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MAK M20 Operating Instructions Manual

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Table Of Contents
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Table of Contents

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General
A0
Engine operating instructions
M20
General
Engine operating instructions
Type
M20
en / 31.10.2001
AA021665
1/1

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Summary of Contents for MAK M20

  • Page 1 General Engine operating instructions General Engine operating instructions Type en / 31.10.2001 AA021665...
  • Page 2 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 Technical engine data Governor-data A1.04 Working pressures of auxiliary equipment A1.05 Temperatures of operating media A1.06 Torsional vibration calculation A1.09 Acceptance Test Records...
  • Page 3 Since the type of fuel used considerably influences the service life of the components, the Caterpil- lar / 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 4 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...
  • Page 5 Technical engine data M20-M601C Technical engine data en / 31.10.2001 AA000103...
  • Page 6 Governor-data A1.04 Governor-data not installed on CD-Rom en / 18.02.2000 AA000097...
  • Page 7 Working pressures of auxiliary equipment A1.05 Lubricating oil at the last main bearing 4,0 - 4,5 bar at rated engine speed Cooling water min. feed head at pump inlet 4 m. water gauge 2,5 - 5,0 bar Fuel at injection pump inlet Distillate fuel 3,0 - 5,0 bar Heavy fuel...
  • Page 8 /s (cSt) to be reached before the injection pumps, corresponding to a dynamic viscosity of 9 - 11 mPas (di- stillate fuel below 10 mm /s or 9 m Pas). Caterpillar / MaK The heavy fuel specifications defined by (e.g. RHM 35 (~ IF 380) give the heavy fuel tempe- rature before engine starting.
  • Page 9 Torsional vibration calculation A1.09 Torsional vibration calculation not installed on CD-Rom en / 16.11.1999 AA020354...
  • Page 10 Acceptance Test Records A1.10 Acceptance test records not installed on CD-Rom en / 16.11.1999 AA000095...
  • Page 11 Operating instructions M20-M601C Operating instructions en / 31.10.2001 AA000108...
  • Page 12 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 Instructions for heavy fuel Operation Care and supervision / Engine fuel A3.04.07.01 Instructions for heavy fuel operation Lubricating oil system...
  • Page 13 Table of contents A3.01 Exhaust system/supercharging A3.06.06.03 Operational supervision Fuel system A3.06.07.00 Operational supervision Changing the type of fuel A3.06.07.01 Operational supervision Lubricating oil system A3.06.08.00 Operational supervision Cooling water system A3.06.09.00 Operational supervision Partial load operation A3.06.18.00 Removal from operation Engine A3.07.00 Removal from operation...
  • Page 14 Table of contents A3.01 Emergency operation With a defective turbocharger A3.12.01.02 Emergency operation With a defective turbocharger A3.12.01.02 Emergency operation Operational misfire A3.12.02.00 Emergency operation Operational misfire A3.12.02.01 en / 31.10.2001 AA020023...
  • Page 15 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 / 12.02.1996...
  • Page 16 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 17 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 18 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 19 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 20 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 21 Instructions for heavy fuel Operation A3.04.07.01 Care and supervision / Engine fuel M20/M282/M332C/M452/M453C/M551/M552C/M601/M601C Care and supervision If you are uncertain of the bunker quality, a careful ascertation of the quality must take place. Principal diagramatic view of the heavy fuel circulatory...
  • Page 22 Both separators are to operate independently of the manufacturers/system. • The operational capacity is designed according to the rules and regulations of the individual manufacturer, whose authorized department has coordinated the design with Caterpillar / MaK-Kiell. Separation temperature 98 °C. en / 19.08.1996 BA000010...
  • Page 23 Instructions for heavy fuel Operation A3.04.07.01 Care and supervision / Engine fuel M20/M282/M332C/M452/M453C/M551/M552C/M601/M601C Self cleaning fuel filter HF4 For fuel, filter elements with a mesh size of 10 µm are required. In the event of filter alarm, which is activated between the flushing intervals if the differential pressure is accessive, the operation of the separators must be checked and the filter cleaned (for servicing instructions see the documents from the manufacturer).
  • Page 24 Instructions for heavy fuel Operation A3.04.07.01 Care and supervision / Engine fuel M20/M282/M332C/M452/M453C/M551/M552C/M601/M601C Final preheater HH1 The preheater is to lower the fuel viscosity to a level that is optimal for injection, 10 -12 mm /s cSt; (1,8 - 2 °E), in order to reach a good atomization and fuel-air mixture.
  • Page 25 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.
  • Page 26 Instructions for heavy fuel Operation A3.04.08.01 Care and supervision / Lubricating Oil M20/M282/M332C/M452/M453C/M551/M552C/M601/M601C Care and supervision In heavy fuel operation, lube oil purification by separators is indispensible for a proper treatment. There is no other means to eliminate from the oil, the products resulting from cleaning and neutralization (carbon and asphalt compounds) including water.
  • Page 27 Instructions for heavy fuel Operation A3.04.08.01 Care and supervision / Lubricating Oil M20/M282/M332C/M452/M453C/M551/M552C/M601/M601C Principal diagrammatic view of the lubricating oil circulatory system Duplex lube oil filter Lube oil force pump Lube oil automatic filter Prelubrication pump Suction strainer Transfer pump (separator)
  • Page 28 Instructions for heavy fuel Operation A3.04.08.01 Care and supervision / Lubricating Oil M20/M282/M332C/M452/M453C/M551/M552C/M601/M601C Prelubrication LP2 (standby or prelubrication pump) Only a sufficient prelubrication will produce the necessary oil film on all bearings for engine starting. • Check the oil pressure build-up at the last main bearing (if there is no automatic engine locking).
  • Page 29 Instructions for heavy fuel Operation A3.04.08.01 Care and supervision / Lubricating Oil M20/M282/M332C/M452/M453C/M551/M552C/M601/M601C Attention: The functioning of the entire series of filters is indispensible for proper filtration of the lube oil. The automatic filter is the main filter and as such it has the finest filtration. It must therefore only be bypassed in extreme emergencies.
  • Page 30 Initial operation A3.05.00 Engine Initial operation en / 14.02.2001 BA000022...
  • Page 31 Initial operation A3.05.07.00 Fuel system M20-M601C 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 32 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,...
  • Page 33 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 34 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. •...
  • Page 35 Initial operation A3.05.15.00 General performance testing M20/M25/M32/M43 General performance testing • Ensure that the air admission into the engine room is in order. • Drain the water from the exhaust piping after the turbocharger and check pipe for free passage.
  • Page 36 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 37 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...
  • Page 38 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 39 These are not dealt with in this section. Unless these facilities are included in the contractual supply scope of Caterpillar / MaK, then a functional scheme and description of the functional scheme applying especially to this particular system will be prepared and coordinated (see book C).
  • Page 40 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 41 Initial operation A3.05.18.04 Putting into service/loading M20-M601C Loading during the warming up of a generator motor Caterpillar / MaK Precondition: The jacket water has been preheated to the temperature (t) given below when running on: t = 40 °C Distillate fuel Heavy oil fuel t = 5 - 10 °C below working temperature at the engine...
  • Page 42 DIN/ISO is possible. The diagram shows guide values for load stages in % engine rating depending on the mean effective piston pressure of rated output, on the example of a 6 M20-engine with a full load = 21.9 bar.
  • Page 43 Loading within the shortest period possible, depends on various factors. If higher load increases are required than previously recommended, then in every instance these must be discussed with Caterpillar / MaK. The time between two load increases must never be shorter than the settling time to rated speed (entry into the steady-state band).
  • Page 44 Operational supervision A3.06.00 Engine Operational supervision en / 15.02.2001 BA000058...
  • Page 45 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.
  • Page 46 Operational supervision A3.06.06.00 Exhaust system/supercharging Exhaust gas temperatures A comparison of the exhaust gas temperatures with the values from the acceptance test and the records during the tests/sea trials is best suited to assess the thermodynamic performance of the engine and to analyze any deviations from the new condition of the engine (supercharging, injection, combustion).
  • Page 47 Exhaust system/supercharging Assessment of the engine behaviour The assessment of the thermal behaviour and the engine performance on the M20 engine has been simplified to a considerable extent by means of a number of new constructional solutions and higher series precision of the individual components. This also means that tim e-consuming adjustments and balancing (even when replacing parts) is no longer necessary.
  • Page 48 Operational supervision A3.06.06.00 Exhaust system/supercharging Turbocharger: compressor/turbine During operation, a fine adhesive dust is deposited on the inner air-carrying parts of the turbocharger and this can progressively lessen the performance of the compressor. For cleaning the compressor, see book C. •...
  • Page 49 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 50 Operational supervision A3.06.06.02 Exhaust system/supercharging M20/M25/M32/M43/M552C/M601C Exhaust temperatures A comparison of the exhaust temperatures with the values in the acceptance test certificate or the records during testing/sea trials is best suited to assess the thermodynamic performance of the engine and to analyse any deviations from the new condition of the engine (supercharging, injection, combustion).
  • Page 51 Operational supervision A3.06.06.02 Exhaust system/supercharging M20/M25/M32/M43/M552C/M601C The exhaust temperatures before and after the turbocharger are used to assess the thermodynamic load condition of the engine as they cover the overall thermodynamics of the engine, exhaust turbine and intake condition. The temperatures after the turbocharger should not exceed the full load value in the acceptance test certificate A1.10 by more than 30 K.
  • Page 52 Operational supervision A3.06.06.02 Exhaust system/supercharging M20/M25/M32/M43/M552C/M601C Indication of the firing pressure Use the following electronic indicator for gauging the pressure: • Lemag PREMET LS This method is useful to determine changes in the firing pressure of individual cylinders. Indication is always necessary if the assessment of the exhaust temperatures shows that there are changes in individual cylinders.
