Inspection: a) of two crankshaft bearings every 15,000 h...
  • Page 282 Main Bearings A5.05. 02.05.01.30 Inspection / Disassembly 30000, 15000 Attention! Do not place any body parts under equipment which is under pressure! Ensure that the en- gine cannot be started. Attention: The neighboring bearings must be securely mounted during installation and for gap mea- surements.
  • Page 283 Main Bearings A5.05. 02.05.01.30 Inspection / Disassembly 30000, 15000 1.3.5 Loosen the round nut with a pin. Turn the round nut back 10 holes. Note: If the round nut cannot be loosened with the pin, the pressure on the uniform strength bolt can be increased to p = 50 bar more.
  • Page 284 Main Bearings A5.05. 02.05.01.30 Inspection / Disassembly 30000, 15000 1.4.2 Connect the hydraulic cylinder of the rig (W10) to the high pressure pump (W1) by means of the high pressure line (W2). 1.4.3 Bring the carrying arm into position and place the chute (10) between the crankcase and carrying arm.
  • Page 285 Main Bearings A5.05. 02.05.01.30 Inspection / Disassembly 30000, 15000 1.4.4 Loosen the round nuts on the crankshaft bearing bolts with the hydraulic rig. 1.4.5 Place the hydraulic clamping element (W5) level on the plate above the chute (10). Remove the chute.
  • Page 286 Main Bearings A5.05. 02.05.01.30 Inspection / Disassembly 30000, 15000 Note: If the round nuts cannot be loosened with the pin, the pressure on the uniform strength bolts can be increased to p = 50 bar more. If the pressure is increased further, the threading may stretch, which can cause the round nuts to lock into place! Open the valve on the high pressure pump, the hydraulic clamping elements (W5) are depressu- rized.
  • Page 287 Main Bearings A5.05. 02.05.01.30 Inspection / Disassembly 30000, 15000 Run the carrying arm of the rig (W10) to the crankshaft bearing cover. Bolt the bearing cover to the plate. Remove the round nuts. Lower the carrying arm carefully to the lower stop with the main bearing cover and lower bearing shell.
  • Page 288 Main Bearings A5.05. 02.05.01.30 Inspection / Disassembly 30000, 15000 1.12 Inspect and evaluate the bearing shells, see 02.03.03.nn and 02.03.07.nn. 1.13 Check the wear and wall thickness with a micrometer in the main wear zone at the indicated measurement points (X). Wear = Nominal size - current size 1.14 The bearing shells must be changed when...
  • Page 289 Main Bearings A5.05. 02.05.01.30 Inspection / Disassembly 30000, 15000 2.1.2 Raise the bearing cap with the rig. Tighten the round nuts until the bearing shells barely touch. 2.1.3 Measure the gap “K“ between the crankcase and the bearing cover on the exhaust and control side and add both values.
  • Page 290 Main Bearings A5.05. 02.05.02.30 Maintenance / Reassembly See also: 02.05.01.nn Spare parts list: B1.05.03.431110 Time requirement: 2 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Tools: Tools W1 - W11 see maintenance sheet 02.05.01.nn Turning unit 439225-001 Torque wrench 20 - 200 Nm...
  • Page 291 Main Bearings A5.05. 02.05.02.30 Maintenance / Reassembly Procedure: Install bearing shells. Note: The upper bearing shell is equipped with a lubrication groove and oil bore. Oil the running surface of the upper bea- ring shell thoroughly, dry the back of the bearing and turn the bearing shell into the bearing as far as possible.
  • Page 292 Main Bearings A5.05. 02.05.02.30 Maintenance / Reassembly Turn the upper bearing shell into place. Make sure that the bearing shell is centered. The posi- tioning nose must slide into the guide groove in the bearing seat. Raise the rig (W10), remove the round nuts (12). Lower the rig (W10) again and remove the carri- er (W11) and the turning unit (W12).
  • Page 293 Main Bearings A5.05. 02.05.02.30 Maintenance / Reassembly Close the valve on the high pressure pump and extend the uniform strength bolts with a pressure p = 380 bar Attention: The pressure must remain constant when the hydraulic pump is not being actuated to pre- vent the bolts from being tightened incorrectly! Tighten the round nut (23) with a pin.
  • Page 294 Main Bearings A5.05. 02.05.02.30 Maintenance / Reassembly Place the hydraulic clamping element (W5) level on the plate above the chute. Remove the chute. Raise the carrying arm. Place the hydraulic clamping element on the round nut (12) and tighten. Make sure that the slits (13) are easily accessible. en / 31.01.2008 IB024459...
  • Page 295 Main Bearings A5.05. 02.05.02.30 Maintenance / Reassembly Repeat the installation procedure on the opposite side. Connect the hydraulic clamping elements (W5) to the high pressure pump (W1) by means of the high pressure lines (W2, W6). Close the valve on the high pressure pump and extend both main bearing bolts with a pressure of p = 2250 bar Attention: The pressure must remain constant when the hydraulic pump is not being actuated to pre-...
  • Page 296 Main Thrust Bearings A5.05. 02.05.05.30 Inspection / Disassembly 30000 See also: 02.03.03.nn, 02.03.07.nn Spare parts list: B1.05.03.431110 Time requirement: 2 Pers./ 1,00 h Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Inspection: Main thrust bearings every 30,000 h...
  • Page 297 Main Thrust Bearings A5.05. 02.05.05.30 Inspection / Disassembly 30000 The 1st main bearing must be removed, inspected and measured before the lapse of the indica- ted intervals when: foundation deformations or web deflection changes occur after sea damage. Procedure: Measure axial clearance “s“. Open the cover under the gear drive and the first coupling side crankcase cover on the control and exhaust sides.
  • Page 298 Main Thrust Bearings A5.05. 02.05.05.30 Inspection / Disassembly 30000 Removing main thrust bearing. Turn the piston of the 1st cylinder 90° after crankshaft TDC or 90° before crankshaft TDC. Loosen the round nuts (23) on the lateral uniform strength bolts with the hydraulic rig. 2.2.1 Remove the protective caps.
  • Page 299 Main Thrust Bearings A5.05. 02.05.05.30 Inspection / Disassembly 30000 Insert rig. 2.3.1 Lift the rig (W10) into the crankcase collapsed and place in the guide rails of the oil pan. Insert carrier arm. 2.3.2 Connect the hydraulic cylinder in the rig (W10) with the high pressure pump (W1) by means of the high pressure line (W2).
  • Page 300 Main Thrust Bearings A5.05. 02.05.05.30 Inspection / Disassembly 30000 2.3.3 Bring the carrying arm into position and place the chute (10) between the crankcase and carrying arm. 2.3.4 Loosen the round nuts on the crankshaft bearing bolts with the hydraulic rig. 2.3.5 Place the hydraulic clamping element (W5) level on the plate above the chute (10).
  • Page 301 Main Thrust Bearings A5.05. 02.05.05.30 Inspection / Disassembly 30000 2.3.7 Connect the hydraulic clamping elements (W5) with the high pressure pump (W1) by means of the high pressure lines (W2, W6). 2.3.8 Close the valve on the high pressure pump and subject both crankshaft bearing bolts to a pressu- re of p = 2250 bar 2.3.9...
  • Page 302 Main Thrust Bearings A5.05. 02.05.05.30 Inspection / Disassembly 30000 Run the carrying arm of the rig (W10) to the crankshaft bearing cover. Bolt the bearing cover to the plate. Remove the round nuts. Lower the carrying arm with main bearing cover and bottom bearing shell carefully as far as pos- sible.
  • Page 303 Main Thrust Bearings A5.05. 02.05.05.30 Inspection / Disassembly 30000 2.11 Secure the bearing cover to the hoists on both sides (exhaust gas side and camshaft side). Ten- sion the slings evenly. 2.12 Separate the carrying arm of the device (W10) from the bearing cover. 2.13 Shift the device (W10) towards cyl.
  • Page 304 Main Thrust Bearings A5.05. 02.05.05.30 Inspection / Disassembly 30000 Measure the gap. Loosen both round nuts (12) hydraulically. Lower the rig (see step 2.3). Raise the bearing cap with the rig. Tighten the round nuts until the bearing shells barely touch. Measure the gap “K“...
  • Page 305 Main Thrust Bearings A5.05. 02.05.06.30 Maintenance / Reassembly See also: 02.05.05.nn Spare parts list: B1.05.03.431110 Time requirement: 2 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Tools: Tools W1 - W12 see maintenance sheet 02.05.05.nn Turning unit 439225-001 Auxiliary materials:...
  • Page 306 Main Thrust Bearings A5.05. 02.05.06.30 Maintenance / Reassembly Procedure: Install bearing shells. Note: The upper bearing shell is equipped with a lubrication groove and oil bore. Insert up- per thrust washer segments if removed. Oil the running surface of the upper bea- ring shell thoroughly, dry the back of the bearing and turn the bearing shell into the bearing as far as possible.
  • Page 307 Main Thrust Bearings A5.05. 02.05.06.30 Maintenance / Reassembly Turn the upper bearing shell into place. Make sure that the bearing shell is centered. The posi- tioning nose must slide into the guide groove in the bearing seat. Raise the rig (W10), remove the round nuts (12). Lower the rig (W10) again and remove the carri- er (W11) and the turning unit (W12).
  • Page 308 Main Thrust Bearings A5.05. 02.05.06.30 Maintenance / Reassembly Note: Measure the gap “K“ after installing the bearing shells (see 02.05.01.nn). After replacing the bearing shells or the thrust washer segments the axial clearance must also be measured (see 02.05.01.nn). Lower the rig (W10). Tighten the lateral round nuts of the adjacent bearing .
  • Page 309 Main Thrust Bearings A5.05. 02.05.06.30 Maintenance / Reassembly Attention: The pressure must remain constant when the hydraulic pump is not being actuated to pre- vent the bolts from being tightened incorrectly! 3.10 Tighten the round nut (23) with a pin. 3.11 Check to ensure that the round nut is seated properly.
  • Page 310 Main Thrust Bearings A5.05. 02.05.06.30 Maintenance / Reassembly Place the hydraulic clamping element (W5) level on the plate above the chute. Remove the chute. Raise the carrying arm. Place the hydraulic clamping element on the round nut (12) and tighten. Make sure that the slits (13) are easily accessible.
  • Page 311 Main Thrust Bearings A5.05. 02.05.06.30 Maintenance / Reassembly Attention: The pressure must remain constant when the hydraulic pump is not being actuated to pre- vent the bolts from being tightened incorrectly! Tighten the round nuts (12) with a pin. Check to ensure good action (no stiffness). Check to ensure that the round nut is seated properly.
  • Page 312 Piston A5.05. 02.06.01.30 Maintenance / Disassembly See also: 01.06.01.nn, 02.07.01.nn, 03.04.01.nn Spare parts list: B1.05.02.432601 Time requirement: 2 Pers./ 0,30 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Tools: Piston lifting unit 432134 A Hydraulic set consisting of High pressure pump High pressure line...
  • Page 313 Piston A5.05. 02.06.01.30 Maintenance / Disassembly Procedure: Open the indicator valves, remove the crankcase cover for the respective cylinder on both sides. Turn crank journal ca. 20° to the control side from TDC. Remove cylinder head (01.06.01.nn). Place cylinder liner retainer (Fig. Y/W9) on coolant distributor housing (1).
  • Page 314 Piston A5.05. 02.06.01.30 Maintenance / Disassembly Split the connecting rod shank. 14.1 Insert a socket wrench with a square head (Fig. 3/W6) in the hydraulic wrench (W5). Mount the support (Fig. 4/W7) on the hydraulic wrench. en / 05.05.2004 IB024471...
  • Page 315 Piston A5.05. 02.06.01.30 Maintenance / Disassembly Attention: In order to avoid damages to the hydraulic wrench (W5), adjust a maximum pressure of p = 425 bar on the high-pressure pump. Adjustment instructions see A6.05.90.10.nn . Note the direction of rotation, relocate the socket wrench with square head if necessary and turn the hydraulic wrench.
  • Page 316 Piston A5.05. 02.06.01.30 Maintenance / Disassembly Attention: Remove the big end if the piston will be stored for a longer period of time to prevent vibra- tion damage in the cylinder liner area. Seal off the oil bore in the connecting rod shank split with a protective cap. en / 05.05.2004 IB024471...
  • Page 317 M43/VM43 See also: 02.06.01.nn, 02.07.01.nn, 02.08.01.nn Spare parts list: B1.05.02.432601 Time requirement: 2 Pers./ 0,70 h Personnel qualification: Cat/MaK-specialist Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Tools: Piston lifting unit (piston crown) 439223 A Piston lifting unit (big end)
  • Page 318 Piston Crown A5.05. 02.06.02.04 Maintenance / Replace M43/VM43 Loosen the hexagon nuts (Fig. 3/5) and remove with piston skirt (12). Clean piston crown (8) and piston skirt (12). Make sure that the contact surfaces of piston parts and spacer sleeves (6) are clean. Attention: Check the contact surfaces for friction marks / cold welding (Fig.
  • Page 319 Piston Crown A5.05. 02.06.02.04 Maintenance / Replace M43/VM43 Clean and inspect the oil bores in the piston skirt (Fig. 3/12). Piston assembly Clean the contact surfaces of piston skirt (12) and piston crown (8) and check for unevenness. Carefully smooth out any raised spots with oil stone. Clean bores for piston screws (7) and contact surfaces for spacer sleeves (6) in the piston skirt (12).
  • Page 320 Piston Crown A5.05. 02.06.02.04 Maintenance / Replace M43/VM43 2.10 Insert new O-ring (13) untwisted into groove. 2.11 Put on piston skirt (12), fixation hole and spring dowel pin (11) must match. 2.12 Lubricate inside thread and bearing surfaces of the hexagon nuts (5) with Molykote paste. 2.13 Tighten piston screws (5) crosswise to a torque of M = 170 Nm.
  • Page 321 Do not remove the graphite layer from the piston shaft. After installing new piston rings, the engine must be broken in in accordance with the break in procedure A3.10.01.nn!. Worked pistons with chromed 1st ring grooves may only be re-worked by MaK or MaK certified workshops. Procedure: Piston inspection (7.500 h)
  • Page 322 Replace the piston if there is significant damage or scoring. Measure the groove height h (Fig. 2) in the forward groove area across and along the engine. If the wear limit has been exceeded, have the ring grooves reworked by MaK. 1.10 Measure the ring height h (Fig.
  • Page 323 Clean all rings and check the wear. If the chrome layer is worn away entirely or in sections, send the pistons to MaK for re- pair. Measure the groove height h as defined in 1.9.