  • Page 53 Operational supervision A3.06.06.02 Exhaust system/supercharging M20/M25/M32/M43/M552C/M601C Turbocharger: Compressor During operation fine adhesive dust is deposited on the inner air carrying parts of the turbocharger which can significantly reduce the performance of the compressor. For cleaning the compressor, refer to the operating instructions for the turbocharger in manual C.
  • Page 54 Operational supervison A3.06.06.03 Exhaust system/supercharging Exhaust gas temperatures A comparison of the exhaust gas temperatures with the records of the acceptance test and the sea trails is best suited to assess the thermodynamic performance of the engine and to analyse any de- viations from the brand new condition of the engine (supercharging, injection, combustion).
  • Page 55 Operational supervison A3.06.06.03 Exhaust system/supercharging The exhaust gas temperatures after the turcbcharger are used for the assessment of the thermody- namic load condition of the engine, as they include the complete thermodynamic of engine and tur- bocharger. The temperature after the turbine should nor exceed the full-load figure on the acceptance test re- cord A1.10 by more than 30K.
  • Page 56 Operational supervison A3.06.06.03 Exhaust system/supercharging Indicating For pressure measurement the following torsion bar indicators are to be employed: • Torsion bar indicator, Type S1- 1/5 piston / S50 Tool No. 1.9410 F Only hand-drawn indicator cards can be made with the existing instruments. Although it is im- possible to obtain an exact relation between the pressure development in the cylinder and a crank angle, it is nevertheless possible to see changes in the cycle of a cylinder and to find the cause rather soon.
  • Page 57 Operational supervison A3.06.06.03 Exhaust system/supercharging Turbocharger: compressor/turbine During operation, a fine adhesive dust is deposited on the inner air-carrying parts of the turbochar- ger and this can progressively lessen the performance of the compressor. For cleaning the compres- sor, see the operating instructions of the turbocharger in book C. •...
  • Page 58 Operational supervision A3.06.07.00 Fuel system M20/M282/M332C/M452/M453C/M551/M552C/M601/M601C Fuel system • Drain the water from the day fuel tank and check it at regular intervals. • Inspect the fuel treatment plant. • If the engine is running on heavy fuel, change over to distillate fuel in time. See Changing the Type of Fuel A3.06.07.nn.
  • Page 59 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 60 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.
  • Page 61 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 62 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.
  • Page 63 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 64 Removal from operation A3.07.00 Engine Removal from operation en / 16.02.2001 BA000094...
  • Page 65 The scope of this placement from service deals exlusively with the engine stop procedure on the generator engine.The function of the remote control within the Caterpillar / MaK scope of supply, is described by a functional diagram in the documentation (see book C).
  • Page 66 Removal from operation A3.07.18.01 Placing out of service/stopping M20/M25/M32 If the engine is to be started again after a short interval To avoid the accumulation of heat immediately before or after shutting down, start all system circuits and keep the engine at working or preheating temperature according to the duration of the stop and the type of fuel used (see A3.05.18.nn).
  • Page 67 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 68 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...
  • Page 69 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 70 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.
  • Page 71 Danger of frost A3.08.00 Engine Danger of frost en / 16.02.2001 BA000106...
  • Page 72 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 73 (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...
  • Page 74 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.
  • Page 75 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 76 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 77 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 78 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 79 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 80 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!
  • Page 81 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!
  • Page 82 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 83 Running-in A3.10.00 Engine Running-in en / 16.02.2001 BA000242...
  • Page 84 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 85 Fault tracing A3.11.00 Engine Fault tracing en / 19.02.2001 BA000130...
  • Page 86 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.
  • Page 87 Fault tracing A3.11.18.02 Remedial measures M20-M601C Engine starts poorly or does not start at all Possible cause: Remedy: • See A1.05 for required bottle pressure Air pressure in the starting air bottle is too • Solenoid valve to the air starter is defective •...
  • Page 88 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 89 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 90 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 A5.05.03.03.01.nn...
  • Page 91 Emergency operation A3.12.00 Engine Emergency operation en / 19.02.2001 BA000142...
  • Page 92 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 93 Emergency operation A3.12.01.01 With a defective turbocharger Emergency operation of the generator engine Plant service permitting, the set with a defective turbocharger should be shut down and separated from the mains. If an engine shut-down is not possible, disconnect all consumption as far as is possible, so that the motor can operate with a ≈...
  • Page 94 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 95 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 96 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 97 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 98 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 99 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 100 Emergency operation A3.12.02.01 Operational misfire M20-M601C Operational misfire In general, „operational misfire“ means that the engine is operated with non-uniformly loaded cylinders. This will cause additional loads which are the higher the more the march of the gas pressu- re of a defective cylinder deviates from the remaining cylinders.
  • Page 101 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 102 Operating media Operating media en / 31.10.2001 AA020105...
  • Page 103 Table of contents A4.01 Operating media Table of contents A4.01 Introduction A4.02 Safety instructions A4.03 Regulations and care Engine A4.05.00 Regulations and care Engine fuel A4.05.07.00 Regulations and care Distillate fuel A4.05.07.01 Regulations and care Heavy fuels A4.05.07.02 Regulations and care CCAI-limit curves A4.05.07.03.01 Regulations and care...
  • Page 104 Introduction A4.02 M20-M601C The use of suitable and unobjectionable operating media is an assumption for working readiness and reliability 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 105 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 106 Regulations and care A4.05.00 Engine Regulations and care en / 21.02.2001 BA000158...
  • Page 107 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 equipment condition two product groups of fuels are allowed, these are: • Destillate fuel • Heavy oil en / 28.06.1996...
  • Page 108 Regulations and care A4.05.07.01 Distillate fuel M20-M601C Distillate fuel The fuel should be a high quality mineral oil product, have good anti-oxidant properties, not sepa- rate in storage or block the filters with wax exudation and should be free of mineral acids.
  • Page 109 Regulations and care A4.05.07.01 Distillate fuel M20-M601C Choice of ISO 8217 : 1996 Table 1 – Requirements for marine distillate fuels Note The values in this table are maximum or minimum values for each property. The actual values for any batch of fuel may vary within these limits.
  • Page 110 Regulations and care A4.05.07.01 Distillate fuel M20-M601C ISO-F-DMB and -DMC have viscosity limit of 11 or 14 mm /s (cSt)/40 °C which is, however, not fully utilized in commercial fuels from the large international fuel suppliers. Pre-heating of the fuel can be dispensed with if the viscosity of the bunkered fuel at 40 °C is below 7 mm /s (cSt).
  • Page 111 Regulations and care A4.05.07.02 Heavy fuels M20-M601C Heavy fuels (Viscosity in mm /s (cSt) at 100 °C, in the past at 50 °C) All fuels are called heavy fuels that consits in the main of residual oils from oil refining.
  • Page 112 – 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 113 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 114 Caribbean area. It will frequently happen in the near future that the limits of the Caterpillar / MaK heavy fuel specification 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 115 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 116 Regulations and care A4.05.07.03.01 CCAI-limit curves M20-M601C CCAI-limit curves CCAI Density 1,02 (kg/l 15 °C) 1,01 1,00 0,99 0,98 0,97 0,96 to be avoided * 0,95 limited approved * 0,94 permissible 0,93 0,92 Viscosity (cSt 50 °C) 50 60 80 100...
  • Page 117 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 118 Regulations and care A4.05.07.05 Heavy fuel specification M20-M601C en / 15.12.1997 BA000186...
  • Page 119 Regulations and care A4.05.07.06 Viscosity temperature sheet M20-M601C Kinematische Viskosität Viskosität/Viscosity in mm/ s (cST) Kinematic Viscosity en / 28.06.1996 BA000190...
  • Page 120 This is usually given as the Base Number (BN), or as Alkalinity 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 121 In most cases, the firm’s name is part of the brand designation of the lubricating oil and should, when ordering, be placed in front of the designation to avoid confusion. Caterpillar/MaK has insuf- ficient experience with brands of lubricating oil listed in column II. The intended use of any of these oils must therefore be discussed with the engine manufacturer beforehand as otherwise the war- ranty is no longer valid.
  • Page 122 TOTAL RUBIA FP HMA SUPER X 420 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. Other- wise the warranty cover is invalid.
  • Page 123 HMA SUPER X 440 ´ 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. Other- wise the warranty cover is invalid.
  • Page 124 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 125 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 con- tent increases to above 1 % weight the oil must be separated more intensively.
  • Page 126 Regulations and care A4.05.08.00 Lubricating Oil M20-M601C Lubricating oil for exhaust turbocharger, hydraulic governor and change-over controls A turbine or hydraulic oil with very good anti-oxidation properties of between 68 and 90 mm /s (cSt) at 40 °C should be selected. For highly loaded ABB-turbochargers fully synthetic special oils (see footnote) are recommended.
  • Page 127 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 ENEGREASE LS 2 CALTEX MULTIFAK EP 2 CASTROL...
  • Page 128 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 129 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 130 Association for Internal Combustion Engines Inc). MaK 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 is unable to control the recipe and treatment.
  • Page 131 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 Diesel engines at the moment: Manufacturer Additive Limit value of...
  • Page 132 Regulations and care A4.05.09.01 Treatment of cooling water M20-M601C 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 checking the anti-corrosion oil contents every 600 operating hours. During prolonged operating breaks, a monthly check should be made.