  • Page 324: Piston Pin

    Piston Pin A5.05. 02.08.01.00 Inspection / Disassembly and reassembly See also: 02.06.01.nn, 02.09.01.nn Spare parts list: B1.05.02.432601 Time requirement: 2 Pers./ 1,00 h Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Tools: Piston installation / disassembly unit 439223 A Piston installation / disassembly unit...
  • Page 325 Piston Pin A5.05. 02.08.01.00 Inspection / Disassembly and reassembly Disassembly Mark the connecting rod eye (1), piston (2) and piston pin (3) for proper alignment during re-in- stallation. Lift the connecting rod eye slightly with the crane to relive pressure on the piston pin. Remove the circlips (4).
  • Page 326 The exact installation of a small end bearing is generally impossible with the equipment normally found on board. This must be completed at the MaK plant or at an MaK certified workshop. The small end bearing in the offset connecting rod eye has an electroplated running surface, see 02.03.03.nn.
  • Page 327 Small End Bearing A5.05. 02.09.01.01 Maintenance / Measuring M43/VM43 30000 Smallest Largest Operational clearance clearance clearance limit 0.06 0.092 0.12 Connecting rod eye Ø (A) Piston pin Ø (C) Small end bushing Ø (B) 0.302 0.31 Piston pin Ø (C) Eye clearance (D) Bushing width (X) en / 29.07.2008...
  • Page 328 M43/VM43 30000 emoval of the small end bearing Note: The following work should only be completed by MaK or by an MaK certified workshop. This work may only be completed on board in an emer- gency! When removing the small end bearing, be sure to use as litt- le force as possible.
  • Page 329 Piston A5.05. 02.10.01.30 Maintenance / Reassembly See also: 02.06.01.nn, 02.07.01.nn Spare parts list: B1.05.02.432601 Time requirement: 2 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Tools: Tools W1 - W9 see 02.06.01.nn Piston installation ring 439220 B Piston installation guide (steel collar)
  • Page 330 Piston A5.05. 02.10.01.30 Maintenance / Reassembly Place the piston installation unit (Fig. 1/ W13) over the piston ring zone and tighten the clamping bolts (1). Attention: When tightening the clamping bolts, make sure that the piston rings are not on the outer edge of the ring groove. Loosen any rings by tapping lightly on the piston installation unit.
  • Page 331 Piston A5.05. 02.10.01.30 Maintenance / Reassembly Install piston and connecting rod. 13.1 Apply Molykote to threads and contact sur- faces of the uniform strength bolts (Fig. 3/ 20). 13.2 Place segments (21) on the connecting rod split and tighten uniform strength bolts hand tight with ring wrench.
  • Page 332 Piston A5.05. 02.10.01.30 Maintenance / Reassembly 13.5 Place socket wrench (Fig. 4/W6) with square head into the hydraulic wrench (W5). Mount support (W7) on hydraulic wrench. Attention: In order to avoid damages to the hydraulic wrench (W5), adjust a maximum pressure of p = 425 bar on the high-pressure pump.
  • Page 333 Piston A5.05. 02.10.01.30 Maintenance / Reassembly Safety note: During pressure build-up no parts of the body between support of the hydraulic wrench and connecting rod or balance weight. 13.8 Close the valve on the high pressure pump (W3) and tighten all uniform strength bolts (20) on one side at a time with a pressure of p = 400 bar + 25 bar If necessary, move the cylinder in the hydraulic wrench back and forth several times by releasing...
  • Page 334 Explosion relief valve A5.05. 03.01.01.02 Inspection / Checking 1500 See also: 02.01.01.nn Spare parts list: B1.05.03.431633 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Check: Ease of movement of the explosion relief valve every 1,500 h Tools: Torque wrench 20 - 200 Nm...
  • Page 335 Explosion relief valve A5.05. 03.01.01.02 Inspection / Checking 1500 Tighten screws (8) to a torque of M = 25 Nm. After assembly check the explosion relief valve for proper operation by actuating it by hand. When mounting the explosion relief valve on the crankcase door care has to be taken to ensure proper sealing between seat and crankcase door.
  • Page 336 Coolant Distributor Housing A5.05. 03.02.00.00 Maintenance / Disassembly and reassembly See also: 01.06.01.nn, 02.06.01.nn, 03.03.01.nn, 03.04.01.nn, 03.04.02.nn Spare parts list: B1.05.03.431110 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Maintenance: Replace O-rings Tools:...
  • Page 337 Coolant Distributor Housing A5.05. 03.02.00.00 Maintenance / Disassembly and reassembly Loosen the sleeves (2) from the starting air channel and slide into opposite distributor housing. Remove the distributor housing mounting bolts (3). Screw the eye bolts (Fig. 3/W1) into the coolant distributor housing (6) and lift housing with crane.
  • Page 338 Coolant Distributor Housing A5.05. 03.02.00.00 Maintenance / Disassembly and reassembly Install coolant distributor housing. Set coolant distributor housing (6) into pla- ce on the crankcase with a crane. Replace coolant block gasket (Fig. 2/7). Tighten coolant distributor housing moun- ting bolts (3). Slide sleeves (2) for starting air channel into place and secure.
  • Page 339 Cylinder Liner A5.05. 03.03.01.01 Inspection / Measuring M43/VM43 30000, 15000 See also: 02.06.01.nn, 03.04.01.nn Spare parts list: B1.05.03.431110, B1.05.03.431611 Time requirement: 1 Pers./ 0,20 h Personnel qualification: Chief engineer Operating medium: Heavy fuel ---------------------------------------------------------------------------------------------------------------------------------- Inspection: of one cylinder liner every 15,000 h of all cylinder liners every...
  • Page 340 When the wear limit has been reached, normally at the point at which the top piston ring reverses direction (TDC, 1st ring) or other threshold values in the table (Fig. 3 and Fig. 4)have been met, replace the cylinder liner. The cylinder liners can only be reworked by Caterpillar/MaK . Cylinder liner wear chart Evaluation criteria...
  • Page 341 Cylinder Liner A5.05. 03.04.01.00 Maintenance / Disassembly 30000 See also: 02.06.01.nn, 03.03.01.nn Spare parts list: B1.05.03.431110, B1.05.03.431611 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Maintenance: Remove cylinder liner, replace O-ring every 30,000 h...
  • Page 342 Cylinder Liner A5.05. 03.04.01.00 Maintenance / Disassembly 30000 Clean the sealing surface and O-ring groove thoroughly and check for damage. Clean coolant area on the cylinder liner collar thoroughly. Clean cylinder liner collar seat, upper and lower fitting bore in crankcase thoroughly. en / 28.07.1999 IB020188...
  • Page 343 Cylinder Liner A5.05. 03.04.02.00 Maintenance / Reassembly See also: 03.03.01.nn, 03.04.01.nn Spare parts list: B1.05.03.431110, B1.05.03.431611 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Tools: Cylinder liner rig Auxiliary materials: Liquid beef suet or green potassium soap Note:...
  • Page 344 Cylinder Liner A5.05. 03.04.02.00 Maintenance / Reassembly Connect hoisting unit to the eye bolt on the rig (Fig. 1/W1) and lower the cylinder liner into the crankcase (3). Mount rig onto the cylinder liner to be installed in accordance with steps 1.3 and 1.4 of the disas- sembly instructions (03.04.01.nn).
  • Page 345 Check the control and monitoring equipment to ensure secure fit. Cables and impulse lines may not chafe. Check foundation bolts and fitted pieces by tapping. Check web deflection after tightening loose foundation bolts (02.02.01.nn). Obtain tightening values from MaK customer service. Check elastic bearing elements for damage. en / 25.08.2003...
  • Page 346 Wear limit 0.26 - 0.32 Note: When the wear limit has been reached, replace camshaft bearing (MaK customer service) and check the bearing clearance of all camshaft bearings. Check the bearing journal running surfaces of the corresponding camshaft bearing. en / 28.07.1999...
  • Page 347 Attention: The camshaft bearing between the camshaft gear and the 1st cylinder may only be dis- mantled and installed by MaK customer service! Check the running surface of one camshaft bearing and the corresponding camshaft sec- tion after the 1st cylinder.
  • Page 348 Camshaft Bearing A5.05. 04.01.02.00 Inspection / Disassembly and reassembly 30000, 15000 Loosen the hex head bolts (Fig.1/1) on the left flange of the camshaft section (3). Turn the cams- haft to access and remove all bolts which are inaccessible. Remove all hex head bolts. Re- place two opposing hex head bolts with longer bolts (W2).
  • Page 349 Camshaft Bearing A5.05. 04.01.02.00 Inspection / Disassembly and reassembly 30000, 15000 Note: When removing the hex head bolts, make sure that the injector cam faces up vertically (TDC) af- ter turning the engine for the last time. Attention: The camshaft may only be turned when the connecting bolts are loosened when the rocker arms of the camshaft section to be replaced and all rocker arms to the right of the section to be replaced have been removed and the camshaft section is pulled out far enough, that the straight pin (5) and the recess...
  • Page 350 Camshaft Bearing A5.05. 04.01.02.00 Inspection / Disassembly and reassembly 30000, 15000 1.10 Check crankshaft bearing. Replace (04.04.01.nn) if: - the wear pattern is bad (running surface, lower bearing area, scoring). 1.11 Check the camshaft bearing for scuffing on the back of the bearing and replace if necessary (04.04.01.nn).
  • Page 351 Camshaft Bearing A5.05. 04.01.02.00 Inspection / Disassembly and reassembly 30000, 15000 Slide the camshaft to the side (1.4 to 1.7). Prop up the oscillation damper and the camshaft section above the 1st cylinder. Check the running surfaces of the bearing journals of all camshaft sections for scoring. Replace defective camshaft sections (04.04.01.nn).
  • Page 352 Bottom part for Valve Mechanism A5.05. 04.02.00.30 Maintenance / Disassembly and reassembly See also: 01.01.01.nn, 01.02.01.nn, 07.02.01.nn Spare parts list: B1.05.04.433502 Time requirement: 2 Pers./ 2,00 h Personnel qualification: skilled engine hand / Assistant engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Mounting and removal device for lower valve drive...
  • Page 353 Bottom part for Valve Mechanism A5.05. 04.02.00.30 Maintenance / Disassembly and reassembly Remove oil pipes (9). Remove clamping screw (10) and both lower fastening screws (11). 1.10 Bring into position support (W1.1) and firmly mount to cam follower bracket. 1.11 Bring into position arms (W1.5) and tension them by means of tubular hexagon box wrench (W1.8).
  • Page 354 Bottom part for Valve Mechanism A5.05. 04.02.00.30 Maintenance / Disassembly and reassembly 1.12 In case of disassembly and assembly at cylinder 1 mount support (W1.6). Here the camshaft cov- er is bigger. W1.6 1.13 Mount guide rail (W1.2). Firmly tighten the nuts only after having aligned all parts of the device. W1.4 W1.2 1.14...
  • Page 355 Bottom part for Valve Mechanism A5.05. 04.02.00.30 Maintenance / Disassembly and reassembly holes coincide. W1.7 W1.2 W1.4 1.15 Screw together carriage (W1.4) and support (W1.1). Use screws (W1.7). 1.16 Remover upper fastening screws (12) of the cam follower bracket. 1.17 Bring into position bracket with hoist (W1.3).
  • Page 356 Bottom part for Valve Mechanism A5.05. 04.02.00.30 Maintenance / Disassembly and reassembly 1.18 Engage hoist in support (W1.1) and tension it. 1.19 Roll out valve drive completely on the carriage. W1.3 W1.5 W1.1 Attention: Rope of the hoist must be evenly coiled, otherwise there is a risk of injury. 1.20 Separate support (W1.1) from carriage (W1.4) by removing screws (W1.7).
  • Page 357 Bottom part for Valve Mechanism A5.05. 04.02.00.30 Maintenance / Disassembly and reassembly Assembly: Bring into position support (W1.1) and firmly mount to cam follower bracket. Bring into position arms (W1.5) and tension them by means of tubular hexagon box wrench (W1.8).
  • Page 358 Bottom part for Valve Mechanism A5.05. 04.02.00.30 Maintenance / Disassembly and reassembly 2.18 Remove support (W1.1). 2.19 Lubricate threads and contact faces of screws (10, 11, 12) with Molykote Paste "G Rapid Plus". 2.20 Insert the two lower fastening screws (11) with extension sleeves (14) and slightly tighten them. 2.21 Tighten fastening screws (11, 12) "crosswise"...
  • Page 359 Camshaft A5.05. 04.04.01.06 Repair / Disassembly and reassembly See also: 01.01.01.nn, 01.02.01.nn, 04.01.01.nn, 04.01.02.nn, 07.02.01.nn Spare parts list: B1.05.04.433120 Time requirement: 1 Pers./ 3,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Tools: Sling W1 * 439230 A Hex bolts...
  • Page 360 Camshaft A5.05. 04.04.01.06 Repair / Disassembly and reassembly Remove the injection pump of the corresponding cylinder and for all cylinders to the right of the cylinder being checked (07.03.01.nn). Remove the lifters and the camshaft section for the corresponding cylinder and all camshaft sec- tions to the right of the camshaft section being removed.
  • Page 361 Camshaft A5.05. 04.04.01.06 Repair / Disassembly and reassembly When removing the last camshaft section: 1.5.1 Remove the oscillation damper (Fig. 2/10) (04.09.01.nn) and slide to the right as far as possible. 1.5.2 Remove the intermediate piece (12). Place the sling (Fig. 3/W1) around the camshaft section (3) between the exhaust cam and injector cam and connect to the lifting unit through the injection pump bore...
  • Page 362 Camshaft A5.05. 04.04.01.06 Repair / Disassembly and reassembly Drive the right camshaft bearing (Fig. 1/4) out of the camshaft section with a suitable wood block and rubber mallet. Fill the camshaft bearing (4) with cardboard. 1.10 Loosen the hex head bolts (Fig. 1/1) on both camshaft section (3) flanges. Turn the engine to make access any inaccessible hex head bolts and remove all bolts from the left flange.
  • Page 363 Camshaft A5.05. 04.04.01.06 Repair / Disassembly and reassembly Attention: Apply no excessive or sudden force when sliding! Do not damage the bearings or bearing journals. 1.13 Secure the right end of the camshaft with wooden wedges. Attention: Do not tilt the camshaft sections too much! Be very careful! 1.14 Fill the camshaft trough with cardboard or a similar material.
  • Page 364 Camshaft A5.05. 04.04.01.06 Repair / Disassembly and reassembly Oil the inside and outside of the camshaft bearing (Fig. 1/4) thoroughly and place on intake cam of the right camshaft section. Place camshaft section (3) facing the coupling side in the corresponding camshaft trough on card- board or similar material.
  • Page 365 Camshaft A5.05. 04.04.01.06 Repair / Disassembly and reassembly 2.12 Drive the camshaft bearing (4) into place evenly with a suitable wood block and rubber mallet. Do not tip the bearing. The bearing shell must face the retaining bore. 2.13 Apply Molykote to the retaining bolt (11) and install. Tighten the bolt to M = 130 Nm 2.14 Lower the lifting unit and remove the sling (Fig.
  • Page 366 Camshaft A5.05. 04.04.01.06 Repair / Disassembly and reassembly 2.16.3 Install the oscillation damper (10 ) (04.09.01.nn). 2.17 Install valve actuators and the injection pump drives. 2.18 Install the lifters. 2.19 Install the rocker arms and check valve clearance (01.01.01.nn). 2.20 Install injection pump (07.02.01.nn).
  • Page 367 Timing Gear Train A5.05. 04.08.01.02 Inspection / Checking 15000, 3750 See also: 02.01.01.nn Spare parts list: B1.05.04.435140 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Inspection: of the tooth profiles and oil nozzle every 3,750 h the axial clearance of the step gear...
  • Page 368 Timing Gear Train A5.05. 04.08.01.02 Inspection / Checking 15000, 3750 Check the tooth profiles on the camshaft gear (Fig. 1/2), step gear (1) and crankshaft gear (3) for pitting, misaligned running, loose metal, etc. Measure the tooth clearance between the step gear and the camshaft gear (2) and between the step gear and the crankshaft gear (3).
  • Page 369 If damage is found on the teeth or if one of the permissible nominal values (tooth or axial clearance) is exceeded, MaK customer service must be informed. Check the gaskets and install the timing gear cover on the exhaust and control side.
  • Page 370 Timing Gear Train A5.05. 04.08.02.02 Maintenance / Disassembly and reassembly See also: 02.01.01.nn Spare parts list: B1.05.04.435140 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 20 - 200 Nm W1 * 1.9454-202 Reversible ratchet 1/2"...
  • Page 371 Timing Gear Train A5.05. 04.08.02.02 Maintenance / Disassembly and reassembly Note: The work specified in the following can only be carried out when the flywheel is removed. Procedure: Replace the O-ring (Fig. 2/6) on the step gear shaft (2). Loosen the hex head bolts (7 and 8) and remove with sleeves (5) and locking plates (3 and 4).
  • Page 372 Timing Gear Train A5.05. 04.08.02.02 Maintenance / Disassembly and reassembly Attention: Do not damage the O-ring (6). Apply Molykote to the contact surfaces and threads of the hex head bolts (7 and 8). Mount hex head bolts (7) and hex head bolts (8) with sleeves (5) and locking plates (3 and 4) and tighten hand tight.
  • Page 373 Governor Drive A5.05. 04.08.03.02 Inspection / Disassembly and reassembly 15000 See also: Spare parts list: B1.05.03.431110, B1.05.04.434111 Time requirement: 1 Pers./ 2,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Inspection: contact pattern at hypoid gear pair every 15,000 h contact pattern at intermediate wheel...
  • Page 374 Governor Drive A5.05. 04.08.03.02 Inspection / Disassembly and reassembly 15000 Removing hexagonal screws (Fig. 2/20) with resilient sleeves (21). Lightly attach governor drive housing (23) with sling to hoist and carefully lift out of cylinder crank housing. Attention: Risk of damage to lubricating oil passage sleeve (30) and O-ring (31). Deposit governor drive housing (23) onto suitable surface.
  • Page 375 Governor Drive A5.05. 04.08.03.02 Inspection / Disassembly and reassembly 15000 Check tooth profiles of hypoid gears (Fig. 3/40, 41) for pitting, off-track running or blow-outs. Check intermediate wheel (42). Check channel toothing of governor drive shaft (43) and governor (Fig. 1/10) for wear, clean if necessary.
  • Page 376 Governor Drive A5.05. 04.08.03.02 Inspection / Disassembly and reassembly 15000 Assembly Provide lubricating oil passage sleeve (Fig. 2/30) with new O-rings (31). Place governor drive housing (23) carefully onto engine block by means of a crane. During this operation absolutely pay attention to lubricating oil passage sleeve (30) and dowel pins (Fig. 3/ 32).
  • Page 377 Vibration Damper on Camshaft A5.05. 04.09.02.30 Repair / Disassembly and reassembly 30000 See also: Spare parts list: B1.05.03.431112, B1.05.04.433140 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 200 - 500 Nm 1.9454-500 * not shown Ancillary materials:...
  • Page 378 Vibration Damper on Camshaft A5.05. 04.09.02.30 Repair / Disassembly and reassembly 30000 Slide new dampers (1) onto intermediate piece (4) and fit screws (2) with extension sleeves (3). Tighten connecting bolts (2) using a torque of M = 420 Nm Fit lateral housing cover.
  • Page 379 Control Shaft Bearings A5.05. 05.01.02.00 Maintenance / Checking M43/VM43 See also: 05.08.01.nn Spare parts list: B1.05.04.434110, B1.05.05.434210, B1.05.05.434523 Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------------------- Maintenance: Oil control shaft every 750 h Auxiliary materials:...
  • Page 380 Starting Valve A5.05. 05.02.01.02 Maintenance / Disassembly and reassembly 7500 See also: A3.05.nn Spare parts list: B1.05.05.1.4906 Time requirement: 1 Pers./ 1,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: of the starting valve every 7.500 h Tools:...
  • Page 381 Starting Valve A5.05. 05.02.01.02 Maintenance / Disassembly and reassembly 7500 Sequence of operations: Close the main shut-off valve on the air receiver. Vent the air pipes on the engine. Disassemble all pipework and cable connections from the starting valve. Disassembly: Unscrew the screws (Fig.
  • Page 382 Starting Valve A5.05. 05.02.01.02 Maintenance / Disassembly and reassembly 7500 Disassemble the protective cover (Fig. 2/2). Disassemble the silencer (3) and remove the solenoid (4). Disassemble the armature (5) by slackening the screw connection (6). Pay attention to the spring (7). Slacken the screw connection (8) and pull out the emergency actuation knob (9).
  • Page 383 Starting Valve A5.05. 05.02.01.02 Maintenance / Disassembly and reassembly 7500 Reassembly: Renew all O-rings, piston guide ring (19) and other sealing rings. Grease the sliding surfaces slightly. Insert a new, completely assembled spindle (14). Assemble all valve parts in inverse disassembly order. Assemble the emergency actuation knob (9) with a new spring (10) and a new O-ring (20).
  • Page 384 Control Rod A5.05. 05.08.01.00 Maintenance / Disassembly and reassembly 7500 See also: 05.01.02.nn Spare parts list: B1.05.05.434210 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Maintenance: Replace the bushings every 7,500 h Procedure:...
  • Page 385 Control Rod A5.05. 05.08.01.00 Maintenance / Disassembly and reassembly 7500 Connect the bracket (6) to the injection pump control rod by installing the pin (3), the washers (4 and 5) and a new nut (2). Tighten the nut (2) with a torque of M = 40 Nm Attention: Check the linkage for ease of movement by pressing against the jointet lever.
  • Page 386 Compressed-Air Filter A5.05. 05.09.06.00 Maintenance / Cleaning M20/M25/M32/M43/M453C/M552C/M601C 24, 7500 See also: Spare parts list: B1.05.05.1.4900 Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance/cleaning: Drain compressed-air filter: every 24 h Disassemble and clean compressed-air filter: initially...
  • Page 387 Compressed-Air Filter A5.05. 05.09.06.00 Maintenance / Cleaning M20/M25/M32/M43/M453C/M552C/M601C 24, 7500 Sequence of operations: Drain compressed-air filte Loosen drain plug (7) and empty filter completely. Close drain plug. Disassemble compressed-air filter and clean Loosen drain plug (7) and drain filter completely. Close compressed-air feed line and secure.
  • Page 388 Compressed-Air Filter A5.05. 05.09.06.01 Maintenance / Cleaning M20/M25/M32/M43 24, 7500 See also: C5.05.05.45.23.nn Spare parts list: B1.05.05.9.4523 Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance/cleaning: Drain compressed-air filter: every 24 h Disassemble and clean compressed-air filter:...
  • Page 389 Exhaust Line A5.05. 06.01.01.17 Inspection / Checking 7500 See also: Spare parts list: B1.05.06.437210 Time requirement: 2 Pers./ 3,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Inspection: The exhaust line must be checked for leaks every 7,500 operating hours. Auxiliary materials: High temperature thread paste "B &...
  • Page 390 Exhaust Line A5.05. 06.01.01.17 Inspection / Checking 7500 Note: If leaks are not caused by cracks in the lines or loose bolted connections, new gaskets must be installed, see 4.8. Replace any defective exhaust lines as follows: Loosen and remove adjacent compensators (4). Compensators may not be subjected to bending or radial forces! Loosen the hex head bolts (1) far enough that the upper sections of the clamps (3) are still con- nected but can be slid easily.
  • Page 391 Exhaust Line A5.05. 06.01.01.17 Inspection / Checking 7500 Bolt fitted piece or pieces to new exhaust line. Mount exhaust gas pipe with new seal (5) and clamp tops. Remove fitted piece or pieces, install compensator(s) and bolt securely into place. Note the indicated direction of flow when installing the compensators (4), see arrow on the flange.
  • Page 392 Exhaust Line A5.05. 06.01.01.18 Inspection / Checking 7500 See also: Spare parts list: B1.05.06.437210 Time requirement: 2 Pers./ 3,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Inspection: The exhaust line must be checked for leaks every 7,500 operating hours. Auxiliary materials: High temperature thread paste "B &...
  • Page 393 Exhaust Line A5.05. 06.01.01.18 Inspection / Checking 7500 Note: If leaks are not caused by cracks in the lines or loose bolted connections, new gaskets must be installed, see 4.8. Replace any defective exhaust lines as follows: Loosen and remove adjacent compensators (4). Compensators may not be subjected to bending or radial forces! Loosen the hex head bolts (1) far enough that the upper sections of the clamps (3) are still con- nected but can be slid easily.
  • Page 394 Exhaust Line A5.05. 06.01.01.18 Inspection / Checking 7500 Bolt fitted piece or pieces to new exhaust line. Mount exhaust gas pipe with new seal (5) and clamp tops. Remove fitted piece or pieces, install compensator(s) and bolt securely into place. Note the indicated direction of flow when installing the compensators (4), see arrow on the flange.
  • Page 395 Charge Air Cooler A5.05. 06.04.02.30 Maintenance / Disassembly and reassembly See also: Spare parts list: B1.05.06.437250, B1.05.09.438330 Time requirement: 2 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Maintenance: The charge air cooler must be removed and cleaned on the air side when the differential pressure before/after the cooler exceeds 1.5 times the test bench value (see acceptance brake certificate A1.10).
  • Page 396 Charge Air Cooler A5.05. 06.04.02.30 Maintenance / Disassembly and reassembly Remove hexagon screws (Fig. 2/28) with washers (37). Pull the charge air cooler (9) out of the housing (3) on exhaust gas side, suspend with hoist and lower into suitable container for cleaning. Clean the charge air cooler in accordance with the manufacturer's instructions (see Book C).
  • Page 397 Charge Air Cooler A5.05. 06.04.02.30 Maintenance / Disassembly and reassembly Assembly Install charge air cooler in the reverse order as disassembly. Insert new O-ring (8) into O-ring sheet (9). Slide charge air cooler (2) into the housing (3) carefully. Note: Apply a light coat of Molykote paste “G-Rapid Plus”...
  • Page 398 Exhaust gas turbocharger A5.05. 06.05.00.30 Maintenance / Cleaning See also: A5.05.06.13.01.nn, A3.06.06.nn Spare parts list: B1.05.06.437259 nn Time requirement: 1 Pers./ 0,40 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Compressor cleaning RM43C every 24 h Prerequisites:...
  • Page 399 Exhaust gas turbocharger A5.05. 06.05.00.30 Maintenance / Cleaning Push valve handle (3) against the spring and hold for approx. 10 seconds until the entire water volume has been injected. Note: After cleaning the air side, the engine should be run under load for at least 5 minutes. When the compressor impeller was contaminated, the success of a cleaning can be told by the charge air pressure after the turbocharger.
  • Page 400 Exhaust gas turbocharger A5.05. 06.05.00.30 Maintenance / Cleaning Attention: Because of the increased risk of corrosion, only clear water (drinking water) - never salt water - may be used for cleaning. This water should not contain any coolant treatments or other chemicals which may form deposits in the air ducts.
  • Page 401 Exhaust gas turbocharger A5.05. 06.13.01.30 Maintenance / Cleaning See also: A5.05.06.05.00.nn, A3.06.06.nn Spare parts list: B1.05.06.437259 nn Time requirement: 1 Pers./ 0,40 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Turbine cleaning RM43C every 150 h Prerequisites: - wet cleaning wet cleaning of the turbine and the nozzle ring requires low exhaust temperatures and low engine load...
  • Page 402 Exhaust gas turbocharger A5.05. 06.13.01.30 Maintenance / Cleaning Requirements for water and air feeds for washing turbine and nozzle ring: Note: Water flow is controlled by a diaphragm (2) upstream from control valve (1). These are the cleaning parameters for ABB TPL 76-C33 turbocharger: <...
  • Page 403 Exhaust gas turbocharger A5.05. 06.13.01.30 Maintenance / Cleaning Cleaning procedure Note After start of engine or reduction of engine load. The exhaust gas temperature before the turbine may not exceed 430 °C. Lower values will yield improved washing results. Sequence: Wait for 10 to 15 minutes until after the exhaust gas temperature has stabilized and is below 430 °...
  • Page 404 Exhaust gas turbocharger A5.05. 06.13.01.30 Maintenance / Cleaning Open drain valve (3). Note Along the funnel duct at drain valve (3), the operator may see the results of the cleaning from the cleanliness of the draining water. Open shut-off valve (4); pressure meter (5) should indicate a pressure of p = 2,0 ±...
  • Page 405 M43/VM43 12000, 24000, 36000 See also: C5.05.06.10.2n.nn Spare parts list: B1.05.06.43725n, B1.05.06.437259 Time requirement: 2 Pers./ 9,00 h Personnel qualification: Cat/MaK-specialist Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Exhaust gas turbocharger: Dismount, clean and check every 12.000 h Exchange the nozzle ring and the diffuser after 24.000 h...
  • Page 406 Injection Pump A5.05. 07.02.01.00 Repair / Disassembly and reassembly See also: 05.08.01.nn, 07.03.01.nn, 07.05.01.nn, 07.15.01.nn Spare parts list: B1.05.04.433580, B1.05.07.438510, B1.05.07.438540, B1.05.08.438480 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Lifting device for injection pump...
  • Page 407 Injection Pump A5.05. 07.02.01.00 Repair / Disassembly and reassembly Close the shut-off valves. Drain the fuel distributing/collecting line on the fuel duplex filter. Remove the lubricating oil leakage line (Fig. 2/10), fuel leakage line (Fig. 3/20, 21) and control air pipes (Fig. 4/30, 31) of the corresponding injection pump.
  • Page 408 Injection Pump A5.05. 07.02.01.00 Repair / Disassembly and reassembly 1.10 Disassemble the connection (Fig. 5/40) between injection pump control rack (41) and control shaft. en / 16.02.2009 IB020380...
  • Page 409 Injection Pump A5.05. 07.02.01.00 Repair / Disassembly and reassembly 1.11 Push the control rack (41) as far as possible into the injection pump. Safety note: Attention! The spring tension of the injection pump drive acts against the injection pump. For removal the cam follower (Fig. 1/2) of the injection pump drive must be on the base circle of the fuel cam (1), if necessary turn the engine.
  • Page 410 Injection Pump A5.05. 07.02.01.00 Repair / Disassembly and reassembly Attention: The cylinder-specific spacer plates (7) are secured with round head grooved pins and must not be removed. Assembly Clean the contact surfaces of the injection pump (Fig. 1/6) and the spacer plates (7). Clean the contact surfaces of the pressure spring (3) and the pushrod (8) on the tappet body and the bottom spring plate of the injection pump respectively.
  • Page 411 Injection Pump A5.05. 07.02.01.00 Repair / Disassembly and reassembly 2.12 Check the control air pipe (Fig. 4/30) for the stop piston for leakage by means of compressed air. 2.13 Check stop piston / emergency stop device for correct function (10.03.01.nn). 2.14 Mount the camshaft casing cover on camshaft side.
  • Page 412 Injection Pump A5.05. 07.03.01.03 Maintenance / Disassembly and reassembly M43/VM43 15000, 7500 See also: 07.02.01.nn, 07.03.02.nn Spare parts list: B1.05.07.433597 Time requirement: 2 Pers./ 2,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------- Inspection: a) of one injection pump every 7,500 h b) of all injection pumps...
  • Page 413 Injection Pump A5.05. 07.03.01.03 Maintenance / Disassembly and reassembly M43/VM43 15000, 7500 Procedure: Check the pressure valve Place the injection pump next to the injector testing unit (W2) with the help of a crane. Mount adapter (W6) on valve support (Fig. 1/20) and connect to testing unit (W2) via pressure pipe (W1).
  • Page 414 Injection Pump A5.05. 07.03.01.03 Maintenance / Disassembly and reassembly M43/VM43 15000, 7500 Disassembly Clean the outside of the injection pump. Remove deflector bolts (Fig. 1/6). Check defector bolts for cavitation in the deflector surface, replace deflector bolts if necessary (07.03.02.nn). Clamp the injection pump with the valve support (20) down.
  • Page 415 Injection Pump A5.05. 07.03.01.03 Maintenance / Disassembly and reassembly M43/VM43 15000, 7500 2.11 Remove the pump spring and check for corrosion. 2.11.1 Remove the control sleeve (5) with spring plate (7). 2.11.2 Check the toothing in the control housing for damage. 2.11.3 Loosen guide bolt (11), remove control rod (Fig.
  • Page 416 Injection Pump A5.05. 07.03.01.03 Maintenance / Disassembly and reassembly M43/VM43 15000, 7500 Tappet Grooving in the running surface, worn out pressure bar bed. Pressure valve Damaged sealing surfaces, worn out seat, worn pressure valve spring. Stop piston Worn control rod spring (18), grooving in the stop piston (15). Lower spring Grooving / damage in the contact surface.
  • Page 417 Injection Pump A5.05. 07.03.01.03 Maintenance / Disassembly and reassembly M43/VM43 15000, 7500 3.1.3 Tighten cheese head screws (Fig. 4/36) according to the sequence (19, 21, 22, 20) in three steps. 1. Step according to the sequence by applying M 40 Nm 2.
  • Page 418 Deflector Bolts A5.05. 07.03.02.00 Inspection / Replace M43/VM43 3750, 7500 See also: 07.03.01.nn Spare parts list: B1.05.07.433597 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Inspection: Alternate inspection of the deflector bolts of two injection pumps every 3.750 h Replacement of all deflector bolts...
  • Page 419 Deflector Bolts A5.05. 07.03.02.00 Inspection / Replace M43/VM43 3750, 7500 To check this use the depth gauge of the caliper gauge. When the above wear value is reached, replace deflector bolts (6) with new ones. Mount deflector bolts. Lightly lubricate thread and contact faces of the deflector bolts with engine lubricating oil. Tighten new deflector bolts (6) by hand.
  • Page 420 Pressure Valve A5.05. 07.03.03.00 Maintenance / Disassembly and reassembly M43/VM43 See also: 07.05.01.nn Spare parts list: B1.05.07.433597 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 20 - 200 Nm W4 * 1.9454-202 * no picture...
  • Page 421 Pressure Valve A5.05. 07.03.03.00 Maintenance / Disassembly and reassembly M43/VM43 Remove cheese head srews (1 und 2).. Remove valve support (3). Pay attention to dowel pins (5). Remove pressure valve (4). Assembly Insert new pressure valve (4) into valve support (3). Replace O-ring (6).
  • Page 422 Injection Pump A5.05. 07.04.01.00 Maintenance / Replace M43/VM43 See also: 07.02.01.nn Spare parts list: B1.05.07.433597 Time requirement: 0 Pers./ 0,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Attention: After mounting a new injection pump it has to be made sure that the pump is preheated with circulating heavy fuel for at least 20 minutes.
  • Page 423 High-Pressure Injection Pipe A5.05. 07.05.01.00 Maintenance / Disassembly and reassembly M43/VM43 See also: 07.07.01.nn, 07.08.01.nn Spare parts list: B1.05.01.432107, B1.05.07.432260, B1.05.07.438526 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 20 - 200 Nm W1 *...
  • Page 424 High-Pressure Injection Pipe A5.05. 07.05.01.00 Maintenance / Disassembly and reassembly M43/VM43 Disassemble the fillister head screws (Fig. 2/1) with cover (3) and O-ring (2). Loosen the clamping screw (4) (about 5 turns). Loosen the pressure screw (6) and disassemble it. Take the transverse thrust piece (15) out of the receptacle (14).
  • Page 425 (4 and 6). Attention: Use only original MaK spare parts! Insert the sleeve (12) into the cylinder head and lock by means of the spring ring (10). Put the receptacle (14) onto the injection pump connection (17) and tighten the fillister head screws (16) "by hand".
  • Page 426 High-Pressure Injection Pipe A5.05. 07.05.01.00 Maintenance / Disassembly and reassembly M43/VM43 2.11 Tighten the pressure screw (6) and the clamping screw (4) alternately and step by step starting with a torque of M = 100 Nm each, until the prescribed torque of M = 250 Nm is reached for pressure screw (6) and clamping screw (4).
  • Page 427 Fuel Injector A5.05. 07.07.01.02 Maintenance / Disassembly and reassembly M43/VM43 See also: 07.02.01.nn, 07.08.01.nn Spare parts list: B1.05.01.432107, B1.05.07.432260 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Tools: Pulling unit for injector valve 439111 A Cleaning tool for injector seat W2 *...
  • Page 428 (07.08.01.nn). 1.11 Clean the injector seat (Fig. 1/9) in the sleeve (6) by scraping with tool (W2). Cle- an the inside of the sleeve. Assembly Replace O-rings (7). Attention: Only use original MaK replacement parts! en / 25.03.2009 IB025651...
  • Page 429 Fuel Injector A5.05. 07.07.01.02 Maintenance / Disassembly and reassembly M43/VM43 Apply a thin coat of high temperature thread paste to the injector seat, injector element (Fig. 1/5) and nozzle holder. Apply a thin coat of Molykote paste to the threads fo the studs (2), contact surfaces of the nuts (1) and O-rings (7).
  • Page 430 Fuel Injector A5.05. 07.08.01.30 Maintenance / Adjust M43/VM43 See also: 07.07.01.nn, 07.09.01.nn Spare parts list: B1.05.07.432260, B1.05.07.432267 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Nozzle tester 1.9470 H Adapter/nozzle support nozzle tester 439206 A Injector delivery pipe...
  • Page 431 Fuel Injector A5.05. 07.08.01.30 Maintenance / Adjust M43/VM43 Sequence of operations: Remove carbon deposits from the nozzle with a hard brush (no wire brush). Check the nozzle hole for sharp edges, ovalization, corrosion and damage. Place the injector with the adapter (W2) in the tester (W1).
  • Page 432 Fuel Injector A5.05. 07.09.01.30 Repair / Disassembly and reassembly M43/VM43 7500 See also: 07.07.01.nn, 07.08.01.nn Spare parts list: B1.05.07.432267 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Maintenance: Replace all injector elements every 7,500 h Tools:...
  • Page 433 Fuel Injector A5.05. 07.09.01.30 Repair / Disassembly and reassembly M43/VM43 7500 Sequence of operations: Disassembly Insert fuel injector (Fig. 1/13) into retainer (W1). In doing so fit tightly into insert (W3). Mount flange (2) with hexagon screws (1) and tighten the hexagon head screws. Note: Observe the mounting position of the fuel injector in the flange (2)! (Position of the positioning pin Fig.
  • Page 434 Fuel Injector A5.05. 07.09.01.30 Repair / Disassembly and reassembly M43/VM43 7500 Remove adjusting screw (Fig. 2/11), remove spring guide (10), injector spring (4) and pressure pin (5). 1.10 Inspect injector spring (4) and pressure pin (5). 1.11 Carry out a visual inspection of nozzle spring (4) and pressu- re pin (5).
  • Page 435 Fuel Injector A5.05. 07.09.01.30 Repair / Disassembly and reassembly M43/VM43 7500 Put on complete nozzle element (Fig. 2/8+12). Observe position of the pins (7). Screw on nozzle nut (6) and tighten by hand. Attention: In order to avoid damages to the hydraulic wrench (W2), adjust a maximum pressure of p = 465 bar on the high-pressure pump.
  • Page 436 Fuel Duplex Filter A5.05. 07.12.01.08 Maintenance / Cleaning See also: Spare parts list: B1.05.07.n.7667 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Cleaning pistol 1.9100-110 Cartridge drift 1.9100-120 Auxiliary material: Cleansing fluid "Filterclean"...
  • Page 437 Fuel Duplex Filter A5.05. 07.12.01.08 Maintenance / Cleaning Cleaning the filter with built-in cartridges. Safety note: Depressurize filter chambers! 2.2.1 Remove the cover (2) from the shut-off filter chamber. Remove contaminated liquid by opening the drain. 2.2.2 Remove filter insert. 2.2.3 Connect cleaning pistol (Fig.
  • Page 438 Fuel Duplex Filter A5.05. 07.12.01.08 Maintenance / Cleaning 2.3.4 Put the filter insert in a container filled with a suitable cleansing liquid. The cleansing liquid must only reach up to the bottom edge of the element plate (Fig. 3/26) so that no contaminated liquid can enter the cartridges from the top (14) (clean side).
  • Page 439 Fuel Duplex Filter A5.05. 07.12.01.08 Maintenance / Cleaning 2.4.6 Introduce the cleaning pistol into the cartridge, pull the trigger and move down to the bottom of each cartridge. 2.4.7 Remove sticking dirt with a soft brush. Note: If a high-pressure cleaner is available, blast the cartridges from the outside with a fan jet nozzle. Operating pressure of the high-pressure cleaner max.
  • Page 440 Fuel Distributor/Collector Line A5.05. 07.15.01.30 Repair / Disassembly and reassembly See also: Spare parts list: B1.05.07.438510 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Auxiliary materials: Molykote Paste "G-Rapid‘‘ * Procedure: Disassembly Remove pump area shroud.
  • Page 441 Fuel Distributor/Collector Line A5.05. 07.15.01.30 Repair / Disassembly and reassembly Remove the fuel line at the flange (Fig. 2/4). Loosen the locking rings (6) and slide towards the middle of the line. Note: When loosening and sliding the locking rings, be careful not to damage the pipe sealing surfaces! Slide the fuel line (Fig.
  • Page 442 Fuel Distributor/Collector Line A5.05. 07.15.01.30 Repair / Disassembly and reassembly 1.11 Remove fuel lines (supply and return). 1.12 Loosen cap screws (9). 1.13 Remove cap screws and pull the flange (4) from the injection pump bushing (3). Remove O-rings (12). 1.14 Remove the bushings (3) with the O-rings (7) and support ring (11).
  • Page 443 Fuel Pressure Damper A5.05. 07.17.00.01 Maintenance / Replace 7500 See also: 07.15.01.nn Spare parts list: B1.05.07.438533, B1.05.07.438510 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Replacement of the fuel pulsation dampers every 7,500 h Auxiliary materials:...
  • Page 444 Fuel Pressure Damper A5.05. 07.17.00.01 Maintenance / Replace 7500 Assembly Assemble new fuel pulsation dampers (1) in reverse order. Attention: When mounting the leakage monitoring pipe the valve body (3) of the fuel pulsation dam- per must not be twisted. Hold in place the valve body by means of a second wrench! Open the fuel shut-off valves.
  • Page 445 Lubricating Oil Pump A5.05. 08.03.02.04 Maintenance / Disassembly and reassembly See also: Spare parts list: B1.05.08.436417 Time requirement: 0 Pers./ 0,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 20 - 200 Nm W1 * 1.9454-202 Torque wrench 200 - 500 Nm...
  • Page 446 Loosen bolts (16,18). Remove cover (21) und cover (17) from pump housing (20). Remove drive gear (10) and impeller shaft (19). Check bushes (11, 14, and 15), bearing areas of drive and impeller gear shafts for wear and re- place with genuine MaK parts, if necessary. Replace O-rings (12). Note Cool new bushes before assembly.
  • Page 447 Lubricating Oil Pump A5.05. 08.03.02.04 Maintenance / Disassembly and reassembly Assembly: Assemble lube oil pump by reversing above steps. Mount cover (21). Tighten hex bolts (18) to a torque of M = 410 Nm. Mount cover flange (17). Tighten hex bolts (16) to a torque of M = 206 Nm.
  • Page 448 Lubricating Oil Pump A5.05. 08.03.02.04 Maintenance / Disassembly and reassembly 2.10 Check distance S; it should be smaller than measured under 2.6 by 0.57 - 0.67 mm (sliding travel). 2.11 Clean pump flange surface (Fig. 2/17) and pump support surface (Fig. 1/5) and coat with sealant. 2.12 Carefully insert lube oil pump (3) with gear (6) into the cylinder crankcase (tooth faces of drive gears need to engage) and install.
  • Page 449 Lubricating Oil Duplex Filter A5.05. 08.04.01.01 Maintenance / Cleaning See also: Spare parts list: B1.05.08.437657 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Cleaning pistol 1.9100-114 Cartridge drift 1.9100-120 Auxiliary material: Cleansing fluid "Filterclean"...
  • Page 450 Lubricating Oil Duplex Filter A5.05. 08.04.01.01 Maintenance / Cleaning Cleaning the filter with built-in cartridges. Safety note: Depressurize filter chambers! 2.2.1 Remove the cover (2) from the shut-off filter chamber. Remove contaminated liquid by opening the drain. 2.2.2 Remove filter insert. 2.2.3 Connect cleaning pistol (Fig.
  • Page 451 Lubricating Oil Duplex Filter A5.05. 08.04.01.01 Maintenance / Cleaning 2.3.4 Put the filter insert in a container filled with a suitable cleansing liquid. The cleansing liquid must only reach up to the bottom edge of the element plate (Fig. 3/26) so that no contaminated liquid can enter the cartridges from the top (14) (clean side).
  • Page 452 Lubricating Oil Duplex Filter A5.05. 08.04.01.01 Maintenance / Cleaning 2.4.6 Introduce the cleaning pistol into the cartridge, pull the trigger and move down to the bottom of each cartridge. 2.4.7 Remove sticking dirt with a soft brush. Note: If a high-pressure cleaner is available, blast the cartridges from the outside with a fan jet nozzle. Operating pressure of the high-pressure cleaner max.
  • Page 453 Oil pressure control valve A5.05. 08.05.01.01 Maintenance / Adjust M20/M25/M32/M43 15000 See also: Spare parts list: B1.05.08.n.7810 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Disassembly and adjustment of the oil pressure control valve every 15,000 h...
  • Page 454 Oil pressure control valve A5.05. 08.05.01.01 Maintenance / Adjust M20/M25/M32/M43 15000 Clean all parts with gas oil and check them. Check the free passage of the control oil bore (12) in the pressure control valve and in the set screw (5) and remove any deposits. Check the valve seats, balls, piston seating as well as the slide faces and grind them if necessary.
  • Page 455 Oil pressure control valve A5.05. 08.05.01.01 Maintenance / Adjust M20/M25/M32/M43 15000 Reassembly Check the O-rings (2 and 7) and sealing ring (14) and replace them if necessary. Assembly is effected in the reverse sequence of disassembly. Pay attention to the free movement of the pistons (4 and 11)! Check the lubricating oil pressure at the pressure gauge on the control panel and adjust it if ne- cessary.
  • Page 456 Prelubricating pump/Prelubrication A5.05. 08.10.00.00 Maintenance / Checking M20/M25/M32/M43/M453C/M552C/M601C See also: C5.05.08.10.00.nn Spare parts list: Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Prelubrication and turning approximately every 150 h Note: When multi-engine systems run on rigid bearings, the bearings might be damaged by vibration when individual engines are shut down for more than 3 days.
  • Page 457 Stop Piston A5.05. 10.03.01.00 Inspection / Checking M43/VM43 See also: 07.03.01.nn Spare parts list: B1.05.05.434210, B1.05.07.433597 Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ------------------------------------------------------------------------------------------------------------------------------- Inspection: Check the emergency stop function of the stop piston every 750 h Note:...
  • Page 458 Stop Piston A5.05. 10.03.01.00 Inspection / Checking M43/VM43 Attention: This document only describes the pneumatic and mechanical release of an engine stop. In connection with this inspection work all of the emergency stop equipment on the engine is to be checked for proper function. (Please refer to (C5.05.05.10.50.nn) ). (Fig.
  • Page 459 Pressure Switches A5.05. 11.01.02.01 Inspection / Adjust M20-M601C 3750 See also: Spare parts list: B1.05.11.nn.4843 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Adjusting device, electro test instrument Inspection: Inspect the pressure switch for the set operating values every 3,750 working hours.
  • Page 460 Pressure Switches A5.05. 11.01.02.01 Inspection / Adjust M20-M601C 3750 Attention: When loosen/thighten the union nut directly located at the pressure joint of the pressure switch, it should be simultaneously counter acted at the key faces of the pressure joint. Connect the hose (with union nut and cutting) with the adjusting device (Fig. 2). Inspection of the set values Ventilate the pressure switch via the adjustment device.
  • Page 461 Pressure Switches A5.05. 11.01.02.01 Inspection / Adjust M20-M601C 3750 Correction of the adjustment (Perfor- mance with fixed switch difference) (Fig. 3) Note: The scale accuracy is ± 2 % of the span. The instrument is individually calibrated (1 - 2 on) so that no gauge inspection is necessary.
  • Page 462 RPM Switch A5.05. 11.05.01.02 Inspection / Adjust M20/M25/M32/M43 7500 See also: C5.05.05.70.06.43 Spare parts list: Time requirement: 1 Pers./ 1,00 h Personnel qualification: E-specialist Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Inspection: Check the function of the rpm switches every 7,500 operating hours. Note: The engine speed must be constant whilst testing.
  • Page 463 RPM Switch A5.05. 11.05.01.02 Inspection / Adjust M20/M25/M32/M43 7500 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 adjustment of the new plug-in card.
  • Page 464 Lubricating Oil/Cooling Water Thermostat A5.05. 11.06.01.01 Maintenance / Checking M20-M601C 7500 See also: Spare parts list: B1.05.11.1.7837 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Disassembly of lubricating oil/cooling water thermostat, making a funcional check of thermostatic element every 7,500 h Note:...
  • Page 465 Lubricating Oil/Cooling Water Thermostat A5.05. 11.06.01.01 Maintenance / Checking M20-M601C 7500 Functional check of thermostatic element Put thermostatic 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). The thermostatic element (5) must open steadiliy.
  • Page 466 Pressure Switch A5.05. 11.06.05.02 Inspection / Replace M32/M43 22500 See also: 11.06.06.nn Spare parts list: Time requirement: 1 Pers./ 2,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Replacement of all pressure switches after 22,500 h Tools:...
  • Page 467 Pressure Switch A5.05. 11.06.05.02 Inspection / Replace M32/M43 22500 Procedure: Put the engine and the related safety systems out of operation. - > Notify the engine to be ’’unserviceable’’ < -. Attention: Prior to replacing the pressure switches the shut-off cocks of the media must be closed. Prior to installation the pressure switches are to be adjusted to the specified pressure va- lues.
  • Page 468 Pressure Switch A5.05. 11.06.05.02 Inspection / Replace M32/M43 22500 Put the engine and the safety system into normal operating condition again. -> Notify the engine to be "ready for operation" <-. en / 06.10.2008 IB025581...
  • Page 469 Pressure Switch A5.05. 11.06.06.02 Maintenance / Adjust M20/M25/M32/M43 See also: 11.06.05.nn Spare parts list: Time requirement: 1 Pers./ 0,25 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Pressure calibrating device Electric continuity tester (multimeter) * no picture Procedure: Mount new pressure switch, see A5.05.11.06.05.nn.
  • Page 470 Pressure Switch A5.05. 11.06.06.02 Maintenance / Adjust M20/M25/M32/M43 Adjustment of switching point Remove cover (Fig. 2/4). By turning the hexagon socket screw (5) the switching point can be adjusted correspondingly. Assembly: Mount cover (4). Remove pressure calibrating device (W1). Clip on plug to the pressure switch. Open shut-off valve (Fig.
  • Page 471 Crankcase Monitoring Device A5.05. 11.09.01.03 Inspection / Checking M20/M25/M32/M43/M453C/M552C/M601C 1500, 750, 7500 See also: Spare parts list: B1.05.11.nn4810 Time requirement: 2 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and 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...
  • Page 472 Vibration Damper A5.05. 12.04.01.02 Maintenance / Disassembly and reassembly 30000 See also: 08.03.02.nn Spare parts list: B1.05.12.436347 Time requirement: 0 Pers./ 0,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: of the vibration damper after 30,000 h check size of gap "s"...
  • Page 473 Vibration Damper A5.05. 12.04.01.02 Maintenance / Disassembly and reassembly 30000 Sequence of operations: Dismantling Dismantle the lubricant pump (08.03.02.nn). Dismantle lubricant piping and pump bea- rer plate (4), completely removing all sili- con sealant. Drain the oil: • Turn oil flow boring to lower position (30).
  • Page 474 Vibration Damper A5.05. 12.04.01.02 Maintenance / Disassembly and reassembly 30000 1.12 Measure gap (Fig. 2/"s" ) between spring ends and groove flanks of the interior using a feeler gauge. Maximum permitted value for gap "s" between spring ends and groove flanks: Damper No.
  • Page 475 Vibration Damper A5.05. 12.04.01.02 Maintenance / Disassembly and reassembly 30000 Note: When critical values have been reached the damper should be replaced (AT procedure). If criti- cal values have been exceeded, the engine should be operated only at reduced power and avoiding critical speeds;...
  • Page 476 A5.05. 12.04.02.00 Maintenance / Replace 45000 See also: Spare parts list: B1.05.02.432520, B1.05.12.436347 Time requirement: 2 Pers./ 2,00 h Personnel qualification: Cat/MaK-specialist Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance/ replace: Vibration damper: Replacement (on an exchange basis) after...
  • Page 477 Turning Device A5.05. 12.08.01.01 Maintenance / Disassembly and reassembly 30000, 750, 3750 See also: Spare parts list: B1.05.12.437330, B1.05.12.437332 Time requirement: 1 Pers./ 0,10 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Oil level check every 3.750 h or 6 months...
  • Page 478 Turning Device A5.05. 12.08.01.01 Maintenance / Disassembly and reassembly 30000, 750, 3750 Disengaging the turning device 1.2.1 Move blockinglever (1) to position “V“ and hold. Move lever (2) to position“ Y “, so that the gearwheel of the turning device is disengaged from the 1.2.2 flywheel toothing.
  • Page 479 Turning Device A5.05. 12.08.01.01 Maintenance / Disassembly and reassembly 30000, 750, 3750 Maintenance Oil level check Note: If a topping up should be necessary, only the prescribed gear oil is to be used ! 2.1.1 Check oil level at the oil level glas (10) and fill in gear oil ( e.g. Shell Omala Oil 460 ) up to the oil level marke.
  • Page 480 Tools Tools en / 26.05.2009 AA000112...
  • Page 481 Table of contents A6.01 Tools Table of contents A6.01 Tools A6.05.22.69 Hydraulic tensioning equipment A6.05.90.10.00 Hydraulic wrench A6.05.90.10.01 High-Pressure Coupling Nipple A6.05.90.10.02 en / 26.05.2009 AA020050...
  • Page 482 Tools A6.05.22.69 en / 02.04.2009 AA045052 1/28...
  • Page 483 Werkzeug-Zusam m enstellung List of tools Liste des Outils Lista de las herram ientas Lista de ferram entas Verktøy-oversikt Oversigt over værktøj Com pilazione degli utensili M 43 Kostenträger-Nr. M otor-Nr. Record No. Engine No. De Référence No. M oteur No. De Referencia No.
  • Page 484 A6.05.01 Zylinderkopf Cylinder head M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Steckschlüssel 1.9100-060 Socket w rench Aufbewahrungskasten 1.9101 B Storage Box Hydraulikaggregat 433420 F Maximator Hochdruckschlauch 433420 A High-pressure hose en/03.04-2 WB000001 1/11...
  • Page 485 A6.05.01 Zylinderkopf Cylinder head M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Spannzylinder für Grundlager 1.9213 K Hydraulic jack for m ain bearings Spannzylinder für Seitenschrauben 1.9213 F Hydraulik jack for side screw s Spannzylinder für Zylinderkopf und 1.9213 P Gegengewicht Hydraulik jack for cylinder head and...
  • Page 486 A6.05.01 Zylinderkopf Cylinder head M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Spannzylinder für Pleuellager 1.9213 N Hydraulic jack for big-end bearing Spannzylinder für Kipphebelbock 1.9213 H Hydraulic jack for rocker arm bracket Innensechskantschlüssel 436500 A Hexagon socket screw key Drehmomentschrauber 435100 A...
  • Page 487 A6.05.01 Zylinderkopf Cylinder head M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Druckschlauch 433420 C Delivery hose Einsatz SW 32 435102 A Socket SW 32 Reaktionsarm 435100 B Reaction arm Einsatz SW 41 435102 B Socket SW 41 en/03.04-2 WB000001 4/11...
  • Page 488 A6.05.01 Zylinderkopf Cylinder head M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Einsatz SW 55 439208-001 Socket SW 55 Sonderabstützung 435100 C Special support Dichtung, Spannzyl. M 25x3 433311-054 Dichtung, Spannzyl. M 27x3 433311-048 Seal for Hydraulic jack Dichtung, Drehm .-Schrauber 435100-001 Seal for Torque screw driver...
  • Page 489 A6.05.01 Zylinderkopf Cylinder head M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Gabelschlüssel 436500 D Fork w rench Gabelschlüssel 436500 E Fork w rench Hochdruckschlauch, 1,0 m 433420 E High-pressure hose Prüfmanometer 100 433420 G Check gauge en/03.04-2 WB000001 6/11...
  • Page 490 A6.05.01 Zylinderkopf Cylinder head M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Dichtung, Spannzyl. 433311-061 Seal for Hydraulic jack Dichtung, Spannzyl. 433311-052 Seal for Hydraulc jack Dichtung, Spannyzl. 433311-059 Seal for Hydraulc jack Verschleissteilpaket, hydr. 432505-009 Wearing part set en/03.04-2 WB000001...
  • Page 491 A6.05.01 Zylinderkopf Cylinder head M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Stift 0.9203-111 Spannvorrichtung 439222 D Clam ping device Zange für Sicherungsringe 1.9067-440 Circlip pliers C 40 Ventileinschleifvorrichtung 439224 A Valve grinding device en/03.04-2 WB000001 8/11...
  • Page 492 A6.05.01 Zylinderkopf Cylinder head M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Sicherungsringzange 431020 A Cirlip pliers Ventilsitzfräsvorrichtung 439224 B Valve reseating tool Spitzendruckindikator 1.9410 K Peak pressure indicator Hebezeug, Zylinderkopf 432005 A Hoist, cylinder head en/03.04-2 WB000001 9/11...
  • Page 493 A6.05.01 Zylinderkopf Cylinder head M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Zylinderdeckeldrehvorrichtung 432006 B Cylinder head turning device Zapfenschlüssel 0.9105 A Pin w rench Ventilsitzfräser 439224 C Valve reseating tool en/03.04-2 WB000001 10/11...
  • Page 494 A6.05.01 Zylinderkopf Cylinder head M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Einführring, Anlassventilkolben 439227 A Guide Ring, starting valve piston Andrückvorrichtung 439222 C Pressing device en/03.04-2 WB000001 11/11...
  • Page 495 A6.05.02 Triebwerk Running gear M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Manschette 439220 A collar Kolben-Montagering 439220 B Piston m ounting sleeve M ontagezange für Kolbenring 431001 A Piston ring expander Sicherungsringzange für Kolbenbolzen 431019 A Cirlip pliers for piston pin en/03.04-2 WB000001...
  • Page 496 A6.05.02 Triebwerk Running gear M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure M ontagehilfe, Kolbenbolzen 439220 C M ounting device for piston pin Kurbelwangen-Meßgerät 1.9425 A Crank w eb deflection dial gauge Ausbauvorrichtung für Kolben 439223 A Rem oving device for piston Ein- und Ausbauvorrichtung 439228 A...
  • Page 497 A6.05.02 Triebwerk Running gear M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Pleuelstangenhalter 439228 B Connecting-rod holder Drehm om entschlüssel 20-200 Nm 1.9454-202 Torque w rench 20-200 Nm en/03.04-2 WB000001...
  • Page 498 A6.05.03 Motorgehäuse Motor casing M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Eintörnvorrichtung 439225-001 M ain bearing shell m ounting device M itnehm er für Lagerschale 439225 B Dog for m ain bearing shell Ein- und Ausbauvorrichtung 439216 A für Zylinderlaufbuchse M ounting and rem oving device for...
  • Page 499 A6.05.03 Motorgehäuse Motor casing M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Halter für Zylinderbuchse 439217 A Cylinder liner hold-dow n Ausdrückvorrichtung Kalibrierring 439216 B Ejector for anti-polishing ring Ein und Ausbauvorrichtung 439214 A für Grundlager M ounting and rem oving device for bearing shell Feinmeß-Innenmikrometer...
  • Page 500 A6.05.03 Motorgehäuse Motor casing M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure M eßlehre für Laufbuchse 439218-001 Ruler for cylinder liner en/03.04-2 WB000001...
  • Page 501 A6.05.04 Steuerung Timing gear M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Ein-u. Ausbauvorrichtung unterer 432135 A Ventilantrieb M ounting and rem oving device for low er valve drive Griff für Deckeldem ontage 432058 A Handle Ein- und Ausbauvorrichtung 439230 A für Nockenw elle...
  • Page 502 A6.05.04 Steuerung Timing gear M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Drehm om entschlüssel 200-500 Nm 1.9454-500 Torque w rench 200-500 Nm Umschaltknarre 1/2" 1.9459-033 Ratchet 1/2" Steckschlüssel-Einsatz SW 30 1.9424-030 Socket w rench insert SW 30 en/03.04-2 WB000001...
  • Page 503 A6.05.06 Abgasanlage / Aufladung Exhaust system/ supercharging M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Sechskantschraube 431011 A Hexagon screw en/03.04-2 WB000001...
  • Page 504 A6.05.07 Kraftstoffsystem Fuel - System M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Einspannvorrichtung für Düsenhalter 439208 A Clam ping device for nozzle holder Ringschlüssel 0.9100-055 spanner Ziehvorrichtung für Einspritzdüse 439111 A Rem oving device for fuel injectors Hebevorrichtung für Einspritzpum pe 439235 B Lifting device for injection pum p...
  • Page 505 A6.05.07 Kraftstoffsystem Fuel - System M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Adapter für Einspritzpum pe 432147 A Adapter Einstellschlüssel 432101 A Adjusting w rench Reinigungspistole 1.9100-114 Cleaning gun Reinigungsrohr 1.9100-115 Cleaning pipe en/07.02-1 WB000001...
  • Page 506 A6.05.07 Kraftstoffsystem Fuel - System M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Schlüssel für Düsenhülse 432119 A Wrench for nozzle sleeve Abspritzdruckprüfvorrichtung 1.9470 H 1.9470-043 1.9470-030 Nozzle tester 1.9470-020 1.9470-010 1.9470-070 Adapter für Düsenhalter 439206 A Union for nozzle holders M aulschlüssel 1.9106 A...
  • Page 507 A6.05.07 Kraftstoffsystem Fuel - System M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Reinigungsw erkzeug 432120 A Cleaning tool en/07.02-1 WB000001...
  • Page 508 A6.05.08 Schmierölsystem Lubricating oil system M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Ausdrückw erkzeug für Siebkerzen 1.9100-120 Ejector for filter cartridges en/03.04-2 WB000001...
  • Page 509 A6.05.13 Zusatzinstallation Additional installation M 43 Benennung St ü ck Werkzeug-Nr. Bild Description Qty. Tool-No. Figure Fühlerlehrensatz 1.9075-003 Set of feeler gauges Diam antpaste 5 g 1.9493-002 Grinding paste 5 g Dicht- u. Füllm asse Silicon 1.9492-002 Siicon sealing com pound Schild 0.9570 A Designation plate...
  • Page 510 Hydraulic tensioning equipment A6.05.90.10.00 M43/VM43 en / 30.03.2005 AA022953 1/32...
  • Page 511 Vorwort Sehr geehrter Betreiber, vor Inbetriebnahme der Spannanlage sollten Sie die Ihnen vorliegende Betriebsanleitung sorg- fältig lesen. Die Spannanlage der Fa. ITH-GmbH werden nach DIN ISO 9001 gefertigt und konstruiert und entsprechen den vorgeschriebenen Sicherheitsbestimmungen nach CE-Norm. Die Handhabung und auch der Betrieb der ITH-Spanngeräte sind aufgrund des hohen Ent- wicklungsstandes der Werkzeuge möglichst einfach und sicher gestaltet.
  • Page 512 I N H A L T S V E R Z E I C H N I S Kap. Beschreibung Druckschrift/Zeichnungs-Nr. Technische Daten 1.1 Stammblatt zum Schraubenspannzylinder 1.2 Stammblatt zum Hochdruckpumpen-Aggregat 1.3 Hydraulische Schraubenspannanlage (schematisch) 33.9 1.4 EG-Konformitätserklärung Hinweise auf Unfall- und Schadensverhütung 2.1 Schraubenspannzylinder 2.2 Schlauchleitung Bedienungsanleitung...
  • Page 513 C O N T E N T S Sec.. Description Print / Drawing-No. Technical data 1.1 Basic data sheet for bolt-tensioning cylinder 1.2 Basic data sheet for high-pressure pump unit 1.3 Hydraulic bolt-tensioning unit 1.4 EEC declaration of conformity Instructions for prevention of accidents and damage 2.1 Bolt-tensioning cylinder 2.2 Hose Operating instruction...
  • Page 514 Kapitel 1.0 Section 1.0 Technische Daten Technical Data Druckschrift/Print : 09.80095d Betriebsanleitung - Kap. 1.0: Technische Daten Seite/Page : 1 von/of 6 Operating Instruction - Section 1.0: Technical data Auf’m Brinke 18 ++49/(0)291/9962-0 D-59872 Meschede Fax ++49/(0)291/9962-11...
  • Page 515 Stammblatt zum Schraubenspannzylinder Basic Data Sheet for Bolt-Tensioning Cylinders 1.1.1 Adressen / Adresses: 1.1.1a Hersteller: ITH-GmbH ITH-GmbH Manufacturer: Auf’’m Brinke 18 P.O. Box 13 65 D-59872 Meschede D-59853 Meschede 1.1.1b Kunde: Customer: 1.1.1c Lieferdatum an den Endkunden: Date of Delivery to Customer: 1.1.2 Technische Daten der Schraubenspannzylinder: Technical Data for Bolt-Tensioning Cylinders: Gewindegröße...
  • Page 516 Stammblatt zum Hochdruckpumpen-Aggregat Basic Data Sheet for High-Pressure Pump Unit 1.2.1 Adressen / Adresses: 1.2.1a Hersteller: ITH-GmbH ITH-GmbH Manufacturer: Auf’m Brinke 18 P.O. Box 136 D-59872 Meschede D-59853 Meschede 1.2.1b Kunde: Customer: 1.2.1c Lieferdatum an den Endkunden: Date of Delivery to Customer: 1.2.2 Technische Daten der Hochdruckpumpen-Aggregate: Technical Data for High-Pressure Pump Unit: Bestell-Nr.
  • Page 517 1.3 EG - Konformitätserklärung [EC - Declaration of Conformity] im Sinne der EG-Maschinenrichtlinie 89/392/EWG, Anhang II A (gemäß Art. 4, Abs. 2/ Anhang II B der Richtlinie). in accordance with the EEC Machine Guidelines 89/392/EEC, Appendix II A] (to Article 4, Section 2, Appendix II B of the Guidelines) Hiermit erklären wir, [We,] ITH-GmbH, Auf´m Brinke 18, D-59872 Meschede...
  • Page 518 Kapitel 2.0 Section 2.0 Hinweise auf Unfall- und Schadensverhütung Prevention of Accidents and Damage to Equipment Druckschrift/Print : 09.80095d Betriebsanleitung - Kap. 2.0: Hinweise auf Unfall- und Schadensverhütung Seite/Page : 1 von/of7 Operating Instruction - Section 2.0: Prevention of Accidents and Damage to Equipment Auf’m Brinke 18 ++49/(0)291/9962-0 D-59872 Meschede...
  • Page 519 2.1. Schraubenspannzylinder / Bolt-Tensioning Cylinder 2.1.1 Betriebsdaten / Operating Data Vor Beginn der Arbeit Be- Study these operating instruc- triebsanleitung sorgfältig lesen. tions carefully before beginning Bitte Hinweise auf Unfall- und work, and observe the notes on Schadensverhütung beachten! prevention of accidents and Betriebsdaten des Schrauben- damage to property.
  • Page 520 2.1.4 Schraubenvorbereitung / Bolt preparation Vor dem Einsatz des Schrau- Before using the bolt-tensioning benspannzylinders sollte das cylinder, grease the thread of Gewinde des zu spannenden the bolt. The grease quality is Schraubenbolzens eingefettet determined by the user. werden. Die Qualtität des Fet- tes ist vom Anwender abhänig.
  • Page 521 2.1.7 Einsatz des SSZ / Using the Bolt-Tensioning Cylinder Schraubenspannzylinder Do noit apply pressure to the darf nur mit Druck beaufschlagt bolt-tensioning cylinder until it is werden wenn er vorher auf firmly screwed down onto the einem Schraubenbolzen aufge- bolt. schraubt worden ist.
  • Page 522 2.2 Schlauchleitung / Hose line 2.2.1 Beschädigung der HD-Schlauchleitung / Damage to High-Pressure Hose Line Vor Einsatz der HD-Schlauch- Before using the high-pressure leitung überprüfen hose, ensure that the hose line Schlauchleitung oder or the protective casing is not Schutzummantelung Knickstel- damaged or kinked.
  • Page 523 2.4 Betriebsdruck / Operating pressure Allgemeine Anleitung: General rule: maximale Betriebsdruck Never exceed the maximum des SSZ darf nicht überschrit- operating pressure of the bolt- ten werden. Entnehmen Sie tensioning cylinder. The maxi- diesen Wert biite der Maß- operating pressure zeichnung (Kap.
  • Page 524 2.7 Sicherheitshinweise (allgemein) / General Safety Instructions Beim Betrieb von hydraulischen When working with hydraulic bolt- Schraubenspannvorrichtungen sind tensioning cylinders, always ob- die allgemeinen VGB 5 zu beachten. serve the general regulations for Wenn die Schraubenspannzylinder accident prevention. When the unter hohem Druck stehen, ist der bolt-tensioning cylinder is under Aufenthalt stirnseitig in Richtung der...
  • Page 525 Kapitel 3.0 Section 3.0 Bedienungsanleitung Operating Instruction Druckschrift/Print : 09.80095d Betriebsanleitung - Kap. 3.0: Bedienungsanleitung Seite/Page : 1 von/of 15 Operating Instruction - Section 3.0: Bedienungsanleitung Auf’m Brinke 18 ++49/(0)291/9962-0 D-59872 Meschede Fax ++49/(0)291/9962-11...
  • Page 526 3.1 Vor Inbetriebnahme von Schraubenspannzylinder / Before Using the Bolt-Tensioning Cylinder 3.1.1 Betriebsanleitung / Operating Instructions Vor Beginn der Arbeit Betriebs- Study these operating instruc- anleitung sorgfältig lesen. Bitte tions carefully before beginning Hinweise Unfall- work, and observe the notes on Schadensverhütung beachten! prevention of accidents and (Kapitel 2.0)
  • Page 527 3.1.4. Kolbenrückstellung / Piston Return Vor Beginn der Arbeit überprü- Before beginning work, ensure fen, ob sich Kolben in Endlage that the piston is in its end posi- befinden. (Endlage entspricht tion (i.e. change bushing is Wechselbuchse plan mit Dec- level with the cover).
  • Page 528 3.2 Anziehen von Schraubenverbindungen Tightening of Bolts 3.2.1 Gewindeüberstand / Thread projection Vor dem Aufschrauben des Before screwing bolt- Schraubenspannzylinders tensioning cylinder onto the die Schraube, ausreichenden botlt, ensure that there is suffi- Gewindeüberstand überprüfen. cient thread projection above In der Regel soltte der Gewin- the nut.
  • Page 529 3.2.4 Druckeinstellung / Pressure Setting 3.2.4a Druckeinstellung bei Motor- bzw. Handpumpen mit Druckbegrenzungsventil Pressure Setting for Electric and Manual Pumps with Pressure Limiting Valve − Pneum. und hydraulisches (falls − Fully open pneumatic vorhanden) Druckbegrenzungs- hydraulic pressure limiting ventil ganz öffnen. valve (if installed).
  • Page 530 3.2.6 Druckaufbau Pressure Accumulation Vorher eingestellten bzw. be- Generate the previously STOP stimmten Druck am Pum- set/determined pressure (see penaggregat erzeugen. section 4.4) Achtung: - Never exceed the maximum - auf keinen Fall max. Hub, in stroke (generally 10 mm) which der Regel 10 mm, über- is indicated by the red groove schreiten.
  • Page 531 3.3 Lösen von Schraubenverbindungen / Loosening of Bolts 3.3.1 Gewindeüberstand / Thread projection Vor dem Aufschrauben des Before screwing bolt- Schraubenspannzylinders tensioning cylinder onto the die Schraube, ausreichenden bolt, ensure that there is suffi- Gewindeüberstand überprüfen. cient thread projection above In der Regel soltte der Gewin- the nut.
  • Page 532 3.3.3b Druckeinstellung bei Handpumpen ohne Druckbegrenzungsventil Pressure Setting for Manual Pumps without Pressure Limiting Valve Schraubenspannzylinder darf noch The bolt-tensioning cylinder must Absperrventil nicht mit Handpumpe verbunden not yet be connected with the Shut -off valve sein: manual pump: − Absperrventil schließen −...
  • Page 533 3.3.6 Lösen der Mutter / Loosening the Nut Nach Erreichen des hydrauli- Once the hydraulic pressure schen Druckes, Aggregat aus- has been reached, switch the schalten. Die Mutter von der unit off. Turn the nut away from Auflagefläche mittels Beistell- the surface with the adjusting stange wegdrehen.
  • Page 534 3.4 Auswechseln der Wechselbuchse (vgl. hierzu auch Kap. 4.1 und 4.2) Replacement of Change Bushing (see sections 4.1 and 4.2) Schraubenspannzylinder Clamp the bolt-tensioning cyl- Anschluß oder mit Zylinder I in inder into the vice by the con- Schraubstock oder Dreibacken- nection or cylinder I.
  • Page 535 3.4.1 Auswechseln der Dichtungen Replacement of the Sealings Druckschrift/Print : 09.80095d Betriebsanleitung - Kap. 3.0: Bedienungsanleitung Betriebsanleitung - Kap. 3.0: Bedienungsanleitung Betriebsanleitung - Kap. 3.0: Bedienungsanleitung Seite/Page : 11 von/of 15 Operating Instruction - Section 3.0: Bedienungsanleitung Operating Instruction - Section 3.0: Bedienungsanleitung Operating Instruction - Section 3.0: Bedienungsanleitung Auf’m Brinke 18 Auf’m Brinke 18...
  • Page 536 3.5 Spannkraftermittlung Determining Tensioning Force 3.5.1 Einheiten für Kraft und Druck Units for Force and Pressure Die Spannkraft [F] der Schrau- The tensioning force (F) of the benspannzylinder ist direkt vom bolt-tensioning cylinder is di- Druck abhängig. Der Druck rectly related to the pressure. kann direkt am Monometer des The pressure is indicated in bar 1000...
  • Page 537 Kurz - Bedienungsanleitung Vor Beginn der Arbeit: unbedingt ausführlich Kap. 2.0 lesen! 3.6.1 Unfall- und Schadensverhütung Während des Druckaufbaus, d.h. bis der Schraubenspannzylinder den vorher eingestellten Druck erreicht hat, immer auf einen ausreichenden Sicherheitsabstand zum Schraubenspannzylinder achten (3-5m). Schraubenspannzylinder nur aufschrauben, wenn Kolben unter Endlage wieder erreicht haben. Dies ist daran zu erkennen, daß...
  • Page 538 Operating Instructions in Brief Before beginning work, study section 2.0 thoroughly! 3.6.1 Prevention of Accidents and Damage During the pressure build-up phase, (i.e. before the bolt-tensioning cylinder has reached the previously set pres- sure) always remain at a safe distance from the bolt-tensioning cylinder (approx. 3 - 5 metres). Do not screw the bolt-tensioning cylinder onto the bolt until the piston has reached its lower end position, i.e.
  • Page 539 Werkzeug größe Maschinen-Nr. Tool size Manufact-no. Datum Anfangswert Endwert Zyklenverbrauch Gesamtverbrauc Unterschrift Cycles used Signature Date Start reading Finish reading Total usage 09.00133 Druckschrift/Print : Logbuch für Zyklenzahlen /log book for cycle numbers Seite/Page : 15 von/of 15 Auf’m Brinke 18 ++49/(0)291/9962-0 D-59872 Meschede Fax ++49/(0)291/9962-11...
  • Page 540 Kapitel 6.0 Section 6.0 Zubehör- und Ersatzteile Accessories and Spare Parts Druckschrift/Print : 09.80095d Betriebsanleitung - Kap. 6.0: Zubehör- und Ersatzteile Seite/Page : 1 von/of 3 Operating Instruction - Section 6.0: Accessories and Spare Parts Auf’m Brinke 18 ++49/(0)291/9962-0 D-59872 Meschede Fax ++49/(0)291/9962-11...
  • Page 541 ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷...
  • Page 542 Hydraulic wrench A6.05.90.10.01 M43/VM43 en / 21.04.2005 AA030963 1/13...
  • Page 543 Vorwort Sehr geehrter Betreiber, vor Inbetriebnahme der Drehmomentschraubanlage sollten Sie die Ihnen vorliegende Be- triebsanleitung sorgfältig lesen. Die Drehmomentschraubanlage der Fa. ITH-GmbH werden nach DIN ISO 9001 gefertigt und konstruiert und entsprechen den vorgeschriebenen Sicherheitsbestimmungen nach CE-Norm. Die Handhabung und auch der Betrieb der ITH-Drehmomentschraubgeräte sind aufgrund des hohen Entwicklungsstandes der Werkzeuge möglichst einfach und sicher gestaltet.
  • Page 544 I N H A L T S V E R Z E I C H N I S Table of contents Kapitel Beschreibung Druckschrift Section Description Document Stammblatt der Drehmomentschraubanlage 09.80035 Adresses and data for torque screw device Konformitätserklärung EEC declaration of conformity Prüfbericht 09.00085 Test report...
  • Page 545 Stammblatt zur Drehmomentschraubanlage Basic Data Sheet for torque wrench unit 1.1. Adressen / Adresses: 1.1.1 Hersteller: ITH-GmbH ITH-GmbH Manufacturer: Auf’’m Brinke 18 P.O. Box 13 65 D-59872 Meschede D-59853 Meschede 1.1.2 Kunde: Customer: 1.1.3 Lieferdatum an den Endkunden: Date of Delivery to Customer: Technische Daten der Drehmomentschraubanlage: Technical Data for torque wrench unit: 1.2.1 Drehmomentschrauber / Torque wrench...
  • Page 546 Drehmomentschrauber Typ: Masch.-Nr.: Dat.: Torque wrench type: Manufact-no.: Date: 1.0 Kunde / Customer: 2.0 Testeinrichtung / Test device: Drehmomentschrauber torque screwer Drehmomentschrauber Torsionswelle torsional wave Torque screwer Dehnmeßstreifen resistance strain gauge Meßverstärker measuring amplifier 3.0 Kalibrierung / Calibration: Hebellänge: 1,0 m Testmoment / test-moment: length of lever: 1,0 m x 50 x 9,80665 = 490,33 Nm...
  • Page 547 2.0 EG - Konformitätserklärung [EC - Declaration of Conformity] im Sinne der EG-Maschinenrichtlinie 89/392/EWG, Anhang II A (gemäß Art. 4, Abs. 2/ Anhang II B der Richtlinie). in accordance with the EEC Machine Guidelines 89/392/EEC, Appendix II A] (to Article 4, Section 2, Appendix II B of the Guidelines) Hiermit erklären wir, [We,] ITH-GmbH, Auf´m Brinke 18, D-59872 Meschede...
  • Page 548 5.0 Bedienungsanleitung für Drehmomentschrauber Typ DG und DR Operating instruction for torque wrench type DG and DR 5.1 Elektroanschluß Electrical Instructions Durch Aufstecken der CEE Kupp- The main power connection is made lung wird der Hauptstromanschluß by plugging in the EEC coupling. hergestellt.
  • Page 549 5.4 Drehmomenteinstellung Torque setting Durch Betätigung weißen The electric motor is switched on by Schalters an der Fernbedienung wird pressing the white switch on the Elektro-Motor eingeschaltet. remote control. Keep the white switch pressed and turn the hand Weißen Schalter gedrückt halten Handrad wheel on the pressure-limiting valve Druckbegrenzungs-ventil...
  • Page 550 5.6 Rechtsdrehen des Drehmoment- schraubers Right-hand turn Die dargestellte Abbildung zeigt den The illustration shows the torque Drehmomentschrauber in der Stel- wrench in the position for right-hand lung, in der er rechtsherum dreht turning (tightening). correct (Anziehen). Das jeweilige Adapter- adapter should be pushed into the stück ist in die gegenüberliegende opposite side.
  • Page 551 5.9 Abstützung am Drehmoment- schrauber Support arm on torque wrench Je nach Art der Schraubenverbin- Depending on the type of bolted dung kann der Drehmomentschrau- joint, the torque wrench can also be ber mit einer Abstützung eingesetzt used with a support arm. The werden.
  • Page 552 5.11 Abstützposition des Drehmo- mentschraubers Support position for torque wrench Drehmomentschrauber mit entspre- Fit the correct insert to the torque chendem Einsatz versehen (Bild wrench (fig. 5.5). Fit the support arm 5.5). Drehmomentschrauber mit Ab- to the torque wrench (fig. 5.9). stützung versehen (Bild 5.9).
  • Page 553 5.13 Erreichen des Drehmomentes Achieving the torque Ist ein Drehmoment gemäß Punkt When a torque is selected according 5.4 vorgewählt, muß der Drehmo- to section 5.4, the torque wrench mentschrauber betätigt werden bis must be operated until the sleeve of sich die Büchse des Drehmoment- the torque wrench with the insert no schraubers mit entsprechendem Ein-...
  • Page 554 5.15 Bedienung mit 4 Drehmomentschraubern / Operation with 4 torque wrenches 5.15.1 Vorbereitung / Preparation Drehmomenteinstellung, Adapter, Abstützung Torque adjusting, adapter, support and hydraulic Hydraulikanschluß für alle vier Drehmomentschrauber connection for all four torque wrenches according to gemäß Bild 5.4 bis 5.12 durchführen. picture 5.4 to 5.12.
  • Page 555 High-Pressure Coupling Nipple A6.05.90.10.02 M43/VM43 en / 01.07.2004 AA028654...
  • Page 556 Überprüfung der Hochdruckkupplungsnippel Checking the High-Pressure Coupling Nipple Beschreibung : Die Hochdruckkupplungsnippel werden metallisch über einen Dichtkonus am Schrauben- spannzylinder und an der Hochdruckschlauchleitung abgedichtet. Materialsetzungen, Schwin- gungen und erhöhte Biegebelastungen können eine Leckage am Dichtkonus hervorrufen. Ei- ne nicht sachgemäße Montage (Nachziehen) kann zum Versagen des Hochdruckkupplungs- nippels führen.
  • Page 557 Überprüfung der Hochdruckkupplungsnippel am Schraubenspannzylinder Checking the high-pressure coupling nipple on the bolt-tensioning cylinder: Schraubenspannzylinder in einem Schraubstock einspannen. Nach dem Lösen des Hochdruck- kupplungsnippels und dem Überprüfen des Dicht- konus auf zu starke plastische Verformungen, Hochdruckkupplungsnippel mit einem kalibrierten Drehmomentschlüssel mit max.
  • Page 558 Überprüfung der Hochdruckkupplungsnippel an der Hochdruckschlauchleitung Checking the high-pressure coupling nipples on the high-pressure hose : Einspannen der Hochdruckschlauchleitung in ei- nem Schraubstock. Nach dem Lösen des Hoch- druckkupplungsnippels und der Überprüfung des Dichtkonus auf zu starke plastische Verformung mit einem kalibrierten Drehmomentschlüssel mit max.
  • Page 559 Spare Parts Catalogue M43C Spare Parts Catalogue M43C Engine No.: Record No.: 68 280 281717 68 281 en / 26.05.2009 AA000620...
  • Page 560 Spare Parts Catalogue M43C Please note the copyright notice pursuant to ISO 16016 "All documents such as drawings, data and programmes, etc. and models, templates etc. shall remain our exclusive property. They are only handed over to the agreed purpose and must not be used for any other purpose.