  • Page 133 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 134 This agent must be changed annually. 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 135 Regulations and careˇ A4.05.09.03 Diagram I M20-M601C Diagram I Determining the cooling water mixture for 10° dGH 10° 5000 11° 4500 12° 4000 13° 14° 3500 15° 16° 3000 17° 18° 19° 20° 2500 21° 22° 24° 2000 26° 28°...
  • Page 136 Regulations and careˇ A4.05.09.04 Diagram II + III M20-M601C Diagram II Emulsion freshening for weak concentration measured oil concentration in vol. % 0,2 0,1 0 0,3 0,4 0,8 1,0 amount of oil to be added in litres to obtain a 0.7 % oil concentration...
  • Page 137 Maintenance Maintenance en / 31.10.2001 AA000026...
  • Page 138 Table of contents A5.01 Maintenance Table of contents A5.01 Introduction A5.02 Safety instructions A5.03 Periodical schedule Distillate fuel A5.04.01 Periodical schedule Heavy fuel A5.04.02 Engine, cylinder head A5.05.01 Valve Clearance A5.05.01.01.01.00 Valve Rocker Brackets A5.05.01.02.01.00 Valve Rocker A5.05.01.02.02.00 Valve Rotator A5.05.01.03.01.00 Valve Guide / Oil Scraper Ring A5.05.01.05.01.00...
  • Page 139 Table of contents A5.01 Big-End Bearings A5.05.02.04.01.00 Big-End Bearings A5.05.02.04.01.01 Big-End Bearings A5.05.02.04.02.00 Main Bearings A5.05.02.05.01.00 Main Bearings A5.05.02.05.01.01 Main Bearings A5.05.02.05.02.00 Piston A5.05.02.06.01.01 Piston A5.05.02.06.01.02 Piston Rings and Grooves A5.05.02.07.01.01 Piston Rings and Grooves A5.05.02.07.01.02 Piston Rings and Grooves A5.05.02.07.01.03 Piston A5.05.02.10.01.01...
  • Page 140 Table of contents A5.01 Compressed-Air Filter A5.05.05.09.06.00 Engine, exhaust gas system/supercharging A5.05.06 Exhaust Manifold A5.05.06.01.01.00 Charge Air Cooler A5.05.06.04.02.00 Charge Air Cooler A5.05.06.04.02.01 Charge Air Cooler A5.05.06.04.02.02 Charge Air Cooler A5.05.06.04.02.03 Turbocharger A5.05.06.05.00.01 Turbocharger A5.05.06.05.00.02 Turbo Charger Sound Absorber A5.05.06.05.01.00 Turbocharger A5.05.06.13.01.00 Turbocharger...
  • Page 141 Table of contents A5.01 Engine, lubricating oil system A5.05.08 Lubricating Oil System A5.05.08.02.01.00 Lube Oil Pump A5.05.08.03.01.00 Lube Oil Pump A5.05.08.03.02.00 Lubricating Oil Duplex Filter A5.05.08.04.01.00 Prelubricating pump/Prelubrication A5.05.08.10.00.00 Engine, cooling water system A5.05.09 Centrifugal Cooling Water Pump A5.05.09.07.01.00 Centrifugal Cooling Water Pump A5.05.09.07.01.01 Centrifugal Cooling Water Pump A5.05.09.07.01.02...
  • Page 142 The explanations are used to make the user of this engine plant familiar with the existing maintenance system of MaK and to interest and deepen the understanding of the user for the problems and importance of the “Scheduled maintenance”.
  • Page 143 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 / 14.02.1997 AA000021...
  • Page 144 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...
  • Page 145 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...
  • Page 146 • Under the designation "tools (W)" only special and additional tools are listed with the MaK tool No. Not all of these tools are included in the normal scope of supply. • Together with the engine type it will be indicated for what engine the job card is valid.
  • Page 147 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!
  • Page 148 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 149 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 150 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 151 Periodical schedule A5.04.01 Distillate fuel 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 152 Periodical schedule A5.04.01 Distillate fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks Fuel Day tank A3.05.07.00 system Desludging of fuel level gauge Fuel Duplex fuel filter A5.05.07.12.01.00 system Cleaning at 50 % diiferential pressure en / 31.10.2001 AA020780...
  • Page 153 Periodical schedule A5.04.01 Distillate fuel 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 A5.05.07.12.01.00 Maintenance/Cleaning at 50 % differential pressure clean strainer 24 h...
  • Page 154 Periodical schedule A5.04.01 Distillate fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks Periodical maintenance procedures ---------------------------------------------------------------------------------------------------------------------- 24 h Compressed air strainer A5.05.05.09.06.00 Maintenance/Cleaning 24 h Turbocharger A5.05.06.05.00.01 Maintenance/Cleaning see book C 150 h Valve rotor A5.05.01.03.01.00 Inspection/Evaluate 150 h Cylinder head A5.05.01.10.00.00...
  • Page 155 Periodical schedule A5.04.01 Distillate fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks 3.750 h Starting fuel limiter A5.05.05.05.01.00 Inspection/Disassembly and reassembly 3.750 h Pressure switch A5.05.11.01.02.01 Inspection/Adjust 3.750 h Pressure switch A5.05.11.01.03.00 Inspection/Adjust 3.750 h Governor Oil change see book C 7.500 h Anti-corrosion oil emulsion...
  • Page 156 Periodical schedule A5.04.01 Distillate fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks 15.000 h Main bearings A5.05.02.05.01.00 Inspection/Disassembly of two main bearings 15.000 h Governor drive A5.05.04.08.03.00 Inspection/Disassembly and reassembly 15.000 h Vibration damper on camshaft A5.05.04.09.01.00 Repair/Disassembly and reassembly 15.000 h Exhaust gas turbocharger...
  • Page 157 Periodical schedule A5.04.01 Distillate fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks Non-interval dependent maintenance procedures ---------------------------------------------------------------------------------------------------------------------- Valve rocker brackets A5.05.01.02.01.00 Maintenance/Disassembly and reassembly Media guiding system A5.05.01.05.50.00 Maintenance/Disassembly and reassembly Cylinder head A5.05.01.06.01.00 Maintenance/Disassembly Inlet and exhaust valve cones A5.05.01.08.01.00 Repair/Checking Valve seat ring...
  • Page 158 Periodical schedule A5.04.01 Distillate fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks Turbocharger A5.05.06.05.00.01 Maintenance/Cleaning see book C Injection pump A5.05.07.02.01.00 Repair/Disassembly and reassembly Injection pump A5.05.07.03.01.00 Maintenance/Disassembly and reassembly Fuel injector A5.05.07.07.01.00 Maintenance/Disassembly and reassembly Fuel injector A5.05.07.08.01.00 Maintenance/Adjust Duplex fuel filter...
  • Page 159 Periodical schedule A5.04.02 Heavy fuel 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; Temperature rise at rated output see also A1.10 Temperature Cooling water A1.06...
  • Page 160 Periodical schedule A5.04.02 Heavy fuel First inspection and maintenance procedures Work to be carried out after the first commissioning or after major repairs ---------------------------------------------------------------------------------------------------------------------- 24 h Duplex fuel filter A5.05.07.12.01.00 Maintenance/Cleaning at 50 % differential pressure clean strainer 24 h Lubricating oil system A5.05.08.02.01.00 Maintenance/Oil change...
  • Page 161 Periodical schedule A5.04.02 Heavy fuel Periodical maintenance procedures ---------------------------------------------------------------------------------------------------------------------- 24 h Compressed air strainer A5.05.05.09.06.00 Maintenance/Cleaning 24 h Turbocharger A5.05.06.05.00.01 Maintenance/Cleaning see book C 150 h Valve rotor A5.05.01.03.01.00 Inspection/Evaluate 150 h Cylinder head A5.05.01.10.00.00 Inspection/Checking of all cylinder units 150 h Prelubricating pump/Prelubrication A5.05.08.10.00.00...
  • Page 162 Periodical schedule A5.04.02 Heavy fuel 3.750 h Starting fuel limiter A5.05.05.05.01.00 Inspection/Disassembly and reassembly 3.750 h Pressure switch A5.05.11.01.02.01 Inspection/Adjust 3.750 h Pressure switch A5.05.11.01.03.00 Inspection/Adjust 3.750 h Governor Oil change see book C 7.500 h Anti-corrosion oil emulsion A4.05.09.02 Changing 7.500 h Inlet and exhaust valves...
  • Page 163 Periodical schedule A5.04.02 Heavy fuel 15.000 h Governor drive A5.05.04.08.03.00 Inspection/Disassembly and reassembly 15.000 h Vibration damper on camshaft A5.05.04.09.01.00 Repair/Disassembly and reassembly 15.000 h Fuel feed pump A5.05.07.13.01.00 Maintenance disassembly and reassembly 15.000 h Lub oil pump A5.05.08.03.01.00 Inspection/Checking 15.000 h Centrifugal cooling water pump A5.05.09.07.01.00...
  • Page 164 Periodical schedule A5.04.02 Heavy fuel Non-interval dependent maintenance procedures ---------------------------------------------------------------------------------------------------------------------- Valve rocker brackets A5.05.01.02.01.00 Maintenance/Disassembly and reassembly Media guiding system A5.05.01.05.50.00 Maintenance/Disassembly and reassembly Cylinder head A5.05.01.06.01.00 Maintenance/Disassembly Inlet and exhaust valve cones A5.05.01.08.01.00 Repair/Checking Valve seat ring A5.05.01.08.02.00 Repair/Checking Cylinder head A5.05.01.11.01.00 Repair/Reassembly...
  • Page 165 Periodical schedule A5.04.02 Heavy fuel Injection valve A5.05.07.07.01.00 Maintenance/Disassembly and reassembly Injection valve A5.05.07.08.01.00 Maintenance/Adjust Duplex fuel filter A5.05.07.12.01.00 Maintenance/Cleaning Fuel Distributor Line/Manifold Line A5.05.07.15.01.00 Repair/Disassembly and reassembly Lubricating oil system A5.05.08.02.01.00 Maintenance/oil change Lub oil pump A5.05.08.03.02.00 Maintenance/Disassembly and reassembly Lubricating oil duplex filter A5.05.08.04.01.00 Maintenance/Cleaning...
  • Page 166 Periodical schedule A5.04.02 Heavy fuel en / 31.10.2001 AA021679...
  • Page 167 Valve Clearance A5.05. 01.01.01.00 Inspection / Adjust 1500 See also: Spare parts list: B1.05.01.2.2107 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: 150 operating hours after first commissioning or after basic overhaul, the valve clearance is to be checked and readjusted, followed by a check after 1,500 operating hours.
  • Page 168 Valve Clearance A5.05. 01.01.01.00 Inspection / Adjust 1500 Adjust a sufficiently large clearance “s” between the valve rocker (Fig. 1/1) and/ or valve bridge by folding back the valve rocker (1) and/or by adjusting the valve adjusting screw (2). Loosen counternut (Fig. 2/3) and unscrew the adjusting screw (4) until there is sufficient clearance when the valve bridge is tipped in the direction of...
  • Page 169 Valve Rocker Brackets A5.05. 01.02.01.00 Maintenance / Disassembly and reassembly See also: 01.01.01.nn Spare parts list: B1.05.01.2.2107 Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 40 - 180 Nm 1/2" W1 * 1.9454-40 Turning rod...
  • Page 170 Valve Rocker Brackets A5.05. 01.02.01.00 Maintenance / Disassembly and reassembly Grease the thread and nut contact face with Molykote paste “G-Rapid Plus” and tighten the nuts gradually (1) with a Torque of 120 Nm and nuts (2) with a Torque of 60 Nm. Set the valve clearance (01.01.01 nn).
  • Page 171 Valve Rocker A5.05. 01.02.02.00 Maintenance / Disassembly and reassembly 30000 See also: 01.02.01.nn Spare parts list: B1.05.01.2.2107 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Disassemble inlet and exhaust valve rocker and inspect the bearing clearances 30,000 h Note:...
  • Page 172 Valve Rocker A5.05. 01.02.02.00 Maintenance / Disassembly and reassembly 30000 Check the surfaces of the ball pin (Fig. 2/10) and adjusting screw (12) for wear and damage. Renew parts if as necessary. Undercool and shrink in ball pin with fluid nitrogen to -195 °C. Observe the marking (x) of the ball pin.
  • Page 173 Valve Rocker A5.05. 01.02.02.00 Maintenance / Disassembly and reassembly 30000 Reassembly Note: Valve rocker axle must be undamaged and free of burrs. Oil surfaces of the bushes of the inlet valve rocker (Fig. 1/3) and exhaust valve rocker (4) and rocker axle and carefully move the valve rocker onto the axle.
  • Page 174 Valve Rotator A5.05. 01.03.01.00 Inspection / Evaluate See also: 01.07.01.nn, 01.10.00.nn Spare parts list: B1.05.01.2.2107 Time requirement: 1 Pers./ 0,10 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: of the valve rotator every 150 h Attention: Heavy fuel operation:...
  • Page 175 Attention: The O-ring is used to adjust the lubricant quantity and must only be replaced by a new original MaK spare part. Clean the groove. Slightly oil the new O-ring and carefully insert the O-ring in the groove. The ring must not be twisted in mounting Fig.
  • Page 176 Replacement of the valve guide Note: If possible replace the valve guide in the workshop of a MaK dealer during the overhaul of cylinder head. There is a risk that the cylinder cover may be damaged when the old valve guide is knocked out.
  • Page 177 Attention: The O-ring is used to adjust the lubricant quantity and must only be replaced by a new original MaK spare part. Clean the groove. Slightly oil the new O-ring and carefully insert the O-ring in the groove. The ring must not be twisted in mounting Fig.
  • Page 178 Replacement of the valve guide Note: If possible replace the valve guide in the workshop of a MaK dealer during the overhaul of cylinder head. There is a risk that the cylinder cover may be damaged when the old valve guide is knocked out.
  • Page 179 Media line A5.05. 01.05.50.00 Maintenance / Disassembly and reassembly See also: Spare parts list: B1.05.01.2.2144 Time requirement: 1 Pers./ 0,25 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Safety note: Depressurize system before commencing work. Auxiliary material: soft green soap* * or product of equal standard...
  • Page 180 Media line A5.05. 01.05.50.00 Maintenance / Disassembly and reassembly Remove sleeves (4) from flanges (3a and 3b). Check O-rings (fig. 2/12) and, if necessary, insert new O-rings untwisted in the grooves using soft soap. Remove seals (11) and clean sealing surfaces. Assembly Mount sleeves (fig.
  • Page 181 Media line A5.05. 01.05.50.00 Maintenance / Disassembly and reassembly Cleaning of fuel leakage monitor Secure pipe (Z/5)! Disassemble pipe (5) with screwed socket (6) and sealing ring (7). Check that bore (Fig. 4/Y) is free and clean if necessary. Assemble pipe (Z/5) with screwed socket (6) and new sealing ring (7).
  • Page 182 Cylinder Head A5.05. 01.06.01.00 Maintenance / Disassembly See also: 01.02.01.nn, 02.06.01.nn, 06.01.01.nn Spare parts list: B1.05.01.2.2107 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Hydr. equipment set consisting of High-pressure pump 0.9204-D High-pressure hose (1 m)
  • Page 183 Cylinder Head A5.05. 01.06.01.00 Maintenance / Disassembly Disassemble lube oil line for the injection pump at the respective block piece of the medium guide and at the injection pump. Attention: Screw off pressure gage line from end flange (lube oil jet cooling) during disassembly of the last cylinder head at counter-coupling side.
  • Page 184 Cylinder Head A5.05. 01.06.01.00 Maintenance / Disassembly Loosen the four cylinder head screws together with the hydraulic tightening device. Attention: Max. lift of 5 mm must not be exceeded. Screw spacer (Fig. 2/W7) on cylinder head screw (11). Place bearing ring (W6) over round nut (12), thereby, make surethe slots (13) are easily accessible.
  • Page 185 Cylinder Head A5.05. 01.06.01.00 Maintenance / Disassembly Press hydraulic tensioning element (Fig. 3/W4) with pin (W8), by turningdown against the bearing ring (W6) onto block length (Valve [Z] at the high-pressure pump [W1] is open) and establish gap of 2.5 mm (approx.
  • Page 186 Nozzle Sleeve A5.05. 01.06.50.00 Maintenance / Disassembly and reassembly 15000 See also: 01.06.01.nn, 07.07.01.nn Spare parts list: B1.05.01.2.2107 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Change the O-rings every 15.000 h Tools: Pin spanner...
  • Page 187 Nozzle Sleeve A5.05. 01.06.50.00 Maintenance / Disassembly and reassembly 15000 Mount the nozzle sleeve Apply a film of green soft soap to the new black O-ring and insert it in the groove (4). Make sure the O-ring is not twisted. Apply a film of green soft soap to the new green O-ring and insert it in the groove (3).
  • Page 188 Inlet and Exhaust Valves A5.05. 01.07.01.00 Inspection / Disassembly and reassembly 15000, 30000 See also: 01.02.01.nn, 01.05.01.nn, 01.06.01.nn, 01.08.01.nn Spare parts list: B1.05.01.2.2107 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: of inlet and exhaust valves of one cylinder after 15,000 h Check contact reflections of the valves and coating.
  • Page 189 Inlet and Exhaust Valves A5.05. 01.07.01.00 Inspection / Disassembly and reassembly 15000, 30000 Remove valve spring compressor (Fig. 1/W1), spring plate (2), internal and external valve springs (3) as well as valve rotators of the inlet valves and the valve spring washers of the exhaust valves from the cylinder head.
  • Page 190 Inlet and Exhaust Valve Cones A5.05. 01.07.01.01 Inspection / Disassembly and reassembly 7500, 15000 See also: 01.02.01.nn, 01.05.01.nn, 01.06.01.nn, 01.08.01.nn Spare parts list: B1.05.01.2.2107 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: of inlet and exhaust valves of one cylinder after 7,500 h...
  • Page 191 Inlet and Exhaust Valve Cones A5.05. 01.07.01.01 Inspection / Disassembly and reassembly 7500, 15000 Remove valve spring compressor (Fig. 1/W1), spring plate (2), internal and external valve springs (3) as well as valve turning device from the cylinder cover. Extract valves from the cylinder head Note: Renew any valves which are heavily worn in the clamping area and any clamping cone halves which have large burrs.
  • Page 192 Valve Cones A5.05. 01.08.01.00 Repair / Checking See also: 01.07.01.nn, 01.08.02.nn Spare parts list: B1.05.01.2.2107 Time requirement: 0 Pers./ 0,00 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Valve refacer 2.9224-A Auxiliary material: Diamond paste Dp 30/10 - 15 µm * Thinner F25 *...
  • Page 193 Valve Cones A5.05. 01.08.01.00 Repair / Checking • when the deviation from the straightness is not greater than the following values (Fig. 1). Measuring range “s” = 200 mm = support points for test device • when the radial run-outs of the valve cones do not exceed the following values: 0,02 0,04 AB 0,02...
  • Page 194 If no such machine is available, the valves should be given to a MaK workshop for regrinding. Regrind valve cone faces in accordance with prescribed angle (Fig. 3). Do not refinish existing concave fillet.