  • Page 561: Total Index

    Total Index B0.01 Book A, B and C Engine Operating Instructions Total Index Book A, B and C A0.01 Introduction A0.02 Safety instructions A0.03 Emergency Stop Safety System A0.04 Technical Engine Data Governor Data A1.04 Working pressures of auxiliary equipment A1.05 Temperatures of operating media A1.06...
  • Page 562 Total Index B0.01 Book A, B and C External Documentation Total Index Book A, B and C C0.01 Introduction Electrical Equipment C0.02 Table of contents C5.01 en / 26.05.2009 AA020059...
  • Page 563 Introduction B0.02 M20-M601C The structure of the contents ensures that you will find the required spares very quickly. Structure of the contents Example: Catalogue sheet No. B1.05.01 8.2220 BB bzw. 252220 BB Book B (Spares parts catalogue) Engine main group/register Chapter spares Subchapter spare parts sheets This spares catalogue has been compiled according to your specific engine equipment, therefore...
  • Page 564 Introduction B0.02 M20-M601C Example of a spare parts sheet Catalogue Sheet No. Item Description Quantity Part No. For further information please refer to: http://www.marine.cat.com en / 26.11.2008 AA000036...
  • Page 565 Caterpillar Motoren GmbH & Co. KG cvb2 Anfrage/Ersatzteilbestellschein / Spare Parts Inquiry or Order Sheet Auftrags-Nr,/Kunden-Referenz-Nr. Auftragsdatum P.O. Number/Customer Ref. No. Order date Käufer/Buyer Empfänger/Consignee Liefertermin Erforderlicher Ankunftstermin (postalisch einwandfreie Anschrift) (genaue Warenempfänger-Anschrift) Date of Delivery (voraussichtliche Ankunftszeit) exact postal address exact addressee of consignee Date of required arrival (eta) Markierung, spezielle Anweisungen, z.

  • Page 566: Spare Parts

    Spare Parts M20-M601C Spare Parts en / 26.05.2009 AA000047...
  • Page 567 Table of contents B1.01 Spare Parts Table of contents B1.01 Safety instructions B1.03 Engine, cylinder head B1.05.01 Cylinder Head B1.05.01.432107 HH Mediums Guide B1.05.01.432144 FF Cylinder Head Cap B1.05.01.432190 BB Valve Rotator B1.05.01.432225 AA Freewheel B1.05.01.432227 CC Engine, gear B1.05.02 Crankshaft with Balance Weights B1.05.02.432520 DD Piston and Connecting-rod...
  • Page 568 Table of contents B1.01 Engine, control B1.05.04 Camshaft B1.05.04.433120 NN Vibration Damper Mounting for Camshaft B1.05.04.433140 PP Bottom Part for Valve Mechanism B1.05.04.433502 ZB Injection Pump Drive B1.05.04.433580 AA Governor Mounting B1.05.04.434110 FF Governor Drive B1.05.04.434111 DD Governor Drive B1.05.04.434118 AA Idle Wheel Mounting B1.05.04.435140 GG Engine, regulation...
  • Page 569 Table of contents B1.01 Engine, fuel system B1.05.07 Fuel Injector B1.05.07.432260 CC Nozzle Holder B1.05.07.432267 CC Fuel Injection Pump B1.05.07.433597 KK Set of Gaskets for Fuel Injection Pump Mounting B1.05.07.433599 AA Fuel Filter Mounting B1.05.07.437660 DD Duplex Fuel Fine Filter B1.05.07.437667 CC Fuel Pipe Covering B1.05.07.437669 BB...
  • Page 570 Table of contents B1.01 Engine, cooling water system B1.05.09 Cover Mounting B1.05.09.436475 CC Cool. Water Distrib./Collecting Pipe B1.05.09.438320 SS Cooling Water Pipe B1.05.09.438330 MM Drain Pipe Mounting B1.05.09.438392 HH Draining for Turbocharger B1.05.09.438395 RR Engine, starting system B1.05.10 Air Admission Pipe B1.05.10.437299 LL Air Pipe on Engine B1.05.10.438610 CC...
  • Page 571 M20-M601C We exp licitly draw it to you r att ention t hat on ly original MaK replacement parts as well as the replacemen t parts o f ou r su ppliers ord ered via aft er- sales services are subject t o MaK qu ality co ntrol.
  • Page 572 Zylinderkopf B1.05.01. 432107 HH Cylinder Head M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ZYLINDERKOPF, VOLLST. 432107 HH CYLINDER HEAD ASSEMBLY FÜHRUNGSBOLZEN 432107-002 GUIDE BOLT VENTILFÜHRUNG, EINLASS 432107-004 INLET VALVE GUIDE VENTILFÜHRUNG, AUSLASS 432107-005 EXHAUST VLAVE GUIDE VENTILKEGEL, EINLASS 432107-006 INLET VALVE STEM VENTILKEGEL, AUSLASS...
  • Page 573 Zylinderkopf B1.05.01. 432107 HH Cylinder Head M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. FLANSCH 432107-039 FLANGE DEHNHÜLSE 9.2107-132 EXTENSION SLEEVE HYDRAULIKMUTTER 432107-041 ROUND NUT HAUBE FÜR ZYLINDERKOPF, VOLLST. SIEHE B1.05.01.432190 CYLINDER HEAD CAP, COMPL. SEE B1.05.01.432190 REDUZIERSTUTZEN 432107-044 REDUCER SICHERHEITSVENTIL, VOLLST.
  • Page 574 Zylinderkopf B1.05.01. 432107 HH Cylinder Head M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. O-RING 1.7084-662 O-RING O-RING 1.7084-655 O-RING O-RING 1.7082-518 O-RING SEITENDRUCKSTÜCK 1.6281-100 BUFFER SICHERUNGSRING 1.0060-041 CIRCLIP SICHERUNGSRING 1.0061-734 CIRCLIP ABSTANDSSTÜCK 1.0520-180 DISTANCE PIECE ABSTANDSSTÜCK 1.0520-181 DISTANCE PIECE ABSTANDSSTÜCK 1.0520-182...
  • Page 575 Zylinderkopf B1.05.01. 432107 HH Cylinder Head M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. VERSCHLUSSDECKEL 1.9027-054 PLUG DICHTRING 1.7010-029 JOINT RING DICHTRING 1.7010-133 JOINT RING DICHTRING 1.7010-273 JOINT RING O-RING 1.7082-623 O-RING O-RING 1.7084-660 O-RING VENTILBRÜCKE, AUSLASS, VOLLST. 433515-100 EXHAUST VALVE CROSS-BAR, COMPL.
  • Page 576 Zylinderkopf B1.05.01. 432107 HH Cylinder Head M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. STÜTZSCHEIBE 432107-052 DISK SICHERUNGSRING 1.0060-277 CIRCLIP KIPPHEBEL, EINLASS 433510-100 INLET VALVE ROCKER BUCHSE 433510-102 BUSH KUGELBOLZEN 433510-103 BALL HEAD PIN EINSTELLSCHRAUBE 433510-104 ADJUSTING SCREW SECHSKANTMUTTER 1.2017-283 HEXAGON THIN NUT...
  • Page 577 Zylinderkopf B1.05.01. 432107 HH Cylinder Head M43/VM43 en / 10.03.2009 EB030459 6/13...
  • Page 578 Zylinderkopf B1.05.01. 432107 HH Cylinder Head M43/VM43 en / 10.03.2009 EB030459 7/13...
  • Page 579 Zylinderkopf B1.05.01. 432107 HH Cylinder Head M43/VM43 en / 10.03.2009 EB030459 8/13...
  • Page 580 Zylinderkopf B1.05.01. 432107 HH Cylinder Head M43/VM43 en / 10.03.2009 EB030459 9/13...
  • Page 581 Zylinderkopf B1.05.01. 432107 HH Cylinder Head M43/VM43 en / 10.03.2009 EB030459 10/13...
  • Page 582 Zylinderkopf B1.05.01. 432107 HH Cylinder Head M43/VM43 en / 10.03.2009 EB030459 11/13...
  • Page 583 Zylinderkopf B1.05.01. 432107 HH Cylinder Head M43/VM43 en / 10.03.2009 EB030459 12/13...
  • Page 584 Zylinderkopf B1.05.01. 432107 HH Cylinder Head M43/VM43 en / 10.03.2009 EB030459 13/13...
  • Page 585 Medienführung B1.05.01. 432144 FF Mediums Guide POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. MEDIENFÜHRUNG, VOLLST. 432144 FF MEDIUMS GUIDE ASSEMBLY ANSCHLUSSFLANSCH 432144-001 CONNECTING FLANGE ANSCHLUSSFLANSCH 432144-002 CONNECTING FLANGE SCHMIERÖLLEITUNG, VOLLST. 432144-104 LUBE OIL PIPE, COMPL. MEDIENKLOTZ 432144-106 DISTRIBUTOR PLATE ABSCHLUSSFLANSCH 432144-007 CONNECTING FLANGE...
  • Page 586 Medienführung B1.05.01. 432144 FF Mediums Guide POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. VERSCHLUSSSCHRAUBE 1.1040-356 SCREW PLUG VERSCHLUSSSCHRAUBE 1.1056-005 SCREW PLUG VERSCHLUSSSCHRAUBE 1.1041-812 SCREW PLUG DICHTRING 1.7010-252 JOINT RING GERADER VERBINDUNGSSTUTZEN 1.5095-027 PIPE UNION # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 587 Medienführung B1.05.01. 432144 FF Mediums Guide en / 30.08.2004 EB027190...
  • Page 588 Medienführung B1.05.01. 432144 FF Mediums Guide en / 30.08.2004 EB027190...
  • Page 589 Medienführung B1.05.01. 432144 FF Mediums Guide en / 30.08.2004 EB027190...
  • Page 590 Medienführung B1.05.01. 432144 FF Mediums Guide en / 30.08.2004 EB027190...
  • Page 591 Zylinderkopfhaube B1.05.01. 432190 BB Cylinder Head Cap M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ZYLINDERKOPFHAUBE, VOLLST. 432190 BB CYLINDER HEAD CAP ASSEMBLY HAUBE 432190-051 COVER GEWINDEBOLZEN 432190-052 STUD KREUZGRIFF 432190-003 PALM GRIP PROFILSCHNUR 432190-004 RUBBER SEAL SPANNSTIFT 1.0039-266 SPRING DOWEL PIN TELLERFEDER...
  • Page 592 Zylinderkopfhaube B1.05.01. 432190 BB Cylinder Head Cap M43/VM43 en / 10.12.2003 EB020906...
  • Page 593 Ventildrehvorrichtung B1.05.01. 432225 AA Valve Rotator M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. VENTILDREHVORRICHTUNG, VOLLST. 432225 AA VALVE ROTATOR ASSEMBLY TELLERFEDER 1.2225-103 CUP SPRING SPRENGRING 1.2225-104 SPRING RING TANGENTIALFEDER 1.2225-106 TANGENTIAL SPRING STAHLKUGEL 1.2225-105 STEEL BALL Jede Bestellung muß folgende Angaben enthalten: Motor-Nr. / Ersatzteilblatt-Nr. / Bestell-Nr. Each order must include the following: Engine No./Spare parts sheet No./Part No.
  • Page 594 Ventildrehvorrichtung B1.05.01. 432225 AA Valve Rotator M43/VM43 en / 10.12.2003 EB011939...
  • Page 595 Freilauf B1.05.01. 432227 CC Freewheel M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. FREILAUF, VOLLST. 432227 CC FREEWHEEL ASSEMBLY FREILAUF, OBERTEIL 432227-001 FREEEWHEEL, UPPER PART FREILAUF, UNTERTEIL 432227-002 FREEEWHEEL, LOWER PART AXIAL-RILLENKUGELLAGER, VOLLST. 432227-103 THRUST BALL BEARING, COMPL. SPRENGRING 1.0060-190 SPRING RING...
  • Page 596 Freilauf B1.05.01. 432227 CC Freewheel M43/VM43 en / 04.07.2003 EB025765...
  • Page 597 Kurbelwelle mit Gegengewichten B1.05.02. 432520 DD Crankshaft with Balance Weights POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KURBELWELLE, VOLLST. 432520 DD CRANKSHAFT ASSEMBLY KURBELWELLE 432520-101 CRANKSHAFT GEGENGEWICHT 432520-002 BALANCE WEIGHT ZAHNRAD 432530-001 GEAR WHEEL SCHWINGUNGSDÄMPFER, VOLLST. SIEHE B1.05.12.436347 VIBRATION DAMPER, COMPL.
  • Page 598 Kurbelwelle mit Gegengewichten B1.05.02. 432520 DD Crankshaft with Balance Weights en / 19.03.2004 EB022677...
  • Page 599 Kurbelwelle mit Gegengewichten B1.05.02. 432520 DD Crankshaft with Balance Weights en / 19.03.2004 EB022677...
  • Page 600 Kolben mit Pleuelstange B1.05.02. 432601 DD Piston and Connecting-rod M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KOLBEN MIT PLEUELSTANGE, VOLLST. 432601 DD PISTON AND CONNECTING-ROD ASSEMBLY LAGERSCHALE, VOLLST. 432601-003 NORMAL BEARING, COMPL. KOLBENBOLZEN, VOLLST. 432601-004 PISTON PIN, COMPL. SICHERUNGSRING 1.0061-303 CIRCLIP...
  • Page 601 Kolben mit Pleuelstange B1.05.02. 432601 DD Piston and Connecting-rod M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KOLBEN, VOLLST. 432670-400 PISTON, COMPL. KOLBENUNTERTEIL 432670-201 PISTON SKIRT KOLBENOBERTEIL 432670-202 PISTON CROWN O-RING 432670-203 O-RING STEHBOLZEN 432670-404 BOLT DISTANZHÜLSE 432670-405 DISTANCE SLEEVE SECHSKANTMUTTER 432670-406...
  • Page 602 Kolben mit Pleuelstange B1.05.02. 432601 DD Piston and Connecting-rod M43/VM43 en / 29.07.2008 EB029119...
  • Page 603 Kolben mit Pleuelstange B1.05.02. 432601 DD Piston and Connecting-rod M43/VM43 en / 29.07.2008 EB029119...

  • Page 604: Piston Rings

    Kolbenringausrüstung B1.05.02. 432617 AA Piston Rings POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KOLBENRINGAUSRÜST., VOLLST. 432617 AA SET OF PISTON RINGS, COMPL. NUT 1 FEUERSTEGRING 432617-001 GROOVE FIRE RING NUT 2 VERDICHTUNGSRING 432617-002 GROOVE COMPRESSION RING NUT 3 ÖLABSTREIFRING 432617-003 GROOVE...
  • Page 605 Deckel-Anbau B1.05.02. 436345 EE Cover Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DECKEL-ANBAU, VOLLST. 436345 EE COVER MOUNTING ASSEMBLY DECKEL 436345-251 COVER DICHTUNG 436345-252 GASKET SECHSKANTSCHRAUBE 1.1387-444 HEXAGON SCREW DICHTRING 1.7010-347 JOINT RING VERSCHLUSSSCHRAUBE 1.1040-375 SCREW PLUG # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 606 Deckel-Anbau B1.05.02. 436345 EE Cover Mounting en / 14.04.2004 EB027334...
  • Page 607 Zylinderkurbelgehäuse B1.05.03. 431110 YY Engine Housing POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ZYLINDERKURBELGEHÄUSE, VOLLST. 431110 YY ENGINE HOUSING ASSEMBLY KURBELWELLE, VOLLST. SIEHE B1.05.02.432520 CRANKSHAFT, COMPL. SEE B1.05.02.432520 KURBELWELLENLAGER, VOLLST. 431110-003 NORMAL BEARING, COMPL. NOCKENWELLENLAGER 431110-004 CAMSHAFT BEARING ANLAUFSCHEIBE 431110-005 THRUST WASHER...
  • Page 608 Zylinderkurbelgehäuse B1.05.03. 431110 YY Engine Housing POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. STIFTSCHRAUBE 431110-122 STUD BUCHSE 431110-018 BUSH ZYLINDERSTIFT 431110-125 DOWEL PIN O-RING 1.7082-845 O-RING BUCHSE 431110-027 BUSH FLANSCH 9.1165-009 FLANGE ZYLINDERSCHRAUBE 1.1152-715 HEXAGON SOCKET HEAD CAP SCREW GEWINDEBOLZEN 1.0017-402 THREADED HEAD...
  • Page 609 Zylinderkurbelgehäuse B1.05.03. 431110 YY Engine Housing POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. VERSCHLUSSSCHRAUBE 1.1040-370 SCREW PLUG SCHEIBE 1.0045-127 WASHER DICHTRING 1.7010-302 JOINT RING DICHTRING 1.7010-252 JOINT RING DICHTUNG 1.7073-737 GASKET O-RING 1.7084-655 O-RING O-RING 1.7084-656 O-RING O-RING 1.7082-523 O-RING O-RING...
  • Page 610 Zylinderkurbelgehäuse B1.05.03. 431110 YY Engine Housing POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. MUTTER 251110-011 LAGER 431110-004 BEARING AUFNAHMEBOLZEN 9.1111-209 BOLT BUCHSE 431110-069 BUSH DICHTUNGSSATZ FÜR KW.-VERTEILERGEHÄUSE SIEHE B1.05.03.431113 SET OF GASKETS FOR COOL. WATER DISTR. CASE SEE B1.05.03.431113 * = IN 431110 YY ENTHALTEN INCLUDED IN 431110 YY # = VERBRAUCHSTEILE...
  • Page 611 Zylinderkurbelgehäuse B1.05.03. 431110 YY Engine Housing en / 17.09.2008 EB027068 5/10...
  • Page 612 Zylinderkurbelgehäuse B1.05.03. 431110 YY Engine Housing en / 17.09.2008 EB027068 6/10...
  • Page 613 Zylinderkurbelgehäuse B1.05.03. 431110 YY Engine Housing en / 17.09.2008 EB027068 7/10...
  • Page 614 Zylinderkurbelgehäuse B1.05.03. 431110 YY Engine Housing en / 17.09.2008 EB027068 8/10...
  • Page 615 Zylinderkurbelgehäuse B1.05.03. 431110 YY Engine Housing en / 17.09.2008 EB027068 9/10...
  • Page 616 Zylinderkurbelgehäuse B1.05.03. 431110 YY Engine Housing en / 17.09.2008 EB027068 10/10...
  • Page 617 Verkleidung für Zylinderkurbelgehäuse B1.05.03.431112 ZP Engine Housing Cover POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. VERKLEIDUNG, VOLLST. 431112 ZP COVERS ASSEMBLY NOCKENWELLENDECKEL, VOLLST. SIEHE B1.05.03.431636 CAMSHAFT COVER, COMPL. SEE B1.05.03.431636 NOCKENWELLENDECKEL, VOLLST. SIEHE B1.05.03.431636 CAMSHAFT COVER, COMPL. SEE B1.05.03.431636 KURBELRAUMDECKEL, VOLLST.
  • Page 618 Verkleidung für Zylinderkurbelgehäuse B1.05.03.431112 ZP Engine Housing Cover POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DEHNHÜLSE 1.0502-138 EXTENSION BUSH VERSCHLUSSSCHRAUBE 1.1041-609 SCREW PLUG DICHTRING 1.7010-133 JOINT RING UNIVERSAL DICHTUNG 1.1000-101 SEALING COMPOUND O-RING 1.7084-636 O-RING O-RING 1.7082-015 O-RING SECHSKANTSCHRAUBE 1.1387-443 HEXAGON SCREW...
  • Page 619 B1.05.03. 431112 ZP Verkleidung für Zylinderkurbelgehäuse Engine Housing Cover en / 27.08.2007 EB031427...
  • Page 620 B1.05.03. 431112 ZP Verkleidung für Zylinderkurbelgehäuse Engine Housing Cover en / 27.08.2007 EB031427...
  • Page 621 Kurbelraumentlüftung-Anbau B1.05.03. 431165 DD Crankcase Breather Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KURBELRAUMENTLÜFTG.-ANBAU, VOLLST. 431165 CC CRANKCASE BREATHER MOUNTING ASS. FLANSCH 1.5340-314 FLANGE FLANSCH 1.5340-131 FLANGE VERSCHLUSSSCHEIBE 1.5341-131 LOCKING WASHER ENTLÜFTUNGSLEITUNG, VOLLST. 431165-004 VENT PIPE DICHTUNG 1.7073-404 GASKET SECHSKANTSCHRAUBE...
  • Page 622 Kurbelraumentlüftung-Anbau B1.05.03. 431165 DD Crankcase Breather Mounting en / 11.02.2002 EB025025...
  • Page 623 Anbau der Ölwanne B1.05.03. 431220 KK Oil Pan Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ANBAU DER ÖLWANNE, VOLLST. 431220 KK OIL PAN MOUNTING ASSEMBLY ÖLWANNE, VOLLST. 431220-001 OIL PAN, COMPL. DICHTUNG 431220-002 GASKET FLANSCH 1.1200-110 FLANGE DICHTUNG 1.1250-052 GASKET...
  • Page 624 Anbau der Ölwanne B1.05.03. 431220 KK Oil Pan Mounting en / 16.09.2004 EB027536...
  • Page 625 Abdeckblech - Anbau B1.05.03. 431360 UU Cover Plate Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ABDECKBLECH - ANBAU, KOMPL. 431360 UU COVER PLATE MOUNTING, COMPL. ABDECKBLECH 431360-051 COVER PLATE ABDECKBLECH 431360-052 COVER PLATE ABDECKBLECH 431360-053 COVER PLATE ABDECKBLECH 431360-054 COVER PLATE...
  • Page 626 Abdeckblech - Anbau B1.05.03. 431360 UU Cover Plate Mounting en / 10.01.2006 EB029067...
  • Page 627 Zylinderbuchse B1.05.03. 431611 AA Cylinder Liner POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ZYLINDERBUCHSE 431110-006 CYLINDER LINER Jede Bestellung muß folgende Angaben enthalten: Motor-Nr. / Ersatzteilblatt-Nr. / Bestell-Nr. Each order must include the following: Engine No./Spare parts sheet No./Part No. en / 18.03.1999 EB012031...
  • Page 628 Zylinderbuchse B1.05.03. 431611 AA Cylinder Liner en / 18.03.1999 EB012031...
  • Page 629 Triebraumdeckel mit Entlastungsventil B1.05.03. 431633 HH Crankcase Cover With Relief Valve POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. TRIEBRAUMDECKEL, VOLLST. 431633 HH CRANKCASE COVER ASSEMBLY TRIEBRAUMDECKEL 431633-201 CRANKCASE COVER PROFILSCHNUR 431633-005 RUBBER SEAL ENTLASTUNGSVENTIL, VOLLST. 431633-600 RELIEF VALVE, COMPL. SECHSKANTSCHRAUBE 1.1367-282 HEXAGON SCREW...
  • Page 630 Triebraumdeckel mit Entlastungsventil B1.05.03. 431633 HH Crankcase Cover With Relief Valve en / 17.11.2008 EB033488...
  • Page 631 Deckel für Nockenwellentrog B1.05.03. 431636 BB Cover for Camshaft Case POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DECKEL FÜR NOCKENWELLENTROG, VOLLST. 431636 BB COVER FOR CAMSHAFT CASE ASSEMBLY NOCKENWELLENDECKEL 431636-101 CAMSHAFT COVER PROFILSCHNUR 431636-103 RUBBER SEAL # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 632 Deckel für Nockenwellentrog B1.05.03. 431636 BB Cover for Camshaft Case en / 24.02.2004 EB026976...
  • Page 633 Deckel für Nockenwellentrog B1.05.03. 431636 CC Cover for Camshaft Case POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DECKEL FÜR NOCKENWELLENTROG, VOLLST. 431636 CC COVER FOR CAMSHAFT CASE ASSEMBLY NOCKENWELLENDECKEL 431636-201 CAMSHAFT COVER PROFILSCHNUR 431636-203 RUBBER SEAL # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 634 Deckel für Nockenwellentrog B1.05.03. 431636 CC Cover for Camshaft Case en / 24.02.2004 EB026978...
  • Page 635 Pumpenraumverkleidung B1.05.03. 431710 PP Pump Covers POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. PUMPENRAUMVERKLEIDUNG, VOLLST. 431710 PP PUMP COVERS ASSEMBLY SPANNSTIFT 1.0039-914 SPRING DOWEL PIN SECHSKANTSCHRAUBE 1.1387-376 HEXAGON SCREW SECHSKANTSCHRAUBE 1.1387-444 HEXAGON SCREW SPANNSCHEIBE 1.0068-222 CONICAL SPRING WASHER SPANNSCHEIBE 1.0068-240 CONICAL SPRING WASHER...
  • Page 636 Pumpenraumverkleidung B1.05.03. 431710 PP Pump Covers POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. VERKLEIDUNG, VOLLST. 431714-300 COVER, COMPL. SPANNSCHEIBE 1.0068-225 CONICAL SPRING WASHER BÜGELGRIFF 1.3060-104 HANDLE SECHSKANTSCHRAUBE 1.1387-338 HEXAGON SCREW VERKLEIDUNG, VOLLST. 431714-400 COVER, COMPL. BUNDBOLZEN 431714-107 BOLT STERNGRIFF 1.3066-706 STAR GRIP...
  • Page 637 Pumpenraumverkleidung B1.05.03. 431710 PP Pump Covers en / 21.04.2004 EB027365...
  • Page 638 Pumpenraumverkleidung B1.05.03. 431710 PP Pump Covers en / 21.04.2004 EB027365...
  • Page 639 Pumpenraumverkleidung B1.05.03. 431710 PP Pump Covers en / 21.04.2004 EB027365...