  • Page 195 Valve Cones A5.05. 01.08.01.00 Repair / Checking Maintenance (check of contact reflection/grinding) Apply small dots of the diamond paste Dp 30/10 - 15 µm with a syringe to the valve seat of the new or refinished valve cone and distribute the paste uniformly (Fig.
  • Page 196 Valve Cones A5.05. 01.08.01.00 Repair / Checking When the contact reflection is poor, the valve must not be reground anymore, however, both sealing faces are to be refinished on a machine. Ensure, that the components (valve cone and seat ring) refaced to one another remain together.
  • Page 197 Inlet Valve Cones A5.05. 01.08.01.01 Repair / Checking See also: 01.07.01.nn, 01.08.02.nn Spare parts list: B1.05.01.2.2107 Time requirement: 0 Pers./ 0,00 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Valve refacer 2.9224-A Auxiliary material: Diamond paste Dp 30/10 - 15 µm *...
  • Page 198 Inlet Valve Cones A5.05. 01.08.01.01 Repair / Checking • when the deviation from the straightness is not greater than the following values (Fig. 1). Measuring range “s” = 200 mm = support points for test device • when the radial run-outs of the valve cones do not exceed the following values: 0,02 0,04 AB 0,02...
  • Page 199 If no such machine is available, the valves should be given to a MaK workshop for regrinding. Regrind valve cone faces in accordance with prescribed angle (Fig. 3). Do not refinish existing concave fillet.
  • Page 200 Inlet Valve Cones A5.05. 01.08.01.01 Repair / Checking Maintenance (check of contact reflection/grinding) Apply small dots of the diamond paste Dp 30/10 - 15 µm with a syringe to the valve seat of the new or refinished valve cone and distribute the paste uniformly (Fig.
  • Page 201 Inlet Valve Cones A5.05. 01.08.01.01 Repair / Checking When the contact reflection is poor, the valve must not be reground anymore, however, both sealing faces are to be refinished on a machine. Ensure, that the components (valve cone and seat ring) refaced to one another remain together.
  • Page 202 Exhaust Valve Cones A5.05. 01.08.01.02 Repair / Checking See also: 01.07.01.nn, 01.08.02.nn Spare parts list: B1.05.01.2.2107 Time requirement: 0 Pers./ 0,00 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Valve refacer 2.9224-A Auxiliary material: Diamond paste Dp 30/10 - 15 µm * Thinner F25 * * or a product of equal standard...
  • Page 203 Exhaust Valve Cones A5.05. 01.08.01.02 Repair / Checking • when the deviation from the straightness is not greater than the following values (Fig. 1). Measuring range “s” = 200 mm = support points for test device • when the radial run-outs of the valve cones do not exceed the following values: 0,02 0,04 AB 0,02...
  • Page 204 If no such machine is available, the valves should be given to a MaK workshop for regrinding. Regrind valve cone faces in accordance with prescribed angle (Fig. 3). Do not refinish existing concave fillet.
  • Page 205 Exhaust Valve Cones A5.05. 01.08.01.02 Repair / Checking Maintenance (check of contact reflection/grinding) Apply small dots of the diamond paste Dp 30/10 - 15 µm with a syringe to the valve seat of the new or refinished valve cone and distribute the paste uniformly (Fig.
  • Page 206 Exhaust Valve Cones A5.05. 01.08.01.02 Repair / Checking When the contact reflection is poor, the valve must not be reground anymore, however, both sealing faces are to be refinished on a machine. Ensure, that the components (valve cone and seat ring) refaced to one another remain together.
  • Page 207 Exhaust Valve Cones A5.05. 01.08.01.03 Repair / Checking See also: 01.07.01.nn, 01.08.02.nn Spare parts list: B1.05.01.2.2107 Time requirement: 0 Pers./ 0,00 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Valve refacer 2.9224-A Auxiliary material: Diamond paste Dp 30/10 - 15 µm * Thinner F25 * * or a product of equal standard...
  • Page 208 Exhaust Valve Cones A5.05. 01.08.01.03 Repair / Checking • when the deviation from the straightness is not greater than the following values (Fig. 1). Measuring range “s” = 200 mm = support points for test device • when the radial run-outs of the valve cones do not exceed the following values: 0,02 0,04 AB 0,02...
  • Page 209 If no such machine is available, the valves should be given to a MaK workshop for regrinding. Regrind valve cone faces in accordance with prescribed angle (Fig. 3). Do not refinish existing concave fillet.
  • Page 210 Exhaust Valve Cones A5.05. 01.08.01.03 Repair / Checking Maintenance (check of contact reflection/grinding) Apply small dots of the diamond paste Dp 30/10 - 15 µm with a syringe to the valve seat of the new or refinished valve cone and distribute the paste uniformly (Fig.
  • Page 211 Exhaust Valve Cones A5.05. 01.08.01.03 Repair / Checking When the contact reflection is poor, the valve must not be reground anymore, however, both sealing faces are to be refinished on a machine. Ensure, that the components (valve cone and seat ring) refaced to one another remain together.
  • Page 212 Inlet Valve Cones A5.05. 01.08.01.04 Repair / Checking See also: 01.07.01.nn, 01.08.02.nn Spare parts list: B1.05.01.2.2107 Time requirement: 0 Pers./ 0,00 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Valve refacer 2.9224-A Auxiliary material: Diamond paste Dp 30/10 - 15 µm *...
  • Page 213 Inlet Valve Cones A5.05. 01.08.01.04 Repair / Checking • when the deviation from the straightness is not greater than the following values (Fig. 1). Measuring range “s” = 200 mm = support points for test device • when the radial run-outs of the valve cones do not exceed the following values: 0,02 0,04 AB 0,02...
  • Page 214 If no such machine is available, the valves should be given to a MaK workshop for regrinding. Regrind valve cone faces in accordance with prescribed angle (Fig. 3). Do not refinish existing concave fillet.
  • Page 215 Inlet Valve Cones A5.05. 01.08.01.04 Repair / Checking Maintenance (check of contact reflection/grinding) Apply small dots of the diamond paste Dp 30/10 - 15 µm with a syringe to the valve seat of the new or refinished valve cone and distribute the paste uniformly (Fig.
  • Page 216 Inlet Valve Cones A5.05. 01.08.01.04 Repair / Checking When the contact reflection is poor, the valve must not be reground anymore, however, both sealing faces are to be refinished on a machine. Ensure, that the components (valve cone and seat ring) refaced to one another remain together.
  • Page 217 Valve Seat Ring A5.05. 01.08.02.00 Repair / Checking See also: 01.07.01.nn, 01.08.01.nn Spare parts list: B1.05.01.2.2107 Time requirement: 0 Pers./ 0,00 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Valve refacer W1 * 2.9222-A Valve seat milling machine...
  • Page 218 Valve Seat Ring A5.05. 01.08.02.00 Repair / Checking Fig. 2 Sequence of operations: Check of valve condition The hardness of the valve seats is designed in such a manner that a certain adaptability is present with regard to the valve face. Carbon deposits are therefore a normal indication and not hazardous if good cooling is present (Fig.
  • Page 219 Maintenance (refinishing the valve seat rings) Note: Refinishing is to be carried out with the MaK precision seat grinding machine (W1) in a workmanlike manner. Refer to special operating instructions. Alternatively the seats may be refinished by means of the MaK valve seat milling device (Fig.
  • Page 220 Valve Seat Ring A5.05. 01.08.02.00 Repair / Checking Place cutter head (Fig. 6/2) on greased 3.1.3 mandrel, screw in knurled thumb screw (1), until resistance becomes noticeable. 3.1.4 Rotate valve seat (clockwise) uniformly and slowly and remill the seat in one operation pass.
  • Page 221 Valve Seat Ring A5.05. 01.08.02.00 Repair / Checking If the milling cutters are blunt, the cutter head is to be sent to MaK for refinishing. 3.1.7 3.1.8 Dismount the milling device. Grind sharp edges with the fine emery cloth. Check of contact reflection/grinding Apply small dots of the diamond paste Dp 30/10 - 15 µm with a syringe to the valve seat of...
  • Page 222 Valve Seat Ring A5.05. 01.08.02.01 Repair / Checking See also: 01.07.01.nn, 01.08.01.nn Spare parts list: B1.05.01.2.2107 Time requirement: 0 Pers./ 0,00 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Valve refacer W1 * 2.9224 A Valve seat milling machine...
  • Page 223 Valve Seat Ring A5.05. 01.08.02.01 Repair / Checking Fig. 2 Sequence of operations: Check of valve condition The hardness of the valve seats is designed in such a manner that a certain adaptability is present with regard to the valve face. Carbon deposits are therefore a normal indication and not hazardous if good cooling is present (Fig.
  • Page 224 Maintenance (refinishing the valve seat rings) Note: Refinishing is to be carried out with the MaK precision seat grinding machine (W1) in a workmanlike manner. Refer to special operating instructions. Alternatively the seats may be refinished by means of the MaK valve seat milling device (Fig.
  • Page 225 Valve Seat Ring A5.05. 01.08.02.01 Repair / Checking Place cutter head (Fig. 6/2) on greased 3.1.3 mandrel, screw in knurled thumb screw (1), until resistance becomes noticeable. 3.1.4 Rotate valve seat (clockwise) uniformly and slowly and remill the seat in one operation pass.
  • Page 226 Valve Seat Ring A5.05. 01.08.02.01 Repair / Checking If the milling cutters are blunt, the cutter head is to be sent to MaK for refinishing. 3.1.7 3.1.8 Dismount the milling device. Grind sharp edges with the fine emery cloth. Check of contact reflection/grinding Apply small dots of the diamond paste Dp 30/10 - 15 µm with a syringe to the valve seat of...