  • Page 640: Crankshaft Seal

    Kurbelwellenabdichtung B1.05.03. 437340 AA Crankshaft Seal POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KURBELWELLENABDICHTUNG, VOLLST. 437340 AA CRANKSHAFT SEAL ASSEMBLY SCHWUNGRADNABE 437340-001 FLYWHEEL HUB ABSCHLUSSDECKEL 437340-002 COVER SPRITZRING, VOLLST. 437340-003 SPLASH RING, COMPL. SECHSKANTSCHRAUBE 1.1376-273 HEXAGON BOLT SECHSKANTSCHRAUBE 1.1387-447 HEXAGON SCREW SPANNSCHEIBE...
  • Page 641 Kurbelwellenabdichtung B1.05.03. 437340 AA Crankshaft Seal en / 13.01.1998 EB011764...
  • Page 642 Nockenwelle B1.05.04. 433120 NN Camshaft POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. NOCKENWELLE, VOLLST. 433120 NN CAMSHAFT ASSEMBLY NOCKENWELLENTEILSTÜCK 433120-001 CAMSHAFT SECTION LAGERZAPFEN 433120-152 BEARING JOURNAL DECKEL 433120-053 COVER ANLAUFSCHEIBE 433120-004 THRUST WASHER ZAHNRAD 433120-005 GEARWHEEL SECHSKANTSCHRAUBE 1.1374-461 HEXAGON BOLT SECHSKANTSCHRAUBE 1.1372-469...
  • Page 643 Nockenwelle B1.05.04. 433120 NN Camshaft en / 17.04.2002 EB025205...
  • Page 644 Schwingungsdämpfer-Anbau B1.05.04. 433140 PP für Nockenwelle Vibration Damper Mounting for Camshaft POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCHWINGUNGSDÄMPFER-ANBAU, VOLLST. 433140 PP VIBRATION DAMPER MOUNTING ASSEMBLY SCHWINGUNGSDÄMPFER, VOLLST. 433140-101 VIBRATION DAMPER, COMPL. ZWISCHENSTÜCK 433140-202 INTERMEDIATE PIECE DEHNHÜLSE 1.0502-177 EXTENSION SLEEVE SECHSKANTSCHRAUBE 1.1367-705...
  • Page 645 Schwingungsdämpfer-Anbau B1.05.04. 433140 PP für Nockenwelle Vibration Damper Mounting for Camshaft en / 10.12.2007 EB032037...
  • Page 646 Unterer Ventilantrieb B1.05.04. 433502 ZB Bottom Part for Valve Mechanism POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. UNTERER VENTILANTRIEB, VOLLST. 433502 ZB BOTTOM PART FOR VALVE MECHANISM ASS. ÖLROHR 433502-052 OIL PIPE ÖLROHR 433502-053 OIL PIPE ÖLROHR 433502-105 OIL PIPE BLECH 433502-055...
  • Page 647 Unterer Ventilantrieb B1.05.04. 433502 ZB Bottom Part for Valve Mechanism POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. VENTILANTRIEB, VOLLST. 433505-900 VALVE MECHANISM, COMPL. SCHWINGHEBELBOCK 433505-001 ROCKING LEVER BRACKET SCHWINGHEBELACHSE 433505-052 ROCKING LEVER AXLE DEHNHÜLSE 1.0502-186 EXTENSION SLEEVE SECHSKANTSCHRAUBE 1.1367-553 HEXAGON BOLT SPANNSTIFT...
  • Page 648 Unterer Ventilantrieb B1.05.04. 433502 ZB Bottom Part for Valve Mechanism POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. BUCHSE 9.3565-105 BUSH SPANNSTIFT 1.0039-921 SPRING DOWEL PIN * = IN 433502 ZB ENTHALTEN INCLUDED IN 433502 ZB # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 649 Unterer Ventilantrieb B1.05.04. 433502 ZB Bottom Part for Valve Mechanism en / 20.03.2004 EB027094...
  • Page 650 Unterer Ventilantrieb B1.05.04. 433502 ZB Bottom Part for Valve Mechanism en / 20.03.2004 EB027094...
  • Page 651 Unterer Ventilantrieb B1.05.04. 433502 ZB Bottom Part for Valve Mechanism en / 20.03.2004 EB027094...
  • Page 652 Unterer Ventilantrieb B1.05.04. 433502 ZB Bottom Part for Valve Mechanism en / 20.03.2004 EB027094...
  • Page 653 Einspritzpumpenantrieb B1.05.04. 433580 AA Injection Pump Drive POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. EINSPRITZPUMPENANTRIEB, VOLLST. 433580 AA INJECTION PUMP DRIVE ASSEMBLY EINSPRITZPUMPE, VOLLST. SIEHE B1.05.07.433597 INJECTION PUMP, COMPL. SEE B1.05.07.433597 DRUCKSTANGE 433580-005 THRUST ROD FEDERTELLER 433580-006 SPRING PLATE DRUCKFEDER 433580-008 COMPRESSION SPRING...
  • Page 654 Einspritzpumpenantrieb B1.05.04. 433580 AA Injection Pump Drive POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SECHSKANTMUTTER 1.2035-045 HEXAGON NUT WITH COLLAR HALBRUNDKERBNAGEL 1.0036-864 GROOVED DRIVE STUD O-RING 1.7084-681 O-RING # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß folgende Angaben enthalten: Motor-Nr. / Ersatzteilblatt-Nr. / Bestell-Nr. Each order must include the following: Engine No./Spare parts sheet No./Part No.
  • Page 655 Einspritzpumpenantrieb B1.05.04. 433580 AA Injection Pump Drive en / 23.10.2000 EB011779...
  • Page 656 Regleranordnung B1.05.04. 434110 FF Governor Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. REGLERANORDNUNG, VOLLST. 434110 FF GOVERNOR MOUNTING ASSEMBLY REGLER, VOLLST. SIEHE BUCH C GOVERNOR, COMPL. SEE BOOK C FEDERGLIED, VOLLST. 434110-002 ELASTIC CONNECTING-ROD, COMPL. HEBEL 434110-003 LEVER HEBEL 434110-004...
  • Page 657 Regleranordnung B1.05.04. 434110 FF Governor Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. GELENKKOPF 9.4110-026 LINK HEAD GELENKKOPF 9.4110-027 LINK HEAD SECHSKANTSCHRAUBE 1.1367-380 HEXAGON SCREW DEHNHÜLSE 1.0502-131 EXTENSION BUSH SECHSKANTSCHRAUBE 1.1387-444 HEXAGON SCREW # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß folgende Angaben enthalten: Motor-Nr. / Ersatzteilblatt-Nr. / Bestell-Nr. Each order must include the following: Engine No./Spare parts sheet No./Part No.
  • Page 658 Regleranordnung B1.05.04. 434110 FF Governor Mounting en / 08.04.2008 EB029076...
  • Page 659 Regleranordnung B1.05.04. 434110 FF Governor Mounting en / 08.04.2008 EB029076...
  • Page 660 Reglerantrieb B1.05.04. 434111 DD Governor Drive POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. REGLERANTRIEB-ANBAU, VOLLST. 434111 DD GOVERNOR DRIVE MOUNTING ASSEMBLY REGLERANTRIEB, VOLLST. SIEHE B1.05.04.434118 GOVERNOR DRIVE, COMPL. SEE B1.05.04.434118 HÜLSE 251110-014 SLEEVE DICHTUNG 434111-103 GASKET DICHTUNG 434111-104 GASKET DICHTRING 1.7010-160...
  • Page 661 Reglerantrieb B1.05.04. 434111 DD Governor Drive en / 08.05.2002 EB025333...
  • Page 662 Reglerantrieb B1.05.04. 434118 AA Governor Drive M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. REGLERANTRIEB, VOLLST. 434118 AA GOVERNOR DRIVE ASSEMBLY REGLERANTRIEBSWELLE 434118-001 GOVERNOR DRIVE SHAFT ZWISCHENWELLE 434118-002 INTERMEDIATE SHAFT SCHRAUBRAD 434118-003 SPIRAL-TOOTHED GEAR WHEEL EINSTECKGEHÄUSE 434118-004 HOUSING ZWISCHENRAD 434118-005 INTERMWDIATE WHEEL...
  • Page 663 Reglerantrieb B1.05.04. 434118 AA Governor Drive M43/VM43 en / 25.03.2004 EB025128...
  • Page 664 Zwischenrad-Anbau B1.05.04. 435140 GG Idle Wheel Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ZWISCHENRAD-ANBAU, VOLLST. 435140 GG IDLE WHEEL MOUNTING ASSEMBLY STUFENRAD, VOLLST. 435140-301 IDLE WHEEL, COMPL. ACHSE, VOLLST. 435140-302 AXLE, COMPL. SICHERUNGSBLECH 435140-303 LOCKING PLATE SICHERUNGSBLECH 435140-304 LOCKING PLATE DEHNHÜLSE...
  • Page 665 Zwischenrad-Anbau B1.05.04. 435140 GG Idle Wheel Mounting en / 13.03.2004 EB027110...
  • Page 666 Bedienstand B1.05.05. 1.4523 AA Control Stand M20/M25/M32/M43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. BEDIENSTAND, VOLLST. 1.4523 AA CONTROL STAND ASSEMBLY ZEIGER, VOLLST. 1.4523-001 POINTER, COMPL. RASTE, VOLLST. 1.4523-002 DETEND, COMPL. WARTUNGSEINHEIT, VOLLST. SIEHE BUCH C MAINTENANCE UNIT, COMPL. SEE BOOK C HEBEL MIT LAGER UND BUCHSE 1.4523-004...
  • Page 667 Bedienstand B1.05.05. 1.4523 AA Control Stand M20/M25/M32/M43 en / 24.03.2009 EB032120...
  • Page 668 Druckluftfilter B1.05.05. 1.4900 HH Compressed-Air Filter M20-M601C POS. BENENNUNG STCK BEST.-NR NORMTEIL ITEM DESCRIPTION NUMBER PART NO. STANDARD NO. 10.0 DRUCKLUFTFILTER, VOLLST. 1.4900 HH COMPRESSED-AIR FILTER ASSEMBLY 10.0-1 O-RING O-RING 10.0-2 FILTERELEMENT FILTER ELEMENT 10.0-3 O-RING O-RING * = E-PÄCKCHEN, NUR VOLLST. 1.4900-908 (BEI REPARATUR KOMPLETT AUSWECHSLEN) COMPLETE SET OF SPARE PARTS...
  • Page 669 ã Druckluftfilter B1.05.05. 1.4900 HH Compressed-Air Filter M20-M601C en / 28.10.1996 EB000413...
  • Page 670 3/2 Wegeventil B1.05.05. 1.4906 ZM 3/2 Way Valve M25/M32/M43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. 3/2 WEGEVENTIL, VOLLST. 1.4906 ZM 3/2 WAY VALVE ASSEMBLY VENTILTELLER, VOLLST. VALVE DISK, COMPL. KOLBEN PISTON O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING FEDER...
  • Page 671 3/2 Wegeventil B1.05.05. 1.4906 ZM 3/2 Way Valve M25/M32/M43 en / 26.04.2001 EB010999...
  • Page 672 3/2 Wegeventil B1.05.05. 1.4906 ZM 3/2 Way Valve M25/M32/M43 en / 26.04.2001 EB010999...
  • Page 673 Reguliergestänge B1.05.05. 434210 RR Injection Pump Control Shaft POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. REGULIERGESTÄNGE, VOLLST. 434210 RR INJECTION PUMP CONTROL SHAFT ASSEMBLY REGULIERWELLE 434210-301 CONTROL SHAFT LAGERBOCK, VOLLST. 434210-103 BEARING BRACKET, COMPL. LAGERBOCK, VOLLST. 434210-003 BEARING BRACKET, COMPL. STELLRING 1.0090-047 SET COLLAR...
  • Page 674 Reguliergestänge B1.05.05. 434210 RR Injection Pump Control Shaft POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCHEIBE 1.0040-223 WASHER INNENRING 9.4212-065 INNER RING * = IN 434210 RR ENTHALTEN INCLUDED IN 434210 RR # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß folgende Angaben enthalten: Motor-Nr. / Ersatzteilblatt-Nr. / Bestell-Nr. Each order must include the following: Engine No./Spare parts sheet No./Part No.
  • Page 675 Reguliergestänge B1.05.05. 434210 RR Injection Pump Control Shaft en / 09.06.2008 EB027119...
  • Page 676 Reguliergestänge B1.05.05. 434210 RR Injection Pump Control Shaft en / 09.06.2008 EB027119...
  • Page 677 Reguliergestänge-Anbau B1.05.05. 434217 DD Control Linkage Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. REGULIERGESTÄNGE, VOLLST. 434217 DD CONTROL LINKAGE MOUNTING ASSEMBLY STANGE 434217-201 HEBEL 434110-004 LEVER BOLZEN 9.4110-111 BOLT DISTANZBUCHSE 9.4110-009 SPACER SECHSKANTSCHRAUBE 1.1367-243 HEXAGON BOLT SPANNSTIFT 1.0039-289 SPRING DOWEL PIN SECHSKANTMUTTER...
  • Page 678 Reguliergestänge-Anbau B1.05.05. 434217 DD Control Linkage Mounting en / 06.03.2004 EB027130...
  • Page 679 Stoppleitung-Anbau B1.05.05. 434241 ZH Air Pipe for Engine Stop Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. STOPPLEITUNG.ANBAU, VOLLST. 434241 ZH AIR PIPE FOR ENGINE STOP ASSEMBLY STOPPLEITUNG, VOLLST. 434241-001 AIR PIPE, COMPL. STOPPLEITUNG, VOLLST. 434241-302 AIR PIPE, COMPL. VERBINDUNGSLEITUNG, VOLLST.
  • Page 680 Stoppleitung-Anbau B1.05.05. 434241 ZH Air Pipe for Engine Stop Mounting en / 20.04.2006 EB029691...
  • Page 681 Füllungsgeber-Anbau B1.05.05. 434243 DD Filling Transmitter Mounting M32/M43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. FÜLLUNGSGEBER-ANBAU, VOLLST. 434243 DD FILLING TRANSMITTER MOUNTING ASSEMBLY HALTER 434243-101 BRACKET NOCKENSCHEIBE, VOLLST. 1.4243-201 CAM DISK, COMPL. FÜLLUNGSGEBER FILLING TRANSMITTER * = AUF ANFRAGE ON INQUIRY Jede Bestellung muß...
  • Page 682 Füllungsgeber-Anbau B1.05.05. 434243 DD Filling Transmitter Mounting M32/M43 en / 17.11.2006 EB026182...
  • Page 683 Bedienstand-Anbau B1.05.05. 434520 PP Control Stand Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. BEDIENSTAND-ANBAU, VOLLST. 434520 PP CONTROL STAND MOUNTING ASSEMBLY BEDIENSTAND, VOLLST. SIEHE B1.05.05.nn4523 CONTROL STAND, COMPL. SEE B1.05.05.nn4523 MANOMETERTAFEL, VOLLST. SIEHE B1.05.11.434630 GAUGE PANEL, COMPL. SEE B1.05.11.434630 HALTER 434520-305...
  • Page 684 Bedienstand-Anbau B1.05.05. 434520 PP Control Stand Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. VERBINDUNGSLEITUNG, VOLLST. 434520-329 CONNECTING PIPE, COMPL. VERBINDUNGSLEITUNG, VOLLST. 434520-330 CONNECTING PIPE, COMPL. VERBINDUNGSLEITUNG, VOLLST. 434520-331 CONNECTING PIPE, COMPL. STUTZEN 1.5099-425 PIPE UNION L-STUTZEN 1.5093-340 ADJUSTABLE MALE RUN TEE GEWINDWREDUZIERUNG 1.5036-052...
  • Page 685 Bedienstand-Anbau B1.05.05. 434520 PP Control Stand Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SECHSKANTSCHRAUBE 1.1367-372 HEXAGON SCREW SECHSKANTMUTTER 1.2007-034 HEXAGON NUT SECHSKANTMUTTER 1.2007-038 HEXAGON NUT HUTMUTTER 1.2031-602 DOMED CAP NUT SCHEIBE 1.0040-220 WASHER SCHEIBE 1.0040-223 WASHER SPANNSTIFT 1.0039-293 SPRING DOWEL PIN DEHNHÜLSE...
  • Page 686 Bedienstand-Anbau B1.05.05. 434520 PP Control Stand Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. MEGI-PUFFER 1.6280-000 BONDED RUBBER PAD # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß folgende Angaben enthalten: Motor-Nr. / Ersatzteilblatt-Nr. / Bestell-Nr. Each order must include the following: Engine No./Spare parts sheet No./Part No. en / 21.04.2009 EB030515...
  • Page 687 Bedienstand-Anbau B1.05.05. 434520 PP Control Stand Mounting en / 21.04.2009 EB030515...
  • Page 688 Bedienstand-Anbau B1.05.05. 434520 PP Control Stand Mounting en / 21.04.2009 EB030515...
  • Page 689 Bedienstand-Anbau B1.05.05. 434520 PP Control Stand Mounting en / 21.04.2009 EB030515...
  • Page 690 Bedienstand-Anbau B1.05.05. 434520 PP Control Stand Mounting en / 21.04.2009 EB030515...
  • Page 691 Anschlußarmaturen B1.05.06. 1.7259 NN für Turbolader-Reinigungsanlage Connection Fittings for Turbocharger Cleaning Device M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ANSCHLUSSARMATUREN, VOLLST. 1.7259 NN SET OF CONNECTING FITTINGS, COMPL. SCHLAUCHLEITUNG 1.7259-201 HOSE PIPE ROHR 1.9050-095 TUBE SCHNEIDRING 1.5059-217 CUTTING RING ÜBERWURFMUTTER 1.5040-141...
  • Page 692 Anschlußarmaturen B1.05.06. 1.7259 NN für Turbolader-Reinigungsanlage Connection Fittings for Turbocharger Cleaning Device M43/VM43 en / 04.06.2008 EB031716...
  • Page 693 Deckel-Anbau B1.05.06. 431775 AA Cover Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DECKEL-ANBAU, VOLLST. 431775 AA COVER MOUNTING ASSEMBLY DECKEL 437240-005 COVER DICHTUNG 437240-004 GASKET DECKEL 437240-006 COVER DICHTUNG 437240-007 GASKET SECHSKANTSCHRAUBE 1.1387-490 HEXAGON SCREW # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 694 Deckel-Anbau B1.05.06. 431775 AA Cover Mounting en / 14.04.2004 EB027367...
  • Page 695 Abgasstutzen B1.05.06. 437208 AA Exhaust Nozzle M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ABGASSTUTZEN, VOLLST. 437208 AA EXHAUST NOZZLE ASSEMBLY ABGASSTUTZEN 437208-001 EXHAUST NOZZLE DICHTUNG 437208-003 GASKET FLANSCH 1.5383-205 WELDING FLANGE DICHTUNG 1.7073-568 GASKET BLINDFLANSCH 1.5340-314 BLANK FLANGE DICHTRING 1.7010-390 JOINT RING...
  • Page 696 Abgasstutzen B1.05.06. 437208 AA Exhaust Nozzle M43/VM43 en / 12.03.2008 EB032384...
  • Page 697 Abgasleitung-Anbau B1.05.06. 437210 ZA Exhaust Manifold Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ABGASLEITUNG-ANBAU, VOLLST. 437210 ZA EXHAUST MANIFOLD MOUNTING ASSEMBLY ABGASROHR 437210-051 EXHAUST PIPE ABGASROHR 437210-152 EXHAUST PIPE SPANNSCHELLE, VOLLST. 437210-002 CLAMP, COMPL. ABGASROHR 437210-154 EXHAUST PIPE KOMPENSATOR, VOLLST.
  • Page 698 Abgasleitung-Anbau B1.05.06. 437210 ZA Exhaust Manifold Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DICHTRING 1.7010-104 JOINT RING VERSCHLUSSSCHRAUBE 1.1041-805 SCREW PLUG DEHNHÜLSE 1.0502-164 EXTENSION BUSH # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß folgende Angaben enthalten: Motor-Nr. / Ersatzteilblatt-Nr. / Bestell-Nr. Each order must include the following: Engine No./Spare parts sheet No./Part No.
  • Page 699 Abgasleitung-Anbau B1.05.06. 437210 ZA Exhaust Manifold Mounting en / 23.03.2005 EB028123...
  • Page 700 Abgasleitung-Anbau B1.05.06. 437210 ZA Exhaust Manifold Mounting en / 23.03.2005 EB028123...
  • Page 701 Abgasleitung-Anbau B1.05.06. 437210 ZZ Exhaust Manifold Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ABGASLEITUNG-ANBAU, VOLLST. 437210 ZZ EXHAUST MANIFOLD MOUNTING ASSEMBLY ABGASROHR 437210-051 EXHAUST PIPE ABGASROHR 437210-152 EXHAUST PIPE SPANNSCHELLE, VOLLST. 437210-002 CLAMP, COMPL. ABGASROHR 437210-104 EXHAUST PIPE KOMPENSATOR, VOLLST.
  • Page 702 Abgasleitung-Anbau B1.05.06. 437210 ZZ Exhaust Manifold Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DICHTRING 1.7010-104 JOINT RING VERSCHLUSSSCHRAUBE 1.1041-805 SCREW PLUG DEHNHÜLSE 1.0502-164 EXTENSION BUSH # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß folgende Angaben enthalten: Motor-Nr. / Ersatzteilblatt-Nr. / Bestell-Nr. Each order must include the following: Engine No./Spare parts sheet No./Part No.
  • Page 703 Abgasleitung-Anbau B1.05.06. 437210 ZZ Exhaust Manifold Mounting en / 23.03.2005 EB028121...
  • Page 704 Abgasleitung-Anbau B1.05.06. 437210 ZZ Exhaust Manifold Mounting en / 23.03.2005 EB028121...
  • Page 705 Verkleidung für Abgasleitung B1.05.06. 437220 VV Exhaust Line Covering POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. VERKLEIDUNG FÜR ABGASLEITUNG, VOLLST. 437220 VV EXHAUST LINE COVERING ASSEMBLY VERKLEIDUNG, VOLLST. 437220-301 COVERING, COMPL. VERKLEIDUNG, VOLLST. 437220-302 COVERING, COMPL. VERKLEIDUNG, VOLLST. 437220-303 COVERING, COMPL.
  • Page 706 Verkleidung für Abgasleitung B1.05.06. 437220 VV Exhaust Line Covering POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. STÜTZBLECH, VOLLST. 437220-023 SUPPORT, COMPL. STÜTZBLECH, VOLLST. 437220-824 SUPPORT, COMPL. HALTER, VOLLST. 437220-325 BRACKET, COMPL. HALTER 437220-326 BRACKET HALTER, VOLLST. 437220-327 BRACKET, COMPL. HALTER, VOLLST.
  • Page 707 Verkleidung für Abgasleitung B1.05.06. 437220 VV Exhaust Line Covering POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DICHTBLECH, VOLLST. 437220-344 COVERING PLATE, COMPL. ABSCHIRMBLECH, VOLLST. 437220-346 SCREEN PLATE, COMPL. ABSCHIRMBLECH, VOLLST. 437220-047 SCREEN PLATE, COMPL. SPRITZLECH 437220-851 COVER SPRITZBLECH 437220-852 COVER SPRITZBLECH...
  • Page 708 Verkleidung für Abgasleitung B1.05.06. 437220 VV Exhaust Line Covering POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SECHSKANTSCHRAUBE 1.1387-445 HEXAGON SCREW SPANNSCHEIBE 1.0068-240 CONICAL SPRING WASHER SPANNSCHEIBE 1.0068-222 CONICAL SPRING WASHER SPANNSCHEIBE 1.0068-225 CONICAL SPRING WASHER SPANNSCHEIBE 1.0068-209 CONICAL SPRING WASHER DEHNHÜLSE 1.0502-188 EXTENSION BUSH...
  • Page 709 Verkleidung für Abgasleitung B1.05.06. 437220 VV Exhaust Line Covering en / 04.01.2008 EB032082...
  • Page 710 Verkleidung für Abgasleitung B1.05.06. 437220 VV Exhaust Line Covering en / 04.01.2008 EB032082...
  • Page 711 Verkleidung für Abgasleitung B1.05.06. 437220 VV Exhaust Line Covering en / 04.01.2008 EB032082...
  • Page 712 Verkleidung für Abgasleitung B1.05.06. 437220 VV Exhaust Line Covering en / 04.01.2008 EB032082...
  • Page 713 Verkleidung für Abgasleitung B1.05.06. 437220 VV Exhaust Line Covering en / 04.01.2008 EB032082...
  • Page 714 Turbolader-Anbau B1.05.06. 437250 KK Turbocharger Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. TURBOLADER-ANBAU, VOLLST. 437250 KK TUBOCHARGER MOUNTING ASSEMBLY TURBOLADER, VOLLST. SIEHE BUCH C TURBOCHARGER, COMPL. SEE BOOK C LADELUFTKÜHLER, VOLLST. SIEHE BUCH C CHARGE AIR COOLER, COMPL. SEE BOOK C LUFTEINTRITTSSTUTZEN, VOLLST.
  • Page 715 Turbolader-Anbau B1.05.06. 437250 KK Turbocharger Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SECHSKANTSCHRAUBE 1.1367-720 HEXAGON SCREW SECHSKANTSCHRAUBE 1.1387-446 HEXAGON SCREW SECHSKANTSCHRAUBE 1.1372-373 HEXAGON SCREW SECHSKANTSCHRAUBE 1.1387-239 HEXAGON SCREW SECHSKANTSCHRAUBE 1.1387-372 HEXAGON SCREW SECHSKANTMUTTER 1.2007-040 HEXAGON NUT BOLZEN 1.0252-214 PARALLEL PIN DEHNHÜLSE...
  • Page 716 Turbolader-Anbau B1.05.06. 437250 KK Turbocharger Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. GEHÄUSE FÜR LADELUFTKÜHLER, VOLLST. * 437287-100 HOUSING FOR CHARGE AIR COOLER, COMPL. ABDECKBLECH, VOLLST. 437287-102 COVER PLATE, COMPL. VERSCHLUSSDECKEL 1.9027-054 PLUG VERSCHLUSSSCHRAUBE 1.1041-609 SCREW PLUG DICHTRING 1.7010-133 JOINT RING...
  • Page 717 Turbolader-Anbau B1.05.06. 437250 KK Turbocharger Mounting en / 21.04.2009 EB027141...
  • Page 718 Turbolader-Anbau B1.05.06. 437250 KK Turbocharger Mounting en / 21.04.2009 EB027141...
  • Page 719 Turbolader-Anbau B1.05.06. 437250 KK Turbocharger Mounting en / 21.04.2009 EB027141...
  • Page 720 Turbolader-Anbau B1.05.06. 437250 KK Turbocharger Mounting en / 21.04.2009 EB027141...
  • Page 721 Turbolader-Anbau B1.05.06. 437250 KK Turbocharger Mounting en / 21.04.2009 EB027141...
  • Page 722 Armaturenplatte B1.05.06. 437254 HH Control Board POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ARMATURENPLATTE, VOLLST. 437254 HH CONTROL BOARD ASSEMBLY 3-WEGE-VENTIL, VOLLST. 437254-101 3-WAY VALVE, COMPL. MONTAGEPLATTE 437254-152 MOUNTING PLATE ABSTANDSPLATTE 437254-103 DISTANCE PLATE ROHR-DOPPELNIPPEL 437254-204 TUBE DOUBLE NIPPLE AUSGLEICHSBLOCK 437254-105 DISTANCE BLOCK...
  • Page 723 Armaturenplatte B1.05.06. 437254 HH Control Board POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ROHRLEITUNG, VOLLST. 437259-653 PIPE, COMPL. STUTZEN 1.5094-179 PIPE UNION HALTER 437254-180 BRACKET SECHSKANTSCHRAUBE 1.1367-310 HEXAGON SCREW DICHTRING 1.7010-196 JOINT RING # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß folgende Angaben enthalten: Motor-Nr. / Ersatzteilblatt-Nr. / Bestell-Nr. Each order must include the following: Engine No./Spare parts sheet No./Part No.
  • Page 724 Armaturenplatte B1.05.06. 437254 HH Control Board en / 04.03.2009 EB032903...
  • Page 725 Armaturenplatte B1.05.06. 437254 HH Control Board en / 04.03.2009 EB032903...
  • Page 726 Reinigungsanlage f.Turbolader B1.05.06. 437259 ZY Cleaning Dev. for Turbocharger POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. REINIGUNGSANLAGE, VOLLST. 437259 ZY CLEANING DEVICE ASSEMBLY HALTER 437259-051 BRACKET HALTER 437259-402 BRACKET ROHRLEITUNG, VOLLST. 437259-554 PIPE, COMPL. ROHRLEITUNG, VOLLST. 437259-205 PIPE, COMPL. ROHRLEITUNG, VOLLST.
  • Page 727 Reinigungsanlage f.Turbolader B1.05.06. 437259 ZY Cleaning Dev. for Turbocharger POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SECHSKANTSCHRAUBE 1.1392-458 HEXAGON SCREW SECHSKANTSCHRAUBE 1.1367-742 HEXAGON SCREW SECHSKANTSCHRAUBE 1.1367-242 HEXAGON SCREW SECHSKANTSCHRAUBE 1.1367-239 HEXAGON SCREW SECHSKANTSCHRAUBE 1.1387-311 HEXAGON SCREW SECHSKANTMUTTER 1.2007-034 HEXAGON NUT SECHSKANTMUTTER 1.7260-026...
  • Page 728 Reinigungsanlage f.Turbolader B1.05.06. 437259 ZY Cleaning Dev. for Turbocharger POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. VERBINDUNGSSTUTZEN 1.5095-127 PIPE UNION KONTERMUTTER 1.2047-169 THIN NUT STUTZEN 1.5094-117 PIPE UNION DICHTRING 1.7010-196 JOINT RING DICHTRING 1.7010-066 JOINT RING DICHTRING 1.7010-083 JOINT RING DICHTRING 1.7010-133...
  • Page 729 Reinigungsanlage f.Turbolader B1.05.06. 437259 ZY Cleaning Dev. for Turbocharger en / 04.03.2009 EB032877...
  • Page 730 Reinigungsanlage f.Turbolader B1.05.06. 437259 ZY Cleaning Dev. for Turbocharger en / 04.03.2009 EB032877...
  • Page 731 Reinigungsanlage f.Turbolader B1.05.06. 437259 ZY Cleaning Dev. for Turbocharger en / 04.03.2009 EB032877...
  • Page 732 Reinigungsanlage f.Turbolader B1.05.06. 437259 ZY Cleaning Dev. for Turbocharger en / 04.03.2009 EB032877...
  • Page 733 Druckwächter-Anbau B1.05.06. 438629 GG Differenzdruck Ladeluft Pressure Switch Mounting Differential Pressure for Charge Air POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DRUCKWÄCHTER-ANBAU, VOLLST. 438629 GG PRESSURE SWITCH MOUNTING ASSEMBLY ROHR, VOLLST. 438629-101 PIPE, COMPL. ROHR, VOLLST. 438629-102 PIPE, COMPL. SCHELLE 438629-107 CLAMP...
  • Page 734 Druckwächter-Anbau B1.05.06. 438629 GG Differenzdruck Ladeluft Pressure Switch Mounting Differential Pressure for Charge Air en / 23.09.2004 EB027511...
  • Page 735 Einspritzventil B1.05.07. 432260 CC Fuel Injector M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. EINSPRITZVENTIL, VOLLST. 432260 CC FUEL INJECTOR ASSEMBLY DÜSENHALTER, VOLLST. SIEHE B1.05.07.432267 NOZZLE HOLDER, COMPL. SEE B1.05.07.432267 DÜSE 432260-002 NOZZLE ELEMENT O-RING 1.7084-659 O-RING # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 736 Einspritzventil B1.05.07. 432260 CC Fuel Injector M43/VM43 en / 29.02.2008 EB029122...
  • Page 737 Düsenhalter B1.05.07. 432267 CC Nozzle Holder M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DÜSENHALTER, VOLLST 432267 CC NOZZLE HOLDER ASSEMBLY DÜSENMUTTER 432267-102 NOZZLE NUT DRUCKBOLZEN 432267-103 PRESSURE BOLT EINSTELLSPINDEL 432267-104 ADJUSTING SPINDLE EINSTELLSCHRAUBE 432267-005 ADJUSTING SCREW DRUCKFEDER 432267-107 PRESSURE SPRING SECHSKANTMUTTER...
  • Page 738 Düsenhalter B1.05.07. 432267 CC Nozzle Holder M43/VM43 en / 29.02.2008 EB029125...