  • Page 227 Cylinder Head A5.05. 01.10.00.00 Inspection / Checking See also: 01.03.01.nn, 01.06.01.nn, 01.11.01.nn, 07.07.01.nn Spare parts list: B1.05.01.2.2107 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: of the cylinder heads every 150 h Sequence of operations: Check the sealing between cylinder...
  • Page 228 Cylinder Head A5.05. 01.10.01.00 Maintenance / Cleaning 30000 See also: 01.02.01.nn, 01.06.01.nn, 01.07.01.nn, 07.07.01.nn Spare parts list: B1.05.01.2.2107 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Distillate fuel ---------------------------------------------------------------------------------------------------------------------- Note: Put the cylinder head down with its bottom part only on a wooden support. Sequence of operations: The following parts are disassembled: inlet-, exhaust-, injection valve, valve rocker brackets.
  • Page 229 Cylinder Head A5.05. 01.10.01.01 Maintenance / Cleaning 15000 See also: 01.02.01.nn, 01.06.01.nn, 01.07.01.nn, 07.07.01.nn Spare parts list: B1.05.01.2.2107 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel ---------------------------------------------------------------------------------------------------------------------- Note: Put the cylinder head down with its bottom part only on a wooden support. Sequence of operations: The following parts are disassembled: inlet-, exhaust-, injection valve, valve rocker brackets.
  • Page 230 Cylinder Head A5.05. 01.11.01.00 Repair / Reassembly See also: 01.01.01.nn, 01.02.01.nn, 01.06.01.nn, 02.06.01.nn, 07.07.01.nn Spare parts list: B1.05.01.2.2107 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. Auxiliary material: High-temperature thread paste “Dag S-5080”...
  • Page 231 Cylinder Head A5.05. 01.11.01.00 Repair / Reassembly Sequence of operations: Turn the piston to firing TDC. Clean sealing faces and contact surfaces of cylinder head and liner thoroughly and check for damage. Insert new sealing ring (Fig. 1/1) into cylinder liner collar. Renew the following O-rings: Top O-ring at the cylinder liner collar (X/2), at cylinder head (3), on pushrod passage (4), at the cooling water transition (Y/5) and at charge air intake nozzle (6).
  • Page 232 Cylinder Head A5.05. 01.11.01.00 Repair / Reassembly Note: Insert all O-rings with vaseline or green grease soap untwisted into grooves. Carefully place cylinder head with cylinder head lifting device (W9) and lifting gear onto cooling water distributor housing. Avoid jamming of cooling water transition on pushrod passage.Insert pushrods into cylinder head.
  • Page 233 Cylinder Head A5.05. 01.11.01.00 Repair / Reassembly Screw hydr. tensioning element (Fig. 2/W4) onto spacer (W7) and link with high-pressure pump (W1) via high-pressure hoses (Fig. 3/W2 and W3) distributor (W5). Fig. 3 Press hydraulic tensioning element (Fig. 2/W4) by means of pin (W8) by turning down against the bearing ring (W6) onto block length and tighten hand-tight (valve [Fig.
  • Page 234 Cylinder Head A5.05. 01.11.01.00 Repair / Reassembly Tighten screws for exhaust pipe on alternate sides in 2 stages with a torque of M = 60 and 110 Nm. Fit disassembled block pieces and/or flanges of the medium guide with new seals. Ensure correct fit of the dowel pin.
  • Page 235 Running Gear/Engine Timing A5.05. 02.01.01.00 Inspection / Checking 3750 See also: 03.01.01.nn, 04.08.01.nn Spare parts list: B1.05.03.2.1112 Time requirement: 1 Pers./ 0,50 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Note: Check the bearing temperature when the engine is still warm and the oil circulation has been interrupted.
  • Page 236 Crank Web Deflection A5.05. 02.02.01.00 Inspection / Measuring See also: Spare parts list: B1.05.02.2.2510, B1.05.03.2.1110 Time requirement: 2 Pers./ 1,00 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: In the following cases additional measurements have to be made: In the case of suspect or danger of foundation deformation, e.
  • Page 237 Crank Web Deflection A5.05. 02.02.01.00 Inspection / Measuring Sequence of operations: Bar crank pin from BDC in direction of exhaust side to such an extent that the dial gauge can be applied between the crank webs at the point farthest away from the crank pin and the connectiong rod just passes by the dial gauge (Fig.
  • Page 238 The values below must be observed, if it is impossible to obtain the admissible limits for the plant from MaK. Only the values measured on an engine at operating temperature has to be used for assessment.
  • Page 239 Crank Web Deflection A5.05. 02.02.01.00 Inspection / Measuring Operating hours Vessel Date Engine Type Engine no. Engineer/Service Station Indication of Dial Gauge down Engine cold press Shut down for hours Preheated Draft aft: Draft forward: Cylinder Measuring point = negative = positive en / 13.06.1997 IB001439...
  • Page 240 Bearing Shells A5.05. 02.03.07.01 Inspection / Evaluate See also: 02.05.01.nn Spare parts list: B1.05.03.2.1110 Time requirement: 0 Pers./ 0,00 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Note: Contaminated oil, solid foreign matters, water and tool deficiencies are the cause of 85 % of all cases of bearing damage.
  • Page 241 Bearing Shells A5.05. 02.03.07.01 Inspection / Evaluate Replacement Fig. 4 - The contact reflection shows the presence of heavy pressure on one bearing edge with scratches in the sliding surface made from aluminium alloy. This bearing shell is not reusable. The cause for this damage has to be determined and eliminated.
  • Page 242 Bearing Shells A5.05. 02.03.07.01 Inspection / Evaluate en / 13.06.1997 IB001449...
  • Page 243 Bearing Shells A5.05. 02.03.07.01 Inspection / Evaluate en / 13.06.1997 IB001449...
  • Page 244 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate See also: Spare parts list: B1.05.02.2.2601 Time requirement: 0 Pers./ 0,00 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Criteria for replacement of the grooved bearings The running surface of the bearings consists of approx.
  • Page 245 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate Should more than one of the conditions described appear together, the respectively lowest limits apply. Reuse possible Fig. 2 Condition: Geometrie of the groove is as new. The overlay inside the groove is intact. The dark points are predominantly embedded oil coke particles (Fig.
  • Page 246 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate Reuse possible Fig. 4 Condition: Small foreign particles spread over the entire running surface. No significant alteration of the aluminium allow ridges (Fig. 4). Assessment: Reuse of the bearing shell is possible, since foreign particles are embedded in the grooves. Fig.
  • Page 247 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate Wear Overlay-groove Bearing metal ridge Fig. 6 Condition: The bearing has in some places been worn down to such an extent that the bearing metal ridges and the overlay grooves have reached a ration of 1:1. The width of the bearing metal ridges has increased from 25 % (when new) to 50 %.
  • Page 248 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate Wear and levelling of the ridges (borderline case) Fig. 8 Condition: Bearing metal ridges are worn locally. Wear limits: Fig. 9 a) max. 20 % of width b) max. 5 % of circumference = Bearing metal ridges worn c) max.
  • Page 249 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate Overlay fatigue ruptures Fig. 10 Conditions: Rupture of electroplated overlay in the grooves as a result of overloading at certain points Wear limits: Fig. 11 a) max. 25 % of circumference = Overlay fatigue ruptures b) max.
  • Page 250 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate Overlay fatique ruptures and empty grooves Fig. 12 Condition: In certain areas empty grooves are visible after washing out the ruptured overlay. Wear limits: Fig. 13 a) max. 40 % of width b) max. 10 % of circumferende = Overlay fatique ruptures c) max.
  • Page 251 Big-End Bearings A5.05. 02.04.01.00 Inspection / Disassembly 15000, 30000 See also: 02.03.09.nn Spare parts list: B1.05.02.2.2601 Time requirement: 1 Pers./ 0,50 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: a) of a big-end bearing after 15,000 h b) exchange of all big-end bearings after 30,000 h...
  • Page 252 Big-End Bearings A5.05. 02.04.01.00 Inspection / Disassembly 15000, 30000 Tighten bolts 1 and 2 twice in the sequence 1 - 2 - 1 - 2 with a torque M = 160 Nm. Mark the bolt position or put on a tightening angle gauge Clamp the bolts tight in the sequence 3 - 4 - 1 - 2 with a torque...
  • Page 253 Big-End Bearings A5.05. 02.04.01.00 Inspection / Disassembly 15000, 30000 Removing the big-end bearing cap Turn crankshaft into a convenient position for removing (crankpin 20° before of TDC to the camshaft side). Loosen big-end bearing bolts and screw out off connecting-rod big end. Lift bearing cap out of the crankcase.
  • Page 254 Big-End Bearings A5.05. 02.04.01.00 Inspection / Disassembly 15000, 30000 See also: 02.03.09.nn Spare parts list: B1.05.02.2.2601 Time requirement: 1 Pers./ 0,50 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: a) of a big-end bearing after 15,000 h b) exchange of all big-end bearings after 30,000 h...
  • Page 255 Big-End Bearings A5.05. 02.04.01.00 Inspection / Disassembly 15000, 30000 Tighten bolts 1 and 2 twice in the sequence 1 - 2 - 1 - 2 with a torque M = 160 Nm. Mark the bolt position or put on a tightening angle gauge Clamp the bolts tight in the sequence 3 - 4 - 1 - 2 with a torque...