  • Page 739: Fuel Injection Pump

    Einspritzpumpe B1.05.07. 433597 KK Fuel Injection Pump M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. EINSPRITZPUMPE, VOLLST. 433597 KK å FUEL INJECTION PUMP ASSEMBLY MONOBLOCKPUMPENELEMENT, VOLLST. 433597-401 PUMP ELEMENT, COMPL. STÖSSELKÖRPER 433597-202 TAPPET BODY REGELHÜLSE 433597-105 CONTROL SLEEVE PRALLKÖRPER 433597-206 BAFFLE BODY...
  • Page 740 Einspritzpumpe B1.05.07. 433597 KK Fuel Injection Pump M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. VERSCHLUSSSCHRAUBE 433597-037 SCREW PLUG O-RING 433597-038 O-RING O-RING 433597-039 O-RING O-RING 433597-028 O-RING O-RING 433597-041 O-RING DICHTRING 433597-042 JOINT RING DICHTRING 433597-043 JOINT RING SCHRAUBE 433597-231 SCREW...
  • Page 741 Einspritzpumpe B1.05.07. 433597 KK Fuel Injection Pump M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DRUCKVENTILFEDER 433597-023 DELIVERY VALVE SPRING O-RING 433597-102 O-RING GLEICHDRUCKVENTIL, VOLLST. 433597-103 PRESSURE-BALANCING DELIVERY VALVE, COMPL. VARISEAL 433597-307 VARISEAL O-RING 433597-308 O-RING O-RING 433597-054 O-RING O-RING 433597-055...
  • Page 742 Einspritzpumpe B1.05.07. 433597 KK Fuel Injection Pump M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCHLITZSCHEIBE 433597-026 SLOTTED DISC SCHRAUBE FÜR SCHLITZSCHEIBE 433597-027 SCREW FOR SLOTTED DISC HUBBEGRENZER 433597-124 STROKE LIMITER O-RING 433597-069 O-RING O-RING 433597-041 O-RING # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 743 Einspritzpumpe B1.05.07. 433597 KK Fuel Injection Pump M43/VM43 en / 03.07.2007 EB031154...
  • Page 744 Einspritzpumpe B1.05.07. 433597 KK Fuel Injection Pump M43/VM43 en / 03.07.2007 EB031154...
  • Page 745 Einspritzpumpe B1.05.07. 433597 KK Fuel Injection Pump M43/VM43 en / 03.07.2007 EB031154...
  • Page 746 Einspritzpumpe B1.05.07. 433597 KK Fuel Injection Pump M43/VM43 en / 03.07.2007 EB031154...
  • Page 747 Dichtungssatz für Einspritzpumpe B1.05.07. 433599 AA Anbau Set of Gaskets for Fuel Injection Pump Mounting BENENNUNG STCK BEST.-NR ENTH. IN E-BLATT DESCRIPTION NUMBER PART NO. INCLUDED IN SHEET DICHTUNGSSATZ, VOLLST. 433599 AA SET OF GASKETS ASSEMBLY O-RING 433597-028 B1.05.07.433597 O-RING O-RING 433597-041 B1.05.07.433597...
  • Page 748 Kraftstoffilter-Anbau B1.05.07. 437660 DD Fuel Filter Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KRAFTSTOFFILTER-ANBAU, VOLLST. 437660 DD FUEL FILTER MOUNTING ASSEMBLY KRAFTSTOFFILTER, VOLLST. SIEHE B1.05.07.437667 FUEL FILTER, COMPL. SEE B1.05.07.437667 ZWISCHENTÜCK 437660-103 INTERMEDIATE PIECE DICHTUNG 1.7073-733 GASKET DICHTRING 1.7073-102 JOINT RING...
  • Page 749 Kraftstoffilter-Anbau B1.05.07. 437660 DD Fuel Filter Mounting en / 05.09.2007 EB031472...
  • Page 750 Kraftstoff-Doppel-Feinfilter B1.05.07. 437667 CC Duplex Fuel Fine Filter POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KRAFTSTOFF-FEINFILTER, VOLLST. 437667 CC DUPLEX FUEL FINE FILTER ASSEMBLY GEWINDESTOPFEN 2.7667-003 THREADED PLUG VERSCHLUSSSCHRAUBE 1.1041-679 SCREW PLUG DICHTRING 1.7010-133 JOINT RING O-RING 1.7667-005 O-RING DECKELSICHERUNG 2.7657-006...
  • Page 751 Kraftstoff-Doppel-Feinfilter B1.05.07. 437667 CC Duplex Fuel Fine Filter POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ROHR 437667-043 TUBE LEITUNGSBRUCHSICHERUNG 437667-028 BREAK PROTECTION VERSCHLUSSSCHRAUBE 1.1041-680 SCREW PLUG DICHTRING 1.7010-064 JOINT RING KÜKENANSCHLAG 1.7667-039 STOP PIECE WINKELKUGELHAHN 1.7667-014 ANGLE BALL COCK LÖSBARER DOPPELNIPPEL 1.7667-013 SPACER BLOCK...
  • Page 752 Kraftstoff-Doppel-Feinfilter B1.05.07. 437667 CC Duplex Fuel Fine Filter en / 19.02.2008 EB031478...
  • Page 753 Kraftstoff-Doppel-Feinfilter B1.05.07. 437667 CC Duplex Fuel Fine Filter en / 19.02.2008 EB031478...
  • Page 754 Verkleidung für Kraftstoffleitung B1.05.07. 437669 BB Fuel Pipe Covering POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. VERKLEIDUNG FÜR KRAFTSTOFFLEITG., VOLLST. 1 437669 BB FUEL PIPE COVERING ASSEMBLY VERKLEIDUNG, VOLLST. 437669-101 COVERING PLATE, COMPL. VERKLEIDUNG, VOLLST. 437669-102 COVERING PLATE, COMPL. VERKLEIDUNG, VOLLST.
  • Page 755 Verkleidung für Kraftstoffleitung B1.05.07. 437669 BB Fuel Pipe Covering en / 06.05.2004 EB027431...
  • Page 756 Kraftstoffverteiler-/Sammelleitung B1.05.07. 438510 NN Fuel Distributing-/Collecting Pipe POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KRAFTSTOFFLEITUNG, VOLLST. 438510 NN FUEL PIPES ASSEMBLY KRAFTSTOFFROHR 438510-001 LOW-PRESSURE PIPE FLANSCH 438510-102 FLANGE HÜLSE 438510-003 SLEEVE VERBINDUNGSSTÜCK 438510-104 CONNECTING PIECE ZYLINDERSCHRAUBE 258510-103 CYLINDER HEAD SCREW SICHERUNGSRING 438510-006 CIRCLIP...
  • Page 757 Kraftstoffverteiler-/Sammelleitung B1.05.07. 438510 NN Fuel Distributing-/Collecting Pipe en / 20.03.2004 EB027218...
  • Page 758 Kraftstoffverteiler-/Sammelleitung B1.05.07. 438510 NN Fuel Distributing-/Collecting Pipe en / 20.03.2004 EB027218...
  • Page 759 Einspritzdruckleitung-Anbau B1.05.07. 438526 BB Fuel Injector Delivery Pipe Mounting M43/VM43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. EINSPRITZDRUCKLEITUNG, VOLLST. 438526 BB FUEL INJECTOR DELIVERY PIPE ASSEMBLY RADIALDRUCKSTÜCK 438526-101 RADIAL THRUST PIECE AUFNAHMEKÖRPER 438526-002 RECEIVING CASING QUERDRUCKSTÜCK 438526-103 TRANSVERSE THRUST PIECE DRUCKSCHRAUBE 438526-004 PRESSURE SCREW...
  • Page 760 Einspritzdruckleitung-Anbau B1.05.07. 438526 BB Fuel Injector Delivery Pipe Mounting M43/VM43 en / 22.01.2008 EB026233...
  • Page 761 Kraftstoffdruckdämpfer-Anbau B1.05.07. 438533 CC Fuel Pressure Damper Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KRAFTSTOFFDRUCKDÄMPFER-ANBAU, VOLLST. 438533 CC FUEL PRESSURE DAMPER MOUNTING ASSEMBLY BLASENSPEICHER, VOLLST. 438533-001 FUEL PRESSURE DAMPER, COMPL. HALTER, VOLLST. 438533-052 BRACKET, COMPL. HALTERUNGSSCHELLE 1.5028-758 CLAMP REDUZIERDOPPELNIPPEL 1.5106-214...
  • Page 762 Kraftstoffdruckdämpfer-Anbau B1.05.07. 438533 CC Fuel Pressure Damper Mounting en / 30.04.2004 EB027440...
  • Page 763 Kraftstoffilterleitung-Anbau B1.05.07. 438535 CC Fuel Filter Pipe Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KRAFTSOFFILTERLEITUNG-ANBAU, VOLLST. 438535 CC FUEL FILTER PIPE MOUNTING ASSEMBLY KRAFTSTOFFILTERLEITUNG, VOLLST. 438535-101 FUEL FILTER PIPE, COMPL. KRAFTSTOFFILTERLEITUNG, VOLLST. 438535-102 FUEL FILTER PIPE, COMPL. PLATTE 438535-105 PLATE...
  • Page 764 Kraftstoffilterleitung-Anbau B1.05.07. 438535 CC Fuel Filter Pipe Mounting en / 06.05.2004 EB027436...
  • Page 765 Kraftstoffleckleitung B1.05.07. 438540 MM Leak Fuel Piping POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KRAFTSTOFFLECKLEITUNG, VOLLST. 438540 MM LEAK FUEL PIPING ASSEMBLY MEDIENKLOTZ 438540-501 MEDIA BLOCK STECKROHR 438540-502 PIPE KAFTSTOFFLECKLEITUNG, VOLLST. 438540-006 LEAK FUEL PIPE, COMPL. HALTER 438540-510 BRACKET ROHR, VOLLST.
  • Page 766 Kraftstoffleckleitung B1.05.07. 438540 MM Leak Fuel Piping en / 20.03.2004 EB027179...
  • Page 767 Kraftstoffleckleitung B1.05.07. 438540 MM Leak Fuel Piping en / 20.03.2004 EB027179...
  • Page 768 Kraftstoffleckleitung B1.05.07. 438540 PP Leak Fuel Piping POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KRAFTSTOFFLECKLEITUNG, VOLLST. 438540 PP LEAK FUEL PIPING ASSEMBLY KAFTSTOFFLECKLEITUNG, VOLLST. 438540-001 LEAK FUEL PIPE, COMPL. KAFTSTOFFLECKLEITUNG, VOLLST. 438540-002 LEAK FUEL PIPE, COMPL. KAFTSTOFFLECKLEITUNG, VOLLST. 438540-153 LEAK FUEL PIPE, COMPL.
  • Page 769 Kraftstoffleckleitung B1.05.07. 438540 PP Leak Fuel Piping POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ROHRKLEMME 1.5011-001 PIPE CLAMP ROHRKLEMME 1.5011-002 PIPE CLAMP KUGELHAHN 1.4840-054 BALL COCK GEWINDEEINSATZ 1.1093-704 THREADED INSERT GEWINDEEINSATZ 1.1093-705 THREADED INSERT # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 770 Kraftstoffleckleitung B1.05.07. 438540 PP Leak Fuel Piping en / 03.05.2004 EB027434...
  • Page 771 Zahnrad B1.05.08. 1.6422 XX für Schmierölpumpen-Anbau Gearwheel for Lubricating Oil Pump POS. BENENNUNG STCK BEST.-NR NORMTEIL ITEM DESCRIPTION NUMBER PART NO. STANDARD NO. 1.0-50 ZAHNRAD GEARWHEEL Z = 21 1.6422-21 Z = 22 1.6422-22 Z = 23 1.6422-23 Z = 24 1.6422-24 Z = 25 1.6422-25...
  • Page 772 Schmierölpumpen-Anbau B1.05.08. 436410 DD Lubricating Oil Pump Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCHMIERÖLPUMPEN-ANBAU, VOLLST. 436410 DD LUBRICATING OIL PUMP MOUNTING ASS. ZAHNRADPUMPE, VOLLST. SIEHE B1.05.08.436417 GEAR PUMP, COMPL. SEE B1.05.08.436417 ZAHNRAD 1.6422-033 GEARWHEEL ROHRKRÜMMER 436410-006 BEND SCHEIBE 436440-005...
  • Page 773 Schmierölpumpen-Anbau B1.05.08. 436410 DD Lubricating Oil Pump Mounting en / 12.11.2003 EB026393...
  • Page 774 Schmierölpumpe B1.05.08. 436417 MM linksdrehend Lubricating Oil Pump anti-clockwise POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCHMIERÖLPUMPE, VOLLST. 436417 MM LUBRICATING OIL PUMP ASSEMBLY ANTRIEBSRADWELLE + LAUFRADACHSE 436417-304 POWER ROTOR SHAFT + IMPELLER AXLE BUCHSE 436417-108 BUSH ZYLINDERSCHRAUBE 436417-109 HEXAGON SOCKET HEAD CAP SCREW ZYLINDERSCHRAUBE...
  • Page 775 Schmierölpumpe B1.05.08. 436417 MM linksdrehend Lubricating Oil Pump anti-clockwise en / 28.09.2006 EB030364...
  • Page 776 Schmierölpumpe B1.05.08. 436417 MM linksdrehend Lubricating Oil Pump anti-clockwise en / 28.09.2006 EB030364...
  • Page 777 Schmierölpumpe B1.05.08. 436417 NN rechtsdrehend Lubricating Oil Pump clockwise POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCHMIERÖLPUMPE, VOLLST. 436417 NN LUBRICATING OIL PUMP ASSEMBLY ANTRIEBSRADWELLE + LAUFRADACHSE 436417-304 POWER ROTOR SHAFT + IMPELLER AXLE BUCHSE 436417-108 BUSH ZYLINDERSCHRAUBE 436417-109 HEXAGON SOCKET HEAD CAP SCREW ZYLINDERSCHRAUBE...
  • Page 778 Schmierölpumpe B1.05.08. 436417 NN rechtsdrehend Lubricating Oil Pump clockwise en / 28.09.2006 EB030367...
  • Page 779 Schmierölpumpe B1.05.08. 436417 NN rechtsdrehend Lubricating Oil Pump clockwise en / 28.09.2006 EB030367...
  • Page 780 Schmierölfilter-Anbau B1.05.08. 437650 BB Lubricating Oil Filter Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCHMIERÖLFILTER-ANBAU, VOLLST. 437650 BB LUBRICATING OIL FILTER MOUNTING ASSEMBLY SCHMIERÖLFILTER, VOLLST. SIEHE B1.05.08.437657 LUBRICATING OIL FILTER, COMPL. SEE B1.05.08.437657 O-RING 1.7082-376 O-RING SCHWEISSFLANSCH 1.5340-131 WELDING FLANGE DICHTUNG...
  • Page 781 Schmierölfilter-Anbau B1.05.08. 437650 BB Lubricating Oil Filter Mounting en / 30.08.2007 EB031475...
  • Page 782 Schmieröl-Doppelfilter B1.05.08. 437657 AA Duplex Lubricating Oil Filter POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCHMIERÖL-DOPPELFILTER, VOLLST. 437657 AA DUPLEX LUBRICATING OIL FILTER ASSEMBLY GEWINDESTOPFEN 9.7657-002 THREADED PLUG VERSCHLUSSSCHRAUBE 1.1041-609 HEXAGON HEAD SCREW PLUG DICHTRING 1.7010-133 JOINT RING O-RING 1.7657-406 O-RING...
  • Page 783 Schmieröl-Doppelfilter B1.05.08. 437657 AA Duplex Lubricating Oil Filter POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ZYLINDERSCHRAUBE 2.7657-025 HEXAGON SOCKET HEAD CAP SCREW SECHSKANTMUTTER 1.2007-032 HEXAGON NUT SPANNHÜLSE 1.0039-881 SPRING DOWEL PIN O-RING 437657-028 O-RING DICHTRING 437657-029 JOINT RING VERSCHRAUBUNG 257657-045 SCREWED CONNECTION...
  • Page 784 Schmieröl-Doppelfilter B1.05.08. 437657 AA Duplex Lubricating Oil Filter POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KUGELHAHN 437657-100 BALL COCK EINSCHRAUBSTUTZEN 437657-101 PIPE UNION VERSCHRAUBUNG 437657-102 SCREWED CONNECTION SIEBEINSATZ, VOLLST. 1.7657-450 SIEVE ELEMENT, COMPL. SIEBKERZE 1.7657-456 FILTER CARTRIDGE DECKELSICHERUNG 437657-006 COVERSECURING ENTLÜFTUNGSSCHRAUBE...
  • Page 785 Schmieröl-Doppelfilter B1.05.08. 437657 AA Duplex Lubricating Oil Filter en / 24.05.2000 EB012187...
  • Page 786 Schmieröl-Doppelfilter B1.05.08. 437657 AA Duplex Lubricating Oil Filter en / 24.05.2000 EB012187...
  • Page 787 Druckbegrenzungsventil B1.05.08. 437810 AA Pressure Limitation Valve M32/M43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DRUCKBEGRENZUNGSVENTIL, VOLLST. 437810 AA PRESSURE LIMITATION VALVE ASSEMBLY BLINDFLANSCH 9.7810-001 BLANK FLANGE KOLBEN 256417-204 POPPET GEWINDESTIFT 9.7810-004 SET SCREW DRUCKFEDER 256417-206 COMPRESSION SPRING ZYLINDERSCHRAUBE 1.1152-111 CHEESE HEAD SCREW...
  • Page 788 Druckbegrenzungsventil B1.05.08. 437810 AA Pressure Limitation Valve M32/M43 POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KOLBEN 9.6417-502 PISTON SPINDEL 9.7810-204 SPINDLE KUGEL 1.8090-128 BALL DRUCKFEDER 9.6417-507 COMPRESSION SPRING SPRENGRING 1.0063-516 SPRING RING SICHERUNGSRING 1.0061-024 CIRCLIP SPRENGRING 9.7810-210 SPRING RING SCHEIBE 1.0058-404 WASHER...
  • Page 789 Druckbegrenzungsventil B1.05.08. 437810 AA Pressure Limitation Valve M32/M43 en / 28.10.2008 EB030362...
  • Page 790 Druckbegrenzungsventil B1.05.08. 437810 AA Pressure Limitation Valve M32/M43 en / 28.10.2008 EB030362...
  • Page 791 Druckbegrenzungsventil B1.05.08. 437810 AA Pressure Limitation Valve M32/M43 en / 28.10.2008 EB030362...
  • Page 792 Schmierölleitung B1.05.08. 438420 FF Lube Oil Pipes POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCHMIERÖLLEITUNG, VOLLST. 438420 FF LUBE OIL PIPES ASSEMBLY SCHMIERÖLLEITUNG 438420-001 LUBRICATING OIL PIPE SCHMIERÖLLEITUNG 438420-002 LUBRICATING OIL PIPE DRUCKBEGRENZUNGSVENTIL, VOLLST. SIEHE B1.05.08.437810 PRESSURE LIMITATION VALVE, COMPL. SEE B1.05.08.437810 DICHTUNG 9.8420-007...
  • Page 793 Schmierölleitung B1.05.08. 438420 FF Lube Oil Pipes en / 05.09.2007 EB031469...
  • Page 794 Steuerleitung für Öldruck B1.05.08. 438445 EE Oil Pressure control Pipe POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. STEUERLEITUNG-ANBAU, VOLLST. 438445 EE CONTROL PIPE MOUNTING ASSEMBLY SCHMIERÖLLEITUNG, VOLLST. 438445-301 LUBE OIL PIPE, COMPL. SCHMIERÖLLEITUNG, VOLLST. 438445-302 LUBE OIL PIPE, COMPL. ROHRKLEMME 1.5011-002 PIPE CLAMP...
  • Page 795 Steuerleitung für Öldruck B1.05.08. 438445 EE Oil Pressure control Pipe en / 05.09.2007 EB031466...
  • Page 796 Schmieröldüsen für Zahnräder B1.05.08. 438450 DD Lube Oil Nozzle for Gearwheel POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCMIERÖLDÜSEN FÜR ZAHNRÄDER, VOLLST. 438450 DD LUBE OIL NOZZLE FOR GEARWHEEL ASS. ÖLDÜSE, VOLLST. 438450-004 LUBE OIL NOZZLE, COMPL. SCHRAUBE 438450-002 SCREW ÖLDÜSE...
  • Page 797 Schmieröldüsen für Zahnräder B1.05.08. 438450 DD Lube Oil Nozzle for Gearwheel en / 25.04.2002 EB025286...
  • Page 798 Schmierölleckleitung-Anbau B1.05.08. 438480 KK Leak Oil Pipe Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCHMIERÖLLECKLEITUNG-ANBAU, VOLLST. 438480 KK LEAK OIL PIPE MOUNTING ASSEMBLY LECKAGEROHR 438480-001 LEAK OIL PIPE STECKROHR 438480-002 TUBE SICHERUNGSRING 438480-003 CIRCLIP DICHTUNG 1.7073-805 GASKET SECHSKANTSCHRAUBE 1.1387-376 HEXAGON SCREW...
  • Page 799 Schmierölleckleitung-Anbau B1.05.08. 438480 KK Leak Oil Pipe Mounting en / 13.03.2004 EB027204...
  • Page 800 Schmierölleitung für Turbolader B1.05.08. 438494 PP Lubricating Oil Pipe for Turbocharger POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCHMIERÖLLEITUNG, VOLLST. 438494 PP LUBRICATING OIL PIPE ASSEMBLY ÖLZULAUFLEITUNG, VOLLST. 438494-601 OIL ADMISSION PIPE, COMPL. ÖLZULAUFLEITUNG, VOLLST. 438494-602 OIL ADMISSION PIPE, COMPL. HALTER 438494-253 BRACKET...
  • Page 801 Schmierölleitung für Turbolader B1.05.08. 438494 PP Lubricating Oil Pipe for Turbocharger POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. VERSCHLUSSSCHRAUBE 1.1041-609 HEXAGON HEAD SCREW PLUG DICHTRING 1.7010-133 JOINT RING SECHSKANTSCHRAUBE 1.1387-447 HEXAGON SCREW SCHMUTZFÄNGER 438494-308 STRAINER # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 802 Schmierölleitung für Turbolader B1.05.08. 438494 PP Lubricating Oil Pipe for Turbocharger en / 11.10.2004 EB027611...
  • Page 803 Abdeckbleche für Schmierölfilter B1.05.08. 438815 FF Cover plates for lube oil filter POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ABDECKBLECHE F. SCHMIERÖLFILTER, VOLLST. 438815 FF COVER PLATES FOR LUBE OIL FILTER, COMPL. ABDECKBLECH, VOLLST. 438815-005 COVER PLATE, COMPL. Jede Bestellung muß...
  • Page 804 Abdeckbleche für Schmierölfilter B1.05.08. 438815 FF Cover plates for lube oil filter en / 12.05.2006 EB029875...
  • Page 805 Abdeckbleche für Schmierölleitung B1.05.08. 438815 GG Cover plates for lube oil pipes POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ABDECKBLECHE F. SCHMIERÖLLEITUNG, VOLLST. 1 438815 GG COVER PLATES FOR LUBE OIL PIPES, COMPL. ABDECKBLECH, VOLLST. 438815-001 COVER PLATE, COMPL. ABDECKBLECH, VOLLST.
  • Page 806 Abdeckbleche für Schmierölleitung B1.05.08. 438815 GG Cover plates for lube oil pipes en / 16.01.2008 EB032079...
  • Page 807 Deckel-Anbau B1.05.09. 436475 CC Cover Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DECKEL-ANBAU, VOLLST. 436475 CC COVER MOUNTING ASSEMBLY DECKEL 436475-201 COVER DECKEL 436475-202 COVER SECHSKANTSCHRAUBE 1.1387-443 HEXAGON SCREW VERSCHLUSSSCHRAUBE 1.1041-204 SCREW PLUG DICHTRING 1.7010-083 JOINT RING # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 808 Deckel-Anbau B1.05.09. 436475 CC Cover Mounting en / 09.05.2006 EB029727...
  • Page 809 Kühlwasserverteiler-/Sammelleitung B1.05.09. 438320 SS Cool. Water Distrib./Collecting Pipe POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KÜHLWASSERLEITUNG, VOLLST. 438320 SS COOLING WATER PIPE ASSEMBLY KÜHLWASSERKLOTZ 438320-101 COOLING WATER CONNECTION FLANSCH 438320-002 FLANGE KÜHLWASSERROHR 438320-003 COOLING WATER PIPE DICHTUNG 438320-004 GASKET O-RING 1.7084-680...
  • Page 810 Kühlwasserverteiler-/Sammelleitung B1.05.09. 438320 SS Cool. Water Distrib./Collecting Pipe en / 13.03.2004 EB027163...
  • Page 811 Kühlwasserverteiler-/Sammelleitung B1.05.09. 438320 SS Cool. Water Distrib./Collecting Pipe en / 13.03.2004 EB027163...
  • Page 812 Kühlwasserleitung B1.05.09. 438330 MM Cooling Water Pipe POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KÜHLWASSERLEITUNG, VOLLST. 438330 MM COOLING WATER PIPE ASSEMBLY KÜHLWASSERROHR 438330-401 COOLING WATER PIPE KÜHLWASSERROHR 438330-402 COOLING WATER PIPE KÜHLWASSERROHR 438330-003 COOLING WATER PIPE KÜHLWASSERANSCHLUSS 438330-404 COOLING WATER PIPE KÜHLWASSERLEITUNG...
  • Page 813 Kühlwasserleitung B1.05.09. 438330 MM Cooling Water Pipe POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DICHTRING 1.7010-133 JOINT RING DICHTRING 1.7010-252 JOINT RING VERSCHLUSSSCHRAUBE 1.1041-613 HEXAGON HEAD SCREW PLUG VERSCHLUSSSCHRAUBE 1.1041-609 HEXAGON HEAD SCREW PLUG VERSCHLUSSSCHRAUBE 1.1041-679 SCREW PLUG HALTER 438330-430 BRACKET...
  • Page 814 Kühlwasserleitung B1.05.09. 438330 MM Cooling Water Pipe en / 20.03.2004 EB027177...
  • Page 815 Kühlwasserleitung B1.05.09. 438330 MM Cooling Water Pipe en / 20.03.2004 EB027177...
  • Page 816 Entwässerungsleitung-Anbau B1.05.09. 438392 HH Drain Pipe Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ENTWÄSSERUNGSLTG.-ANBAU, VOLLST. 438392 HH DRAIN PIPE MOUNTING ASSEMBLY ENTWÄSSERUNGSLEITUNG, VOLLST. 438392-251 DRAIN PIPE, COMPL. ENTWÄSSERUNGSLEITUNG, VOLLST. 438392-252 DRAIN PIPE, COMPL. ENTWÄSSERUNGSLEITUNG, VOLLST. 438392-253 DRAIN PIPE, COMPL. HALTER 258540-110 BRACKET...
  • Page 817 Entwässerungsleitung-Anbau B1.05.09. 438392 HH Drain Pipe Mounting en / 15.01.2009 EB027402...
  • Page 818 Entwässerung für Turbolader B1.05.09. 438395 RR Draining for Turbocharger POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ENTWÄSSERUNG, VOLLST. 438395 RR DRAINING ASSEMBLY KLOTZ 438395-502 BLOCK HALTER 438395-203 BRACKET DICHTUNG 438494-002 GASKET ROHRKLEMME 1.5011-063 PIPE CLAMP ROHRKLEMME 1.5011-035 PIPE CLAMP SECHSKANTSCHRAUBE 1.1367-276 HEXAGON SCREW...
  • Page 819 Entwässerung für Turbolader B1.05.09. 438395 RR Draining for Turbocharger POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ENTWÄSSERUNGSLEITUNG, VOLLST. 438396-300 DRAIN PIPE, COMPL. ROHRLEITUNG 1.9131-218 STEEL PIPE ROHRLEITUNG 1.9131-218 STEEL PIPE ROHRLEITUNG 1.9131-218 STEEL PIPE FLANSCH 438396-103 FLANGE ÜBERWURFMUTTER 1.5040-143 UNION NUT DICHTRING...
  • Page 820 Entwässerung für Turbolader B1.05.09. 438395 RR Draining for Turbocharger en / 20.04.2009 EB032943...
  • Page 821 Entwässerung für Turbolader B1.05.09. 438395 RR Draining for Turbocharger en / 20.04.2009 EB032943...
  • Page 822 Entwässerung für Turbolader B1.05.09. 438395 RR Draining for Turbocharger POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. Jede Bestellung muß folgende Angaben enthalten: Motor-Nr. / Ersatzteilblatt-Nr. / Bestell-Nr. Each order must include the following: Engine No./Spare parts sheet No./Part No. en / 20.04.2009 EB032943...
  • Page 823 Luftzuführleitung B1.05.10. 437299 LL Air Admission Pipe POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. LUFTZUFÜHRLEITUNG, VOLLST 437299 LL AIR ADMISSION PIPE ASSEMBLY LUFTLEITUNG, VOLLST. 437299-051 AIR PIPE, COMPL. LUFTLEITUNG, VOLLST. 437299-052 AIR PIPE, COMPL. HALTER 437299-055 BRACKET HALTER 438540-012 BRACKET GERADER VERBINDUNGSSTUTZEN...
  • Page 824 Luftzuführleitung B1.05.10. 437299 LL Air Admission Pipe en / 20.04.2004 EB027387...
  • Page 825 Luftleitung für Grundmotor B1.05.10. 438610 CC Air Pipe on Engine POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. LUFTLEITUNG F. GRUNDMOTOR, VOLLST 438610 CC AIR PIPE ON ENGINE ASSEMBLY HALTER 438610-001 BRACKET HÜLSE 438610-003 SLEEVE HÜLSE, VOLLST. 438610-004 SLEEVE, COMPL. ANFAHRVENTIL, VOLLST.
  • Page 826 Luftleitung für Grundmotor B1.05.10. 438610 CC Air Pipe on Engine en / 07.04.2004 EB027292...
  • Page 827 Luftzuführleitung B1.05.10. 438614 DD Air Admission Pipe POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. LUFTZUFÜHRLEITUNG, VOLLST. 438614 DD AIR ADMISSION PIPE ASSEMBLY LUFTLEITUNG, VOLLST. 438614-101 AIR PIPING, COMPL. LUFTLEITUNG, VOLLST. 438614-102 AIR PIPING COMPL. STUTZEN 1.5093-222 MALE CONNECTOR STUTZEN 1.5098-014 MALE CONNECTOR...
  • Page 828 Luftzuführleitung B1.05.10. 438614 DD Air Admission Pipe en / 05.07.2004 EB027513...
  • Page 829 Steuerluftleitung-Anbau B1.05.10. 438617 QQ Control Air Piping POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. STEUERLUFTLEITUNG-ANBAU, VOLLST. 438617 QQ CONTROL AIR PIPING ASSEMBLY STEUERLUFTLEITUNG, VOLLST. 438617-001 CONTROL AIR PIPE, COMPL. STEUERLUFTLEITUNG, VOLLST. 438617-052 CONTROL AIR PIPE, COMPL. STEUERLUFTLEITUNG, VOLLST. 438617-053 CONTROL AIR PIPE, COMPL.
  • Page 830 Steuerluftleitung-Anbau B1.05.10. 438617 QQ Control Air Piping POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SECHSKANTSCHRAUBE 1.1372-184 HEXAGON BOLT SECHSKANTMUTTER 1.2007-032 HEXAGON NUT STEUERLUFTLEITUNG, VOLLST. 438617-030 CONTROL AIR PIPE, COMPL. STEUERLUFTLEITUNG, VOLLST. 438617-031 CONTROL AIR PIPE, COMPL. STEUERLUFTLEITUNG, VOLLST. 438617-032 CONTROL AIR PIPE, COMPL.
  • Page 831 Steuerluftleitung-Anbau B1.05.10. 438617 QQ Control Air Piping en / 06.12.2007 EB029883...
  • Page 832 Druckregeleinheit B1.05.11. 1.4817 AA Pressure Regulator M25-M601C POS. BENENNUNG STCK BEST.-NR NORMTEIL ITEM DESCRIPTION NUMBER PART NO. STANDARD NO. 10.0 DRUCKREGELEINHEIT, VOLLST. 1.4817 AA PRESSURE REGULATOR ASS. 10.0-1 VENTILGEHÄUSE 1.4817-1 HOUSING 10.0-2 FEINDRUCKREGLER SIEHE E-BLATT B1.05.05.1.4902 PRESSURE REDUCER SEE LIST B1.05.05.1.4902 10.0-3 MONTAGEWINKEL 1.4817-3 MOUNTING ANGLE...
  • Page 833 Druckregeleinheit B1.05.11. 1.4817 AA Pressure Regulator M25-M601C en / 20.03.1997 EB000196...
  • Page 834 Zusätzliche Messstellen B1.05.11. 430926 FF Additional Measuring Points POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ZUSÄTZLICHE MESSSTELLEN, VOLLST. 430926 FF ADDITIONAL MEASURING POINTS ASSEMBLY THERMOMETER 430926-051 THERMOMETER SCHUTZROHR 430926-003 PROTECTIVE TUBE THERMOMETER 430926-060 THERMOMETER DICHTRING 1.7010-133 JOINT RING # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 835 Zusätzliche Messstellen B1.05.11. 430926 FF Additional Measuring Points en / 06.05.2004 EB027428...
  • Page 836 Zusätzliche Messstellen B1.05.11. 430926 FF Additional Measuring Points en / 06.05.2004 EB027428...
  • Page 837 Manometertafel B1.05.11. 434630 GG Gauge Panel POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. MANOMETERTAFEL, VOLLST. 434630 GG GAUGE PANEL ASSEMBLY GEHÄUSE 9.4630-001 HOUSING TABLEAU 434630-002 GAUGE BOARD TABLEAU 9.4630-003 GAUGE BOARD TABLEAU 434630-004 GAUGE BOARD SCHUTZWINKEL 434630-019 PROTECTING SQUARE MANOMETER, 0-10 BAR 9.4630-006 PRESSURE GAUGE, 0-10 BAR...
  • Page 838 Manometertafel B1.05.11. 434630 GG Gauge Panel POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. DRUCKHAUBE 0.9963-031 PUSH-BUTTON CAP GLÜHLAMPE 0.3621-956 BULB WAHLSCHALTER 434630-037 SWITCH BEFESTIGUNGSFLANSCH 434630-038 FASTENING FLANGE HILFSSCHALTER 434630-039 SWITCH SCHILDTRÄGER 434630-040 PLATE SUPPORT STECKVERBINDER 0.9963-042 CONNECTOR STECKVERBINDER 0.9963-046 CONNECTOR BUS-PLATINE...
  • Page 839 Manometertafel B1.05.11. 434630 GG Gauge Panel en / 08.08.2008 EB027341...
  • Page 840 Medienleitung B1.05.11. 434639 ZC Media Pipe POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. MEDIENLEITUNG, VOLLST. 434639 ZC MEDIA PIPE ASSEMBLY HALTER 434639-201 BRACKET VERBINDUNGSLEITUNG, VOLLST. 434639-006 PIPE, COMPL. VERBINDUNGSLEITUNG, VOLLST. 434639-011 PIPE, COMPL. VERBINDUNGSLEITUNG, VOLLST. 434639-051 PIPE, COMPL. VERBINDUNGSLEITUNG, VOLLST.
  • Page 841 Medienleitung B1.05.11. 434639 ZC Media Pipe POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. HALTER 434639-228 BRACKET VENTIL, VOLLST. 434843-014 3/2-WAY VALVE, COMPL. DAEMPFUNGSSTUTZEN 438475-007 DAMPING SOCKET STUTZEN 1.5094-186 MALE CONNECTOR STUTZEN 1.5096-881 MALE ELBOW GERADER VERBINDUNGSSTUTZEN 1.5095-042 PIPE UNION WINKELSTUTZEN 1.5093-222 ADJUSTABLE ELBOW...
  • Page 842 Medienleitung B1.05.11. 434639 ZC Media Pipe POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SECHSKANTSCHRAUBE 1.1387-449 HEXAGON SCREW SECHSKANTMUTTER 1.2007-034 HEXAGON NUT SCHEIBE 1.0040-222 WASHER SCHEIBE 1.0040-227 WASHER ROHRKLEMME 1.5011-002 PIPE CLAMP ROHRKLEMME 1.5011-001 PIPE CLAMP ROHRKLEMME 1.5011-081 PIPE CLAMP # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 843 Medienleitung B1.05.11. 434639 ZC Media Pipe en / 20.04.2004 EB027332...
  • Page 844 Medienleitung B1.05.11. 434639 ZC Media Pipe en / 20.04.2004 EB027332...
  • Page 845 Medienleitung B1.05.11. 434639 ZC Media Pipe en / 20.04.2004 EB027332...
  • Page 846 Triebraum-Überwachung B1.05.11. 434810 ZF Crankcase Oil Mist Detector POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. TRIEBRAUM-ÜBERWACHUNG, VOLLST. 434810 ZF CRANKCASE OIL MIST DETECTOR ASSEMBLY TRIEBRAUMÜBERWACHUNGSGERÄT, VOLLST. SIEHE BUCH C CRANKCASE OIL MIST DETECTTOR SEE BOOK C ROHR, VOLLST. 434810-002 PIPE, COMPL.
  • Page 847 Triebraum-Überwachung B1.05.11. 434810 ZF Crankcase Oil Mist Detector en / 07.08.2008 EB032964...
  • Page 848 Triebraum-Überwachung B1.05.11. 434810 ZF Crankcase Oil Mist Detector en / 07.08.2008 EB032964...
  • Page 849 Wassererkennung B1.05.11. 434818 CC Water Detection POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. WASSERERKENNUNG, VOLLST. 434818 CC WATER DETECTION ASSEMBLY, COMPL. LEITUNG, VOLLST. 434818-051 PIPE, COMPL. LEITUNG, VOLLST. 434818-052 PIPE, COMPL. STUTZEN 1.5075-032 PIPE UNION DICHTRING 1.7010-252 JOINT RING ROHRKLEMME 1.5011-002 PIPE CLAMP...
  • Page 850 Wassererkennung B1.05.11. 434818 CC Water Detection en / 11.02.2002 EB025036...
  • Page 851 Halter-Anbau B1.05.11. 438845 FF Bracket Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. HALTER-ANBAU, VOLLST. 438845 FF BRACKET MOUNTING ASSEMBLY HALTER, VOLLST. 438845-201 BRACKET, COMPL. KONSOLE, VOLLST. 438845-202 CONSOLE, COMPL. BLECH 438845-203 PLATE SCHWINGUNGSDÄMPFER 438845-204 VIBRATION DAMPER SECHSKANTSCHRAUBE 1.1387-443 HEXAGON SCREW SECHSKANTMUTTER...
  • Page 852 Halter-Anbau B1.05.11. 438845 FF Bracket Mounting en / 22.05.2006 EB029899...
  • Page 853 Druckwächter B1.05.11. 9.4843 AA Pressure Switch M20-M601C BENENNUNG DRUCKBEREICH / BAR BEST.-NR DESCRIPTION PRESSURE RANGE /BAR PART NO. DRUCKWÄCHTER, VOLLST. 0,9- 1,5 1.4843-044 PRESSURE SWITCH, COMPL. DRUCKWÄCHTER, VOLLST. 0,2- 2,5 1.4843-032 PRESSURE SWITCH, COMPL. DRUCKWÄCHTER, VOLLST. 0- 6 1.4843-033 PRESSURE SWITCH, COMPL. DRUCKWÄCHTER, VOLLST.
  • Page 854 Druckwächter B1.05.11. 9.4843 AA Pressure Switch M20-M601C en / 16.12.2008 EB009411...
  • Page 855 Schwingungsdämpfer B1.05.12. 436347 CC Vibration Damper POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCHWINGUNGSDÄMPFER, VOLLST. 436347 CC VIBRATION DAMPER ASSEMBLY FEDERPAKET 436347-101 SET OF SPRINGS ZWISCHENSTÜCK 436347-102 INSERTION SPANNRING 436347-053 TIGHTENING RING FLANSCH 436347-105 FLANGE SEITENPLATTE 436347-107 SIDE PLATE INNENSTERN 436347-109 STAR...
  • Page 856 Schwingungsdämpfer B1.05.12. 436347 CC Vibration Damper en / 10.10.2000 EB023328...
  • Page 857 Schwungrad-Anbau B1.05.12. 437310 AA Flywheel Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SCHWUNGRAD-ANBAU, VOLLST. 437310 AA FLYWHEEL MOUNTING ASSEMBLY SCHWUNGRAD 437310-001 FLYWHEEL DEHNSCHRAUBE 437310-002 TENSION BOLT SPANNSTIFT 1.0039-642 SPRING DOWEL PIN # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß folgende Angaben enthalten: Motor-Nr. / Ersatzteilblatt-Nr. / Bestell-Nr. Each order must include the following: Engine No./Spare parts sheet No./Part No.
  • Page 858 Schwungrad-Anbau B1.05.12. 437310 AA Flywheel Mounting en / 20.01.1998 EB011818...
  • Page 859 Törnvorrichtung B1.05.12. 437330 EE Barring Gear POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. TÖRNVORRICHTUNG , VOLLST. 437330 EE BARRING GEAR ASSEMBLY TÖRNMASCHINE, VOLLST. SIEHE B1.05.12.437332 TURNING DEVICE, COMPL. SEE B1.05.12.437332 O-RING 1.7084-672 O-RING SECHSKANTSCHRAUBE 1.1387-492 HEXAGON SCREW SECHSKANTMUTTER 1.2011-042 HEXAGON NUT SCHEIBE...
  • Page 860 Törnvorrichtung B1.05.12. 437330 EE Barring Gear en / 06.09.2002 EB025586...
  • Page 861 Törnmaschine B1.05.12. 437332 AA Turning Device POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. TÖRNMASCHINE, VOLLST. 437332 AA TURNING DEVICE ASSEMBLY SCHNECKE 437332-003 WORM DECKEL 9.7332-004 COVER KUPPLUNG 9.7332-105 COUPLING SCHNECKENRAD 437332-006 WORM WHEEL ZWISCHENWELLE 437332-007 INTERMEDIATE SHAFT ZAHNRAD 437332-008 GEAR ABTRIEBSWELLE...
  • Page 862 Törnmaschine B1.05.12. 437332 AA Turning Device POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. ARRETIERHEBEL 9.7332-017 LOCKING LEVER SCHAFT FÜR ARRETIERHEBEL 437332-024 ARM OF LOCKING LEVER ZWISCHENPLATTE 9.7332-025 INTERMEDIATE PLATE HANDRAD 9.7332-026 HANDWHEEL FLANSCH 9.7332-027 FLANGE HÜLSE 9.7332-028 SLEEVE RILLENKUGELLAGER 9.7332-043 BALL BEARING...
  • Page 863 Törnmaschine B1.05.12. 437332 AA Turning Device POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SECHSKANTSCHRAUBE 1.1387-342 HEXAGON SCREW SECHSKANTSCHRAUBE 1.1387-249 HEXAGON SCREW SECHSKANTSCHRAUBE 1.1387-247 HEXAGON SCREW SECHSKANTSCHRAUBE 1.1387-243 HEXAGON SCREW SECHSKANTSCHRAUBE 1.1372-146 HEXAGON SCREW GEWINDESTIFT 1.1102-052 SET SCREW GEWINDESTIFT 1.1102-046 SET SCREW GEWINDESTIFT...
  • Page 864 Törnmaschine B1.05.12. 437332 AA Turning Device POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. GRENZWERTSCHALTER 9.7332-084 MICROSWITCH VERSCHLUSSSCHRAUBE 1.1040-613 PLUG DICHTRING 1.7010-252 JOINT RING ENTLÜFTER 9.7332-156 BREATHER ÖLGLAS 9.7332-070 OIL LEVEL SIGHT GAUGE ELEKTROMOTOR 437332-071 ELECTRIC MOTOR # = VERBRAUCHSTEILE CONSUMABLES Jede Bestellung muß...
  • Page 865 Törnmaschine B1.05.12. 437332 AA Turning Device en / 26.09.2002 EB025609...
  • Page 866 Törnmaschine B1.05.12. 437332 AA Turning Device en / 26.09.2002 EB025609...
  • Page 867 Törnmaschine B1.05.12. 437332 AA Turning Device en / 26.09.2002 EB025609...
  • Page 868 Totpunktanzeiger-Anbau B1.05.12. 437350 AA Dead Centre Indicator Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. TOTPUNKTANZEIGER-ANBAU, VOLLST. 437350 AA DEAD CENTRE INDICATOR MOUNTING ASSEMBLY TOTPUNKTANZEIGER 437350-001 DEAD CENTRE INDICATOR SECHSKANTSCHRAUBE 1.1367-374 HEXAGON SCREW SPANNSCHEIBE 1.0068-240 CONICAL SPRING WASHER DEHNHÜLSE 1.0502-079 EXTENSION SLEEVE...
  • Page 869 Totpunktanzeiger-Anbau B1.05.12. 437350 AA Dead Centre Indicator Mounting en / 11.10.1999 EB021984...
  • Page 870 Kabelführung-Anbau B1.05.14. 434691 MM Cable Guide Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. KABELFÜHRUNG-ANBAU, VOLLST. 434691 MM CABLE GUIDE MOUNTING ASSEMBLY HALTER 434691-001 BRACKET HALTER 434691-202 BRACKET HALTER 344692-022 BRACKET HALTER 434691-006 BRACKET HALTER 434639-016 BRACKET PROFIL 1.7010-223 PROFILE PROFIL...
  • Page 871 Kabelführung-Anbau B1.05.14. 434691 MM Cable Guide Mounting POS. BENENNUNG STCK BEST.-NR ITEM DESCRIPTION NUMBER PART NO. SECHSKANTSCHRAUBE 1.1387-447 HEXAGON SCREW SCHEIBE 1.0040-222 WASHER SCHEIBE 1.0040-220 WASHER SCHEIBE 1.0040-227 WASHER SECHSKANTSCHRAUBE 1.1387-309 HEXAGON SCREW GEWINDEEINSATZ 1.1093-704 THREADED INSERT ROHRKLEMME 1.5011-001 PIPE CLAMP Jede Bestellung muß...
  • Page 872 Kabelführung-Anbau B1.05.14. 434691 MM Cable Guide Mounting en / 03.03.2009 EB030001...
  • Page 873 Kabelführung-Anbau B1.05.14. 434691 MM Cable Guide Mounting en / 03.03.2009 EB030001...
  • Page 874 Stand-by parts Stand-by parts en / 26.05.2009 AA000114...
  • Page 875 Stand-by parts B2.05.20.14 Stand-by parts en / 22.05.2009 AA045561 1/21...
  • Page 896 External Documentation M43C External Documentation Type M43C Engine No.: Record No.: 68 280 281717 68 281 en / 26.05.2009 AA020128...
  • Page 897 External Documentation M43C Please note the copyright notice pursuant to ISO 16016 "All documents such as drawings, data and programmes, etc. and models, templates etc. shall remain our exclusive property. They are only handed over to the agreed purpose and must not be used for any other purpose.

  • Page 898: Emergency Stop Safety System

    Total Index C0.01 Book A, B and C Engine Operating Instructions Total Index Book A, B and C A0.01 Introduction A0.02 Safety instructions A0.03 Emergency Stop Safety System A0.04 Technical Engine Data Governor Data A1.04 Working pressures of auxiliary equipment A1.05 Temperatures of operating media A1.06...
  • Page 899 Total Index C0.01 Book A, B and C External Documentation Total Index Book A, B and C C0.01 Introduction Electrical Equipment C0.02 Table of contents C5.01 en / 26.05.2009 AA020077...
  • Page 900 Introduction C0.02 Electrical Equipment M20-M601C The structure of the contents ensures that you will find the required spares very quickly Example: Electrical Equipment Electrical engine equipment C5.05.05 10.17.93 Book C Chapter Engine Regulation External Documentation These documents reflect your actual engine equipment and are, therefore, not compatible with other or similar engine plants.
  • Page 901 Introduction C0.02 Electrical Equipment M20-M601C Procedure Variant A The damaged component with identification of measuring point must be identified on the engine or cable. Exhaust thermocouple cylinder 1 Next to the plug a metal plate with identification of the measuring point is fitted. Additionally, the measu- ring point number is identified on the cable of the plug-in connection.
  • Page 902 Introduction C0.02 Electrical Equipment M20-M601C Variant B By means of the drawings Sensor - Actuators - Arrangement / Engine General View Here as well measuring point 8211.1 can be found. Procedure as described above. Example B1 8211.1 Thermocouple type K 273 450 450 8211.6 en / 28.11.2006...
  • Page 903 Introduction C0.02 Electrical Equipment M20-M601C A relay can be clearly identified by means of the drawing Junction Box 1. In this example K9 In the chapter Electrical Equipment Engine C5.05.05.10.nn the component with stock No. 213 480 770 is easily found by means of component identification K9. Example B2 K9 Attaching type relay 213 480 770 en / 28.11.2006...
  • Page 904 Introduction C0.02 Electrical Equipment M20-M601C Variant C With the electric documents Sensoric Level Sensor Junction Box 1 / Alarm System Level probe B7301 Water min. Measuring point No. 7301. In the chapter Electrical Equipment Engine C5.05.05.10.nn the component with stock No. 213 483 072 is easily found by means of the measuring point No.7301.
  • Page 905 Introduction C0.02 Electrical Equipment M20-M601C Variant D Ordering a cable If a cable has to be replaced, at least a measuring point or plug designation is to be safely identified. By stating the engine number the part "cable loom" can be ordered. en / 28.11.2006 AA035841...
  • Page 906 Caterpillar Motoren GmbH & Co. KG cvb2 Anfrage/Ersatzteilbestellschein / Spare Parts Inquiry or Order Sheet Auftrags-Nr,/Kunden-Referenz-Nr. Auftragsdatum P.O. Number/Customer Ref. No. Order date Käufer/Buyer Empfänger/Consignee Liefertermin Erforderlicher Ankunftstermin (postalisch einwandfreie Anschrift) (genaue Warenempfänger-Anschrift) Date of Delivery (voraussichtliche Ankunftszeit) exact postal address exact addressee of consignee Date of required arrival (eta) Markierung, spezielle Anweisungen, z.
  • Page 907 Table of contents C5.01 Table of contents C5.01 Engine, measuring points C5.05.02 List of Measuring Points C5.05.02.01.09.89 List of Measuring Points Engine Sensors and Actuators C5.05.02.01.50.88 Engine, control C5.05.04 UG40 Actuator C5.05.04.20.20.34 Booster Servomotor C5.05.04.20.22.01 Digital Speed Control C5.05.04.20.26.02 Oil - Regulations (Woodward) C5.05.04.20.27.01 Engine, regulation...
  • Page 908 Table of contents C5.01 Engine, exhaust gas system/supercharging C5.05.06 Engine Adjusting Valve C5.05.06.09.15.00 Turbocharger C5.05.06.10.21.32 Charge Air Cooler C5.05.06.30.17.36 Engine, cooling water system C5.05.09 Cooling Pump Unit C5.05.09.01.11.56 E-Engine C5.05.09.01.40.05 Cooling Water Preheating Set C5.05.09.09.08.05 Engine Adjusting Valve C5.05.09.09.15.00 Engine control equipment C5.05.11 Oil Mist Detector C5.05.11.02.03.05...
  • Page 909 List of Measuring Points C5.05.02.01.09.89 List of Measuring Points en / 04.02.2009 FD039517 1/14...
  • Page 910 List of measuring points for main engine 9 M43C = Caterpillar: Confidential: Green Datum 12.11.07 1.00.1-09.61.00-35 Meßstellenliste Caterpillar Motoren GmbH & Co. KG Bearb. Behnken List of Measuring Points Gepr. Behnken 281716-721 Blatt/page: 1 Zust. Änderung Datum Name Norm DIN/IEC von/of: 13 Urspr.
  • Page 911 The following example shows how to read the list of measuring points: The example shows the data of the measuring point CM8221 „exhaust gas temp. at turbocharger outlet“ that is part of the section 2 „Load Reduction“. CM indicates that the DICARE software needs this measuring point for Condition Monitoring (CM).
  • Page 912 Exhaust Gas Temperature Monitoring E xh au st G as E n g in e g ro u p 2 T em p. (°C ) 55 0 55 0 absolute alarm turbocharger inlet R E D U C T . 8231 8231 54 0...
  • Page 913 Automatic speed reduction If an automatic speed reduction is not possible due to the special The MaK wiring diagrams and installation documents must be observed for conditions of the plant design ( shaft generator drive ), an automatic further handling of the monitoring equipment.
  • Page 914 function Beschreibung supp. trigger sensor range Bemerkungen action description delay normal signal range remarks Shutdowns 1106 PALL Schmieröldruck letztes Lager 270 kPa 0..400 kPa CO-contact Shutdown lub. oil pressure last bearing 500 kPa binary 1163 PALL Schmieröldruck Getriebe from gearbox Shutdown lub.
  • Page 915 function Beschreibung supp. trigger sensor range Bemerkungen action description delay normal signal range remarks 8218/24 Abgastemperaturen Mittelwertabweichung 0..600° C delay = turn-on delay hT b Load Reduction exhaust gas temp. average deviation/after tubocharg see sheet 3 From alarm system Start Pumps / Functions 1104 Schmieröldruck letztes Lager 330 kPa...
  • Page 916 function Beschreibung supp. trigger sensor range Bemerkungen action description delay normal signal range remarks 9405 Zündrehzahl 80 min-1 0..600 min-1 CO-contact Function Firing speed 500 min-1 binary 9411 Getriebe Reserveschmierölpumpe an-/abschalten 300 min-1 0..600 min-1 CO-contact Start Pump gearbox luboil standby pump switch on/off 500 min-1 binary 9532.1...
  • Page 917 function Beschreibung supp. trigger sensor range Bemerkungen action description delay normal signal range remarks 9677 Override aktiviert NC-contact Alarm override activatet binary Alarms CM 1105 Schmieröldruck letztes Lager 300 kPa 0..1000 kPa analog Alarm lub. oil pressure last bearing 500 kPa 4-20mA order to reduction 1111...
  • Page 918 function Beschreibung supp. trigger sensor range Bemerkungen action description delay normal signal range remarks 5102 Kraftstoffdruck vor Motor 100 kPa 0..1000 kPa analog Alarm fuel oil pressure at engine inlet 400 kPa 4-20mA 5111 PDAH Kraftstoffdifferenzdruck am Doppelfilter 80 kPa 0..80 kPa NC-contact Alarm...
  • Page 919 function Beschreibung supp. trigger sensor range Bemerkungen action description delay normal signal range remarks CM8211.1 TAHH Abgastemperatur nach Zylinder 1 <n-min 0..600 °C analog Alarm exhaust gas temp. after cyl. 1 see page 3 4-20mA CM8211.2 TAHH Abgastemperatur nach Zylinder 2 <n-min 0..600 °C analog...
  • Page 920 function Beschreibung supp. trigger sensor range Bemerkungen action description delay normal signal range remarks 9406 Abschalten der Schmierölreservepumpe NC-contact Alarm switch of luboil standby pump binary extern / yard supply 9504 Steuerungsausfall Ladelufklappe CO-contact Alarm control failure of charge air flap binary charge air flap-requirement 9507...
  • Page 921 function Beschreibung supp. trigger sensor range Bemerkungen action description delay normal signal range remarks DICARE and INDICATIONS CM5201 Kraftstofftemperatur vor Motor 35° C -40..160 °C analog DICARE / Indication fuel oil temp. at engine inlet 40 - 50° C Pt100 CM5206 Kraftstofftemperatur nach Viskosimat -50..200 °C...
  • Page 922 function Beschreibung supp. trigger sensor range Bemerkungen action description delay normal signal range remarks CM9429 Turboladerdrehzahl 0..30000 min-1 analog DICARE / Indication Turbocharger speed <30000 min-1 4-20mA / 0-10V CM9509 Einspritzpumpenfüllung 0..70 mm analog DICARE / Indication fuel pump setting 0-10V 9531 Motorbelastung zu groß...