  • Page 256 Big-End Bearings A5.05. 02.04.01.00 Inspection / Disassembly 15000, 30000 Removing the big-end bearing cap Turn crankshaft into a convenient position for removing (crankpin 20° before of TDC to the camshaft side). Loosen big-end bearing bolts and screw out off connecting-rod big end. Lift bearing cap out of the crankcase.
  • Page 257 Big-End Bearings A5.05. 02.04.01.01 Inspection / Disassembly 15000, 30000 See also: 02.03.09.nn Spare parts list: B1.05.02.2.2601 Time requirement: 1 Pers./ 0,50 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: a) of a big-end bearing after 15,000 h b) exchange of all big-end bearings after 30,000 h...
  • Page 258 Big-End Bearings A5.05. 02.04.01.01 Inspection / Disassembly 15000, 30000 Tighten bolts 1 and 2 twice in the sequence 1 - 2 - 1 - 2 with a torque M = 160 Nm. Mark the bolt position or put on a tightening angle gauge Clamp the bolts tight in the sequence 3 - 4 - 1 - 2 with a torque...
  • Page 259 Big-End Bearings A5.05. 02.04.01.01 Inspection / Disassembly 15000, 30000 Removing the big-end bearing cap Turn crankshaft into a convenient position for removing (crankpin 20° before of TDC to the camshaft side). Loosen big-end bearing bolts and screw out off connecting-rod big end. Lift bearing cap out of the crankcase.
  • Page 260 Big-End Bearings A5.05. 02.04.02.00 Inspection / Reassembly See also: 02.04.01.nn Spare parts list: B1.05.02.2.2601 Time requirement: 1 Pers./ 0,50 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 60 - 420 Nm 3/4" W1 * 1.9454-60 Clamp...
  • Page 261 Big-End Bearings A5.05. 02.04.02.00 Inspection / Reassembly Hold the bearing shells in this position and shift the clamp (Fig. 2/W2) over the shells so that the lower dog of the clamp engages in the oil hole of the bottom shell. The dog of the screw (Fig.
  • Page 262 Big-End Bearings A5.05. 02.04.02.00 Inspection / Reassembly Tightening the big-end bolts. Measuring the gap (02.04.01.nn, sequence of operations 1) is only required if new shells are fitted or the gap was not measured on disaassembly. Tighten the lower bolts 3 and 4 with a torque M = 160 Nm.
  • Page 263 Big-End Bearings A5.05. 02.04.02.00 Inspection / Reassembly Tightening check 3.7.1 Upper bolts 1 and 2: The maximum pointer must have been pulled beyond the angle marking. When checking without gage, the bolts must have turned through an angle of 13° - 16°. Lower bolts 3 and 4: The maximum pointer must have passed the angle marking or the 3.7.2 bolts must have turned through 17°...
  • Page 264 Main Bearings A5.05. 02.05.01.00 Inspection / Disassembly 15000, 30000 See also: 02.03.07.nn Spare parts list: B1.05.03.2.1110 Time requirement: 2 Pers./ 1,00 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: a) of one main bearing bearing after 15,000 h Cylinder...
  • Page 265 Main Bearings A5.05. 02.05.01.00 Inspection / Disassembly 15000, 30000 Note: The bearing caps and bearing shells are marked continuously on the camshaft side starting from the clutch side according to which cylinder they belong and must not be exchanged. New parts are to be marked correspondingly. Even within the prescribed interval, the main bearings are to be removed, checked and measured if: Substructure deformations and/or crank web deflection changes after crashes appear and/...
  • Page 266 Main Bearings A5.05. 02.05.01.00 Inspection / Disassembly 15000, 30000 Loosen bearing bolts with hydraulic tightening equipment. Remove hexagon screws (Fig. 2/11) of the main bearing which is to be removed. 1.3.1 1.3.2 Place bearing ring (W1) over the round nut (12) and turn hydraulic tensioning element (W2) on bearing bolt (13) and screw against bearing ring.
  • Page 267 Main Bearings A5.05. 02.05.01.00 Inspection / Disassembly 15000, 30000 Measure clearance. Remove hexagon screws (Fig. 4/11) of 1.4.1 the respective main bearing on exhaust and camshaft side. 1.4.2 Hydraulically loosen both round nuts (12) in accordance with sequence of operations 1.3. 1.4.3 Relieve hydr.
  • Page 268 Main Bearings A5.05. 02.05.01.00 Inspection / Disassembly 15000, 30000 Insert dog (Fig. 6/W7) into oil bore of the crankshaft and twist out top bearing shell to the exhaust side. Check AL-groove bearings in accordance with rating criteria 02.03.09.nn. 1.10 In the case of 2-material bearings, check wearing of the wall-thickness in the main load region at check points (Fig.
  • Page 269 Main Bearings A5.05. 02.05.01.01 Inspection / Disassembly 15000, 30000 See also: 02.03.07.nn Spare parts list: B1.05.03.2.1110 Time requirement: 2 Pers./ 1,00 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: a) of one main bearing bearing after 15,000 h Cylinder Bearing...
  • Page 270 Main Bearings A5.05. 02.05.01.01 Inspection / Disassembly 15000, 30000 Note: The bearing caps and bearing shells are marked continuously on the camshaft side starting from the clutch side according to which cylinder they belong and must not be exchanged. New parts are to be marked correspondingly. Even within the prescribed interval, the main bearings are to be removed, checked and measured if: Substructure deformations and/or crank web deflection changes after crashes appear and/...
  • Page 271 Main Bearings A5.05. 02.05.01.01 Inspection / Disassembly 15000, 30000 Loosen bearing bolts with hydraulic tightening equipment. Remove hexagon screws (Fig. 2/11) of the main bearing which is to be removed. 1.3.1 1.3.2 Place bearing ring (W1) over the round nut (12) and turn hydraulic tensioning element (W2) on bearing bolt (13) and screw against bearing ring.
  • Page 272 Main Bearings A5.05. 02.05.01.01 Inspection / Disassembly 15000, 30000 Measure clearance. Remove hexagon screws (Fig. 4/11) of 1.4.1 the respective main bearing on exhaust and camshaft side. 1.4.2 Hydraulically loosen both round nuts (12) in accordance with sequence of operations 1.3. 1.4.3 Relieve hydr.
  • Page 273 Main Bearings A5.05. 02.05.01.01 Inspection / Disassembly 15000, 30000 Insert dog (Fig. 6/W7) into oil bore of the crankshaft and twist out top bearing shell to the exhaust side. Check AL-groove bearings in accordance with rating criteria 02.03.09.nn. 1.10 In the case of 2-material bearings, check wearing of the wall-thickness in the main load region at check points (Fig.
  • Page 274 Main Bearings A5.05. 02.05.02.00 Maintenance / Reassembly See also: 02.05.01.nn Spare parts list: B1.05.03.2.1110 Time requirement: 2 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 100 - 750 Nm W9 * 1.9454-100 Further tools see job chart 02.05.01.nn.
  • Page 275 Main Bearings A5.05. 02.05.02.00 Maintenance / Reassembly Lubricate working face of the top bearing shell well, wipe bearing back dry and press bearing shell into the bearing so far that the dog (Fig. 1/W7) can be inserted into the oil bore of the crankshaft.
  • Page 276 Main Bearings A5.05. 02.05.02.00 Maintenance / Reassembly Coat threads and contact surfaces of the hexagon screws (Fig. 3/11) with Molykote paste “G-Rapid Plus” and tighten on alternate sides in 3 stages with torque wrench (W9) with torque 1st stage: M = 100 Nm 2nd stage: M = 300 Nm 3rd stage:...
  • Page 277 Main Bearings A5.05. 02.05.02.00 Maintenance / Reassembly Attention: The pressure must remain constant if the pump is not activated. Otherwise tightening errors occur. Firmly tighten round nuts (1) uniformly with pin (W5). Inspection: Lower pressure by 50 bar. Round nuts (1) should no longer be able to be loosened by hand. Lower pressure at valve (Z) and remove hydraulic tightening equipment.
  • Page 278 Piston A5.05. 02.06.01.01 Maintenance / Disassembly See also: 01.06.01.nn, 02.04.01.nn, 02.07.01.nn Spare parts list: B1.05.02.2.2601 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Dismounting device, calibrating ring 2.9216 B consisting of: liner support W1.1...
  • Page 279 Piston A5.05. 02.06.01.01 Maintenance / Disassembly Attention: The sealing surfaces of the cylinder liner have to be protected against damage! Fill the ring gap between piston (3)and cylinder liner (4) with grease. Carefully scrape off and completely remove carbon deposits in the liner (4) ) between TDC of the first piston ring and the lower edge of the calibrating ring (5).
  • Page 280 Piston A5.05. 02.06.01.01 Maintenance / Disassembly Screw the ring bolt (Fig. 2 / W2)into the piston . Mount the crane to the ring bolt (W2). Slowly pull out the piston; carefully in- sert con-rod foot into the liner and re- move big-end bearing shells.
  • Page 281 Piston A5.05. 02.06.01.02 Maintenance / Disassembly See also: 01.06.01.nn, 02.04.01.nn, 02.07.01.nn Spare parts list: B1.05.02.2.2601 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Sleeve support 2.9216-103 Eye screw M12 1.9080-012 Turning rod 2.9100-380...
  • Page 282 Piston A5.05. 02.06.01.02 Maintenance / Disassembly Procedure: Turn the crank pin with the turning rod (W3) approx. 20°in front of the top section to the control side. Remove the cylinder head (01.06.01.nn) Place a used sealing ring (1) as sealing surface protection on the cylinder sleeve (4). Position sleeve supports (W1) on the used sealing ring (1) as shown in the drawing.