  • Page 923: Sensors And Actuators

    List of Measuring Points Engine C5.05.02.01.50.88 Sensors and Actuators List of Measuring Points Engine Sensors and Actuators en / 01.02.2005 FD029289...
  • Page 924 List of Measuring Points Engine 9M43 Sensors and Actuators Unit Description Sensor range Trigger Remarks Signal range Normal 1104 Pressure switch -20 – 400 kPa 350 kPa Lub. oil pressure low – start stdby pump binary 500 kPa 1105 Pressure transmitter 0 –...
  • Page 925 List of Measuring Points Engine 9M43 Sensors and Actuators Unit Description Sensor range Trigger Remarks Signal range Normal 5201/5202* Resistance thermometer 5201 Fuel oil temp. at engine inlet low – alarm / -40-160° C 5201 : 35° C 1 sensor for 5201 + 5202* Dicare PT 100 40-50°...
  • Page 926 List of Measuring Points Engine 9M43 Sensors and Actuators Unit Description Sensor range Trigger Remarks Signal range Normal 9419.4 Pick up 0-1200 upm Electronic governor 0-15 KHz < 1 KHz 9429 Pick up /transmitter 0-30000 upm *DNV Turbine speed – Alarm*/Dicare 4-20mA <...
  • Page 927 UG40 Actuator C5.05.04.20.20.34 UG40 Actuator en / 18.02.2002 FD022663 1/27...
  • Page 953 We appreciate your comments about the content of our publications. Please send comments to: Woodward Governor Company Attention: Technical Publications PO Box 1519 Fort Collins CO 80522-1519, USA Please include the manual number from the front cover of this publication. Woodward Governor Company/Industrial Controls PO Box 1519, Fort Collins CO 80522-1519, USA 1000 East Drake Road, Fort Collins CO 80525, USA...
  • Page 954 Booster Servomotor C5.05.04.20.22.01 Booster Servomotor en / 20.10.2003 FD022607 1/37...
  • Page 955 36684M Booster Servomotor Single Cylinder (8901-037, -043, -051) Tandem (8901-065, -067) Two-Stage (8901-091, -103) Installation and Operation Manual Manual 36684M...
  • Page 956 WARNING Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage. The engine, turbine, or other type of prime mover should be equipped with an overspeed (overtemperature, or overpressure, where applicable) shutdown device(s), that operates totally independently of the prime mover control device(s)
  • Page 957 Manual 36684 Booster Servomotor Contents 1. G ............1 HAPTER ENERAL NFORMATION Introduction......................1 Description......................1 Types of Boosters....................1 Regulatory Compliance ..................2 2. I ... 7 HAPTER NSTALLING AND DJUSTING A OOSTER ERVOMOTOR General Rules......................7 Installing and Adjusting a Single Cylinder Booster..........7 Installing and Adjusting a Tandem Booster............8 Installing and Adjusting a Two-Stage Booster ............9 3.
  • Page 958 Booster Servomotor Manual 36684 Woodward...
  • Page 959 Manual 36684 Booster Servomotor Chapter 1. General Information Introduction This manual covers the three types of Woodward booster servomotor: Low-volume, single-cylinder booster Medium-volume, double-cylinder (tandem) booster High-volume, two-stage booster Description A booster servomotor supplies pressurized oil to mechanical-hydraulic governors and electro-hydraulic actuators at the instant starting air reaches the engine. This instant oil pressure eliminates the time required for the rotary gear pump in the governor to build up enough oil pressure to move the linkage.

  • Page 960: Regulatory Compliance

    Booster Servomotor Manual 36684 Tandem boosters, with larger volumes of oil and three oil outlets, are appropriate for PG-29/-58, EG-29/-58, and PG-TM 58 governors (39/79 J; 29/58 ft-lb). Two-stage, high-volume boosters meet the boost oil requirements for PG, EGB, and PG-TM governors with 271, 407, and 678 J (200, 300, and 500 ft-lb) power cases.
  • Page 961 Manual 36684 Booster Servomotor Figure 1-1. Schematic of Single Booster Connections to PG-Type Governor Figure 1-2. Schematic of Tandem Booster Connections to PG-Type Governor Woodward...
  • Page 962 Booster Servomotor Manual 36684 Figure 1-3. Outline Drawing of Single Booster Woodward...
  • Page 963 Manual 36684 Booster Servomotor Figure 1-4. Outline Drawing of Tandem Booster Woodward...
  • Page 964 Booster Servomotor Manual 36684 Figure 1-5. Outline Drawing of Two-Stage Booster Woodward...
  • Page 965 Manual 36684 Booster Servomotor Chapter 2. Installing and Adjusting a Booster Servomotor General Rules Observe the following rules when you install a Woodward booster servomotor. Location Install the booster servomotor at a lower level than the governor to prevent air from being trapped in the booster and oil lines.
  • Page 966 Booster Servomotor Manual 36684 If the governor is a PGA, PGPL, or PGG equipped with any shutdown feature, install 6 mm (1/4 inch) steel tubing from oil outlet #2 on the booster to the speed setting servo (the inlet marked “OUTLET #2”) of the governor. Otherwise, plug outlet #2 (this plug is delivered with the booster).
  • Page 967 Manual 36684 Booster Servomotor When all oil and air connections are secure, purge air from the booster and oil lines by cycling air to the booster from a remote source without cranking the engine. Add more oil to the governor as needed. When there is no more air in the booster and oil lines, limit the volume of oil going to the governor by adjusting the two stroke limit screws.
  • Page 968 Booster Servomotor Manual 36684 When all air and oil connections are secure, purge air from the booster and oil lines by cycling air from a remote source to the booster without cranking the engine. Add oil to the governor as needed. When there is no more air in the booster and oil lines, regulate the volume of oil going to the governor by adjusting the stroke limit screw.
  • Page 969 Manual 36684 Booster Servomotor Figure 2-1. Governors Used with Single-Cylinder Boosters Woodward...
  • Page 970 Booster Servomotor Manual 36684 Figure 2-2. Governors Used with Single-Cylinder Boosters Woodward...
  • Page 971 Manual 36684 Booster Servomotor Figure 2-3. Governors Used with Tandem Boosters Woodward...
  • Page 972 Booster Servomotor Manual 36684 Figure 2-4. Governors Used with Two-Stage Boosters Woodward...
  • Page 973 Manual 36684 Booster Servomotor Chapter 3. Principles of Operation How Single-Cylinder and Tandem Boosters Operate First Phase of Operation Refer to Figure 311 (which represents a single-cylinder booster; a tandem booster has two pistons and three oil outlets, but its principle of operation is the same).
  • Page 974 Booster Servomotor Manual 36684 How a Two-Stage Booster Operates First Phase of Operation Figure 3-3. Two-Stage Booster, Phase 1 When compressed air enters the booster, the main piston moves to the right, forcing oil to the shuttle piston cavity and moving the shuttle piston up. The shuttle piston forces oil through oil outlet #2 and blocks oil outlets #1 and #3.
  • Page 975 Manual 36684 Booster Servomotor Third Phase of Operation Figure 3-5. Two-Stage Booster, Phase 3 The air side of the main piston is vented to atmosphere through the starting-air valve. Spring forces return the main booster piston and shuttle piston to their original positions.
  • Page 976 Booster Servomotor Manual 36684 Woodward...
  • Page 977 Manual 36684 Booster Servomotor Chapter 4. Replacement Parts Ordering Replacement Parts When ordering replacement parts, include the following information: 1. The booster servomotor part number shown on the nameplate. 2. The manual number printed on the cover of the manual (this is manual 36684).
  • Page 978 Booster Servomotor Manual 36684 Parts List for Figure 4-1 Part No. Name..........No. Req'd 36684-6 0-ring ...............1 36684-7 Glide Ring............1 36684-15 5/16"-24 Nut.............4 36684-16 0-ring ............1 or2 36684-18 1/8"-27 Steel Plug ..........2 36684-23 Glide Ring..........1 or 2 36684-24 0-ring ............
  • Page 979 Manual 36684 Booster Servomotor Figure 4-1. Exploded View of Single Boosters Woodward...
  • Page 980 Booster Servomotor Manual 36684 Parts List for Figure 4-2 Part No. Name..........No. Req'd 36684- 6 0-ring ...............2 36684- 7 Glide Ring............2 36684-15 5/16"-24 Nut.............6 36684-18 1/8"-27 Steel Plug ..........4 36684-23 Glide Ring..........2 or 4 36684-24 0-ring ............2 or 4 36684-25 Check Valve Assembly ........6 36684-32...
  • Page 981 Manual 36684 Booster Servomotor Figure 4-2. Exploded View of Tandem Boosters Woodward...
  • Page 982 Booster Servomotor Manual 36684 Parts List for Figure 4-3 Part No. Name..........No. Req'd 36684-25 Check Valve Assembly ........4 36684-63 Booster Servo Piston ........1 36684-64 Seal ..............1 36684-65 Block Vee Seal ..........2 36684-66 Backup Ring ............1 36684-67 Seal Retainer ...........1 36684-68 .500 Springlock Washer........9 36684-69...
  • Page 983 Manual 36684 Booster Servomotor Figure 4-3. Exploded View of Two-Stage Boosters Woodward...
  • Page 984 Booster Servomotor Manual 36684 Woodward...
  • Page 985 Manual 36684 Booster Servomotor Chapter 5. Service Options Product Service Options The following factory options are available for servicing Woodward equipment, based on the standard Woodward Product and Service Warranty (5-01-1205) that is in effect at the time the product is purchased from Woodward or the service is performed: Replacement/Exchange (24-hour service) Flat Rate Repair...
  • Page 986 Booster Servomotor Manual 36684 Flat Rate Repair Flat Rate Repair is available for the majority of standard products in the field. This program offers you repair service for your products with the advantage of knowing in advance what the cost will be. All repair work carries the standard Woodward service warranty (Woodward Product and Service Warranty 5-01- 1205) on replaced parts and labor.
  • Page 987 Manual 36684 Booster Servomotor Return Authorization Number When returning equipment to Woodward, please telephone and ask for the Customer Service Department [1 (800) 523-2831 in North America or +1 (970) 482-5811]. They will help expedite the processing of your order through our distributors or local service facility.
  • Page 988 Booster Servomotor Manual 36684 Engineering Services Woodward Industrial Controls Engineering Services offers the following after- sales support for Woodward products. For these services, you can contact us by telephone, by email, or through the Woodward website. Technical Support Product Training Field Service Contact information: Telephone—+1 (970) 482-5811...
  • Page 989 Manual 36684 Booster Servomotor Technical Assistance If you need to telephone for technical assistance, you will need to provide the following information. Please write it down here before phoning: General Your Name Site Location Phone Number Fax Number Prime Mover Information Engine/Turbine Model Number Manufacturer Number of Cylinders (if applicable)
  • Page 990 We appreciate your comments about the content of our publications. Send comments to: icinfo@woodward.com Please include the manual number from the front cover of this publication. Woodward / Industrial Controls PO Box 1519, Fort Collins CO 80522-1519, USA 1000 East Drake Road, Fort Collins CO 80525, USA Phone +1 (970) 482-5811 Fax +1 (970) 498-3058 Email and Website—www.woodward.com FM 57982...
  • Page 991 Digital Speed Control C5.05.04.20.26.02 Digital Speed Control en / 09.11.2004 FD021449 1/79...
  • Page 992 723 PLUS DIGITAL CONTROL CABINET OPERATION AND MAINTENANCE MANUAL APPLICATION NAME : SINGLE ENGINE PROPULSION CUSTOMER NAME : MaK MAIN CHASSIS : 8262-974 MANUAL B36146V2.C...
  • Page 993 WARNING Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage WARNING The engine, turbine, or other type of prime mover should be equipped with an overspeed...
  • Page 994 Manual B36146V2.C Table of Contents TABLE OF CONTENTS GENERAL INFORMATION ....................1-1 ....................1-1 NTRODUCTION TO THE ANUAL ..................... 1-1 SSOCIATED UBLICATIONS ......................1-2 YSTEM OMPLIANCE ..................... 1-2 ENERAL AFETY RECAUTIONS ..................1-2 OTES ARNINGS AND AUTIONS ......................1-2 DENTIFICATION LATE ESD PROTECTION AND HANDLING .................
  • Page 995 Table of Contents Manual B36146V2.C 5.2.6 * SETUP PLC *......................5-5 SERVICE MENU ........................5-6 5.3.1 * DYNAMICS 1*......................5-6 5.3.2 * GAIN 1 Curve * ...................... 5-7 5.3.3 * DYNAMICS 2*......................5-8 5.3.4 * GAIN 2 Curve * ...................... 5-9 5.3.5 * FUEL CONTROL * ....................
  • Page 996 GENERAL INFORMATION Introduction to the Manual The MaK-Basic Single Engine control System is designed to control a single engine plant with a gearbox. This gearbox drives a propeller shaft with a controllable pitch propeller. For the engine type, gearbox type, type of CPP and the type of primary/secondary shaft generator please refer to the engine manufacturer’s documentation.
  • Page 997 General Information Manual B36146V2.C Publication Type Number ® Software Block Diagrams Diagram 9926-659 *** This manual is supplied with the Woodward Control Cabinet. ** These publications are included in this manual. *** These diagrams are only available on special request. System Compliance This system complies with the relevant industry specifications and regulations.
  • Page 998 Manual B36146V2.C ESD Protection and Handling ESD PROTECTION AND HANDLING CAUTION All electronic equipment is static-sensitive, some components more than others. To protect these components from static damage, you must take special precautions to minimize or eliminate electrostatic discharges. Follow these precautions when working with or near the control. Before doing maintenance on the electronic control, discharge the static electricity on your body to ground by touching and holding a grounded metal object (pipes, cabinets, equipment, etc.).
  • Page 999 ESD Protection and Handling Manual B36146V2.C Woodward...
  • Page 1000 Manual B36146V2.C System Description SYSTEM DESCRIPTION Woodward 723plus Control The Woodward 723plus Digital Control governs reciprocating engines (gas, diesel, or dual fuel) used in power generation, marine propulsion, and gas compression/distribution. The control may also be used in cogeneration, power transmission/distribution, process management, pipeline pump stations, utility power generation, emergency standby power, and remote control station operation.
  • Page 1001 System Description Manual B36146V2.C Siemens S7-216 PLC The Siemens S7-216 PLC is the power pack of the SIMATIC S7-200 series (Siemens no. 6ES7 216-2AD00-0XB0, Woodward no. 1797-019). The S7-216 PLC is a PLC with 24 Digital Inputs, 16 Digital Outputs and 2 Communication Ports.
  • Page 1002 Manual B36146V2.C System Description Figure 3.2 Siemens S7- 216 PLC Outline Drawing General Information The Basic Single Engine Propulsion cabinet contains a Woodward 723plus digital control and a Siemens S7-216 PLC. All discrete inputs are hardwired to the Siemens S7-216 PLC, which is programmed for the logic required in the 723plus.
  • Page 1003 System Description Manual B36146V2.C Backup Modes If the engine hase a mechanical backup governor, the mechanical backup governor is activated when the electronic control is switched off or is defective. The speed changes are done from the backup module inside the cabinet or from the mechanical governor itself.
  • Page 1004 The control cabinet consists of one system containing a 723plus Digital Controller in combination with a Siemens S7-216 Programmable Logic Controller (PLC). The 723plus is designed for standard MaK engine plants where the PLC is programmed especially for this application.
  • Page 1005 Description of System Operation Manual B36146V2.C Terminal no. Function Load Limit Clutch / Generator Breaker Feedback In the cabinet, these inputs are not wired. The status of these contacts is transferred from the PLC to 723plus control through modbus communication. These inputs can be used as backup, in case PLC is defective.
  • Page 1006 Manual B36146V2.C Description of System Operation Terminal no. Function 42/43 Generator Load Input [4 – 20 mA] 45/46 Fuel Reference Input [4 – 20 mA] 48/49 Charge Air Pressure Input [4 - 20 mA] 51/52 Remote Speed reference Input [0-5 VDC] 11/12 Speed Sensor #1 Input [Hz] 13/14...
  • Page 1007 Description of System Operation Manual B36146V2.C Figure 4.1 Speed Filter Inside the 723Plus Logic, this frequency must be calculated into the value τ. f = cut-off frequency τ = π The value must be tuned as parameter for FLT Const. Probe #1 and FLT Const.Probe τ...
  • Page 1008 Manual B36146V2.C Description of System Operation Back-up pitch control on overrules the remote Speed Reference and raises the reference to the Raise Speed Limit. Constant speed is selected when the generator breaker is in or when the constant speed contact is activated. Often the constant speed is selected by giving a steady 20 mA (or 5 VDC) signal to the remote speed reference input.
  • Page 1009 Description of System Operation Manual B36146V2.C When an engine is already running, the generator mode can be selected if the clutch is not in. The engine ramps up to rated speed. ☞ In this mode the clutching in of an engine is not possible. If the combination of a propeller and generator is required, first switch over to propulsion mode.
  • Page 1010 Manual B36146V2.C Description of System Operation engine that will function as PTI (Power Take In). This engine will always be in Slave mode. 4.5.2 Detailed description of operation Master The synchronise pulse starts the clutch sequence. The Clutch enable is given when the speed (clutch speed) is above the Lower Speed Limit but under Max Clutch Speed.
  • Page 1011 Description of System Operation Manual B36146V2.C via the mA signal. An external device must monitor the input signal to prevent it going below the lower frequency level of the generator. ☞ In this mode the constant speed mode and rated speed selection are overridden, and their selection is blocked by an external device.
  • Page 1012 Manual B36146V2.C Description of System Operation 3 means major alarm. The following failures will always give a minor alarm: LON communication failure (in the Single engine application this alarm can be switched off) Modbus communication failure. The following failures will always give a major alarm: Overspeed Both speed sensors failed.
  • Page 1013 Description of System Operation Manual B36146V2.C Figure 4.2 Mechanical Back-up Module The switchbox contains the circuits to increase or decrease the mechanical back-up speed reference for one engine. If the switch is turned to FASTER the speed setting motor (which is located in the cover of the governor) increases the speed reference to the maximum position indicated by the red LED.
  • Page 1014 Manual B36146V2.C Tuneables TUNEABLES General This chapter describes the parameters that can be tuned or monitored. Section 5.2 describes the values that can be adjusted in Configure Mode. Section 5.3 describes the values that can be configured in Service Mode. Where applicable, the nominal setting for each tuneable is listed (the nominal values are provided only as a guideline).
  • Page 1015 Tuneables Manual B36146V2.C Overspeed Trip Sets the overspeed level in rpm. When engine speed is exceeding this limit, engine will be shutdown. Gear #1 Teeth Number of teeth on the gear where the speed sensor #1 is mounted on. Gear #2 Teeth Number of teeth on the gear where the speed sensor #2 is mounted on.
  • Page 1016 Manual B36146V2.C Tuneables Use Torsionals ? False --> Torsional Level calculation will be disabled. Not automatic reduction of gain and stability will be achieved. True --> Torsional Level calculation will be enabled. Automatic reduction of P and increasing of I will be achieved in order to prevent further torsional. Spd Flt Ovrd Time The time from when the RUN signal is given to the control, the speed sensor fault is overridden.
  • Page 1017 Tuneables Manual B36146V2.C Description Range Nominal Actual Modbus Format (1, 2) Hardware Config Hardware configuration of the J3 communication port used for Modbus communication. 1 = RS232. 2 = RS422. 3 = RS485. Baudrate This field is the baud rate, which is the number of signal transitions per period of time for the J3 communication Port.
  • Page 1018 Manual B36146V2.C Tuneables 1 = PID Output. 2 = Actual Speed Output. 3 = Actual Load Output (kW). 4 = Actual Limit Output. 5 = Torsional Level Output. 6 = Jump Rate Limiter Output. 7 = Actual Speed Reference. Select Aux 3 With this field, the analog output #3 can be configured.
  • Page 1019 Tuneables Manual B36146V2.C False --> Shaft Generator is NOT present on the engine where this 723plus and PLC is having control. True --> Shaft Generator is present on the engine where this 723plus and PLC is having control. Prim SG Mode Other Primary Shaft Generator Mode Other engine.
  • Page 1020 Manual B36146V2.C Tuneables Integrator Rate 1 Integrator rate is the integral gain term in the PID controller. Integrator rate compensates for lags in the engine control loop. It prevents slow hunting at steady state and controls damping when speed error returns to zero after a speed disturbance. A value too high will result in large, low frequency oscillations in engine speed.
  • Page 1021 Tuneables Manual B36146V2.C Description Range Nominal Actual Speed 1-1 (rpm) (0, 2000) Gain 1-1 (0.01, 100.0) *0.3 Speed 1-2 (rpm) (0, 2000) *400 Gain 1-2 (0.01, 100.0) *0.3 Speed 1-3 (rpm) (0, 2000) *600 Gain 1-3 (0.01, 100.0) *0.3 Speed 1-4 (rpm) (0, 2000) *2000 Gain 1-4...
  • Page 1022 Manual B36146V2.C Tuneables True Æ This value activates a new service menu which allows to setup a 4 point speed dependant gain curve. Proportional Gain 2 See description *DYNAMICS 1*. Integrator Rate 2 See description *DYNAMICS 1*. Derivative Ratio 2 See description *DYNAMICS 1*.
  • Page 1023 Tuneables Manual B36146V2.C 5.3.5 * FUEL CONTROL * Description Range Nominal Actual Min Spd Limit (0.0, 2000.0) *540.0 Max Spd Limit (0.0, 2000.0) *650.0 Ice Brk. Crv. X_1 (0.0, 24.0) *0.0 Ice Brk. Crv. Y_1 (0.0, 100.0) *0.0 Ice Brk. Crv. X_2 (0.0, 24.0) *4.0 Ice Brk.
  • Page 1024 Manual B36146V2.C Tuneables 5.3.6 * JMP RATE LIMIT * Description Range Nominal Actual Jump 1 %/LSS (0.0, 100.0) *35.0 Rate Jump 1 /sec (0.0, 10.0) *0.5 Enbl Jmp2 at % Load (0.0, 100.0) *60.0 Jump 2 %/LSS (0.0, 110.0) *40.0 Rate Jump 2 /sec (0.0, 10.0) *2.0...
  • Page 1025 Tuneables Manual B36146V2.C Window Hunt RPM The window in which Hunting is allowed. When for example this value is set to 1 and the Hunt RPM parameter is set to 2.5, the maximum difference between actual speed and speed reference may be +/- 1 rpm around 2.5. When Hunting occurs outside these limits, action will be taken by means of decreasing P value and increasing I value.
  • Page 1026 Manual B36146V2.C Tuneables Description Range Nominal Actual Aux_1 Out – Gain (0.1, 10.0) *1.0 Aux_2 Out – Offset (-100.0, 100.0) *0.0 Aux_2 Out – Gain (0.1, 10.0) *1.0 Aux_3 Out – Offset (-100.0, 100.0) *0.0 Aux_3 Out – Gain (0.1, 100.0) *1.0 Act_out –...
  • Page 1027 Tuneables Manual B36146V2.C 5.3.9 * INFO OTHER ENG* Description Range Nominal Actual Other Speed ***DISPLAY VALUE*** Other Actuator ***DISPLAY VALUE*** This information will be determined by the LON communication between both the 723plus controls. If no LON connection is made between the cabinets and/or the LON address is not correctly set, this menu will display not the correct values.
  • Page 1028 Manual B36146V2.C Tuneables Description Range Nominal Actual 4 mA Remote Speed (0.0, 2000.0) *400.0 20 mA Remote Speed (0.0, 2000.0) *600.0 Max Clutch Speed (0.0, 2000.0) *430.0 Speed Offset (rpm) (0.0, 60.0) *20.0 Firing Speed This setpoint sets the start point from where the start fuel limit is triggered to ramp from P1 to P2.
  • Page 1029 Tuneables Manual B36146V2.C manufacturer. The offset is removed as soon as the clutch feedback is received or after one minute. 5.3.12 * LOAD SHARING * Description Range Nominal Actual Unload Trip (%act) (0.0, 100.0) *30.0 Load Rate (%act/sec) (0.01, 100.0) *1.0 Unload Rate (%act/s) (0.01, 100.0)
  • Page 1030 Manual B36146V2.C Tuneables Droop (%) Droop is a decrease in speed or frequency, proportional to load. As the load increases, the speed or frequency decreases. If all generator sets in a droop system have the same droop setting, they will each share load proportionally. The amount of load will depend on their speed settings.
  • Page 1031 Tuneables Manual B36146V2.C Strt Lmt P2 (%/LSS) Start limit P2 [%/LSS] is the level at which the startfuel limit will ramp to after start from Start fuel Limit P1 setpoint. Strt Lmt Rate (units/s) Start Limit Rate is the ramp rate at which the start fuel limit will ramp from Start Fuel limit P2 to Start Fuel limit P1.
  • Page 1032 Manual B36146V2.C Tuneables Boost Lim val D (%) Manifold air pressure Limit value D (% Act). This field sets the maximum possible actuator output when the Manifold Air pressure input has reached the value as set in the Boost Lim in D (mA) setpoint. Boost Lim in E (mA) Manifold air pressure input signal (mA) point E.
  • Page 1033 Tuneables Manual B36146V2.C Description Range Nominal Actual Load Input Input (mA) ***DISPLAY VALUE*** Speed Input other (rpm) ***DISPLAY VALUE*** Fuel Demand Input (mA) ***DISPLAY VALUE*** Aux Output #1 (%) ***DISPLAY VALUE*** Aux Output #2 (%) ***DISPLAY VALUE*** Aux Output #3 (%) ***DISPLAY VALUE*** Analog Speed#1 ***DISPLAY VALUE***...
  • Page 1034 Manual B36146V2.C Tuneables Aux Output #3 (%) Auxiliary Output #3 is the actual output on the analog Output #3 of the 723plus. The value will be displayed in 0 - 100% which corresponds with 4 – 20 mA. Which signal is displayed on the output, can be configured in the configure mode.
  • Page 1035 Tuneables Manual B36146V2.C Reset Contact Reset Contact displays the status of the Reset contact input. True --> Contact is made (Reset is active). False --> Contact is not made (Reset is not active). Gen /Prop Contact Gen /Prop Contact displays the status of the Generator / Propulsion mode contact input. True -->...
  • Page 1036 Manual B36146V2.C Tuneables Description Range Nominal Actual Modbus Com Fail ***DISPLAY VALUE*** Load input alm Load Input alarm will be activated if the input signal is higher than 22 mA or lower than 2 mA. Fuel Dmnd input alm Fuel Demand input alarm will be activated if the input signal is higher than 22 mA or lower than 2 mA.
  • Page 1037 Tuneables Manual B36146V2.C Description Range Nominal Actual Spd out at 4 mA (0.0, 1000.0) *0.0 Spd out at 20 mA (0.0, 2000.0) *1000.0 kW out at 4 mA (-100.0, 100.0) *0.0 kW out at 20 mA (0.0, 200.0) *100.0 Limit out at 4 mA (-100.0, 100.0) *0.0 Limit out at 20 mA...
  • Page 1038 Manual B36146V2.C Tuneables Jump out at 20 mA Actual Jump/rate value at 20 mA output signal. This is the 20 mA point on a linear curve block. Spd ref out at 4 mA Actual speed reference value at a 4 mA output signal. This is the 4 mA point on a linear curve block.
  • Page 1039 Tuneables Manual B36146V2.C 5-26 Woodward...
  • Page 1040 Manual B36146V2.C Hand-held Programmer HAND-HELD PROGRAMMER Hand-held Programmer and Menus The Hand-held Programmer is a hand-held computer terminal that gets its power from the 723plus Digital Control. The terminal connects to the RS-422 communication serial port on the control. The programmer does a power-up self-test whenever it is plugged into the control. When the self-test is complete, the screen displays two lines of information.
  • Page 1041 Hand-held Programmer Manual B36146V2.C A Tuneable (*) can be changed by using the “Turtle Up” or the “Rabbit Up” keys to increase the value, and the “Turtle Down” or “Rabbit Down” keys to decrease the value (see also adjusting setpoints). To return to the menu header press the key, or to leave Service, follow the Configure instructions.
  • Page 1042 Manual B36146V2.C Hand-held Programmer Increases setpoint values by one step at a time.  (minus) + (plus) Decreases setpoint values by one step at a time. (solid square) Debug mode. Displays the In-Pulse Woodward logo, application name and software revision. To return to menu header or to main screen.
  • Page 1043 Hand-held Programmer Manual B36146V2.C Woodward...
  • Page 1044 Manual B36146V2.C Control Wiring Diagram CONTROL WIRING DIAGRAM This chapter contains the Control Wiring Diagram 9951-047. Sheet one of the drawing contains notes and additional information. The following sheets identify the system cables and show their interconnections, and give the pin-out detail of each cable connector. Woodward...
  • Page 1045 Control Wiring Diagram Manual B36146V2.C Woodward...
  • Page 1069 If you want to have more detailed information about this equipment, contact Woodward. We appreciate your comments about the content of our publications. Please send comments to: Woodward Hoofdweg 601 2131 BA Hoofddorp The Netherlands Phone: 31-(23)-5661111 Fax: 31-(23)-5636529 23 PLANTS & SUBSIDIARIES 15 BRANCHREGIONAL OFFICES 19 DISTRIBUTORS/REPS.
  • Page 1070 Oil - Regulations C5.05.04.20.27.01 (Woodward) Oil - Regulations (Woodward) en / 06.06.2006 FD032293 1/25...
  • Page 1071 25071J Oils for Hydraulic Controls Manual 25071J...
  • Page 1072 Contents CHAPTER 1. GENERAL INFORMATION ..................1 Introduction ............................1 Oil Characteristics ..........................1 Oil Lubrication Properties......................... 2 Performance Additives ........................3 Lubrication Protective Additives....................... 4 CHAPTER 2. HOW TO SELECT AN OIL ..................7 General Information ......................... 7 Proper Oil Selection ......................... 9 Automatic Transmission Fluids ......................
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