  • Page 283 Piston A5.05. 02.06.01.02 Maintenance / Disassembly Attention: Make sure that the calibration ring is drawn out smoothly when removing the piston. If the calibration ring becomes tilted, lower the piston and align the calibration ring. The connecting rod must not strike the crank pin; if necessary turn the crank pin to the side.
  • Page 284 Piston Rings and Grooves A5.05. 02.07.01.01 Inspection / Checking 7500, 30000 See also: 01.06.01.nn, 02.04.01.nn, 02.06.01.nn Spare parts list: B1.05.02.2.2617 Time requirement: 1 Pers./ 0,50 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: of one piston and its rings after 7,500 h Maintenance: of all pistons and their rings after...
  • Page 285 Measure the groove width h (Fig. 2) in the front area of the groove in longitudinal and transverse directions of the engine. When exceeding the limits, have the ring grooves reconditioned by MaK. 1.10 Measure the ring thickness h (Fig. 2) at 4 different points.
  • Page 286 Piston Rings and Grooves A5.05. 02.07.01.01 Inspection / Checking 7500, 30000 1.11 Determine the clearance by calculation and check it against the table. Ring thicknes h Groove width h Limit of h Groove Nominal Wear limit 1 – 3 4.95 0.65 1.12 Fit piston rings with the marking facing...
  • Page 287 Piston Rings and Grooves A5.05. 02.07.01.02 Inspection / Checking 7500, 30000 See also: 01.06.01.nn, 02.04.01.nn, 02.06.01.nn Spare parts list: B1.05.02.2.2617 Time requirement: 1 Pers./ 0,50 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: of one piston and its rings after 7,500 h Maintenance: of all pistons and their rings after...
  • Page 288 Measure the groove width h (Fig. 2) in the front area of the groove in longitudinal and transverse directions of the engine. When exceeding the limits, have the ring grooves reconditioned by MaK. 1.10 Measure the ring thickness h (Fig. 2) at 4 different points.
  • Page 289 Piston Rings and Grooves A5.05. 02.07.01.02 Inspection / Checking 7500, 30000 1.11 Determine the clearance by calculation and check it against the table. Ring thicknes h Groove width h Limit of h Groove Nominal Wear limit 1 – 2 4.95 0.65 1.12 Fit piston rings with the marking facing...
  • Page 290 Piston Rings and Grooves A5.05. 02.07.01.03 Inspection / Checking 7500, 30000 See also: 01.06.01.nn, 02.04.01.nn, 02.06.01.nn Spare parts list: B1.05.02.2.2617 Time requirement: 1 Pers./ 0,50 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: of one piston and its rings after 7,500 h Maintenance: of all pistons and their rings after...
  • Page 291 Measure the groove width h (Fig. 2) in the front area of the groove in longitudinal and transverse directions of the engine. When exceeding the limits, have the ring grooves reconditioned by MaK. 1.10 Measure the ring thickness h (Fig. 2) at 4 different points.
  • Page 292 Piston Rings and Grooves A5.05. 02.07.01.03 Inspection / Checking 7500, 30000 1.11 Determine the clearance by calculation and check it against the table. Ring thicknes h Groove width h Limit of h Groove Nominal Wear limit 1 – 2 4.95 0.65 1.12 Fit piston rings with the marking facing...
  • Page 293 Piston A5.05. 02.10.01.01 Maintenance / Reassembly See also: 02.04.02.nn, 02.07.01.nn Spare parts list: B1.05.02.2.2601 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Mounting/extraction device for pistons 1.9080-012 Cylinder liner holder 2.9217 A Piston assembly ring 2.9220 B...
  • Page 294 Piston A5.05. 02.10.01.01 Maintenance / Reassembly Slacken the tightening screw (fig. 1/10) until the piston insertion device (W4) has been relieved and can be guided freely over the piston rings. Apply Molykote paste "G-Rapid Plus" to the thread and contact surface of the tightening screw (10).
  • Page 295 Piston A5.05. 02.10.01.01 Maintenance / Reassembly If it has been removed, mount the cylinder liner holder (fig. 3/W2) on the cylinder liner (2). Only screw the hexagon socket screw finger (5) tight against the cylinder crankcase (4). Dismantle the piston insertion device (fig.
  • Page 296 Crankcase Explosion Relief Valves A5.05. 03.01.01.00 Inspection / Checking M20/M282/M332C/M452/M453C/M551/M552C 1500 See also: 02.01.01.nn Spare parts list: B1.05.03.n.1633 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: Check the freedom of movement of the relief valves.
  • Page 297 Zylinderbuchse A5.05. 03.03.01.02 Inspection / Measuring 15000, 30000 See also: 02.06.01.nn Spare parts list: B1.05.03.2.1611 Time requirement: 1 Pers./ 0,50 h Personnel qualification: Chief engineer, skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: Of one cylinder liner after 15,000 h Of all cylinder liners...
  • Page 298 (fig. 3/4; TDC, first ring) or other limit values indicate in the table are reached, then the cylinder liner must be replaced. Reconditioning of the cylinder liners is only possible by Caterpillar / MaK. Cylinder liner wear chart Evaluation criteria Wear limit Explanation (mm) Radius r ≥...
  • Page 299 Cylinder Liner A5.05. 03.04.01.00 Maintenance / Disassembly 30000 See also: 01.06.01.nn, 02.06.01.nn Spare parts list: B1.05.03.2.1110 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Removal of cylinder liners and changing O-rings after 30,000 h Tools: Device for mounting and extracting the...
  • Page 300 Cylinder Liner A5.05. 03.04.02.00 Maintenance / Reassembly See also: 03.04.01.nn Spare parts list: B1.05.03.2.1110 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Device for mounting and extracting the 2.9216-A cylinder liners Auxiliary material:...
  • Page 301 Cylinder Liner A5.05. 03.04.02.00 Maintenance / Reassembly The cylinder liner must slide into the fitting of the cylinder block and crankcase (Fig. 1/5) through its own weight. Note: Insert the cylinder liner in such a way, that the markings (11) (Fig. 2/X, top view liner collar) point in longitudinal direction to the coupling side.
  • Page 302 Check the foundation bolts by knocking. Measure the crank web deflection after tightening slack foundation bolts (02.02.01.nn). Consult MaK aftersales service for tightening values. Check the elastic bearing elements for damages. en / 13.06.1997 IB001402...
  • Page 303 Camshaft A5.05. 04.04.01.00 Repair / Disassembly and reassembly See also: 01.01.01.nn, 01.02.01.nn Spare parts list: B1.05.04.2.3120 Time requirement: 2 Pers./ 2,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Camshaft - mounting device 2.9230-A Locking screw Torque wrench 40 - 180 Nm...
  • Page 304 Camshaft A5.05. 04.04.01.00 Repair / Disassembly and reassembly Turn the camshaft to highest cam elevation (TDC). Remove and fasten the rocker (Fig. 2/1) of the corresponding injection pump drives with locking screws from injection cams (W2). Assemble the camshaft - mounting device (Fig.
  • Page 305 Camshaft A5.05. 04.04.01.00 Repair / Disassembly and reassembly Attention: Do not cant camshaft piece in the camshaft bearings during removal. Handle with utmost caution. Danger of destruction of the bearings. Assembly Note: The camshaft flange (Fig. 4/31) of every piece is pinned according to the cylinder and position in accordance with the firing order (32) and provided with a flange index (33) (see table).
  • Page 306 Camshaft A5.05. 04.04.01.01 Repair / Disassembly and reassembly See also: 01.01.01.nn, 01.02.01.nn Spare parts list: B1.05.04.2.3120 Time requirement: 2 Pers./ 2,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Camshaft - mounting device 2.9230-A Locking screw Torque wrench 40 - 180 Nm...
  • Page 307 Camshaft A5.05. 04.04.01.01 Repair / Disassembly and reassembly Turn the camshaft to highest cam elevation (TDC). Remove and fasten the rocker (Fig. 2/1) of the corresponding injection pump drives with locking screws from injection cams (W2). Assemble the camshaft - mounting device (Fig.
  • Page 308 Camshaft A5.05. 04.04.01.01 Repair / Disassembly and reassembly Attention: Do not cant camshaft piece in the camshaft bearings during removal. Handle with utmost caution. Danger of destruction of the bearings. Assembly Note: The camshaft flange (Fig. 4/31) of every piece is pinned according to the cylinder and position in accordance with the firing order (32) and provided with a flange index (33) (see table).
  • Page 309 Camshaft A5.05. 04.04.01.02 Repair / Disassembly and reassembly See also: 01.01.01.nn, 01.02.01.nn Spare parts list: B1.05.04.2.3120 Time requirement: 2 Pers./ 2,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Camshaft - mounting device 2.9230-A Locking screw Torque wrench 40 - 180 Nm...
  • Page 310 Camshaft A5.05. 04.04.01.02 Repair / Disassembly and reassembly Turn the camshaft to highest cam elevation (TDC). Remove and fasten the rocker (Fig. 2/1) of the corresponding injection pump drives with locking screws from injection cams (W2). Assemble the camshaft - mounting device (Fig.
  • Page 311 Camshaft A5.05. 04.04.01.02 Repair / Disassembly and reassembly Attention: Do not cant camshaft piece in the camshaft bearings during removal. Handle with utmost caution. Danger of destruction of the bearings. Assembly Note: The camshaft flange (Fig. 4/31) of every piece is pinned according to the cylinder and position in accordance with the firing order (32) and provided with a flange index (33) (see table).
  • Page 312 Timing Gear Train A5.05. 04.08.01.00 Inspection / Checking 3750 See also: Spare parts list: B1.05.04.2.5140 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: Working surfaces of the teeth 3,750 h Sequence of operation: Remove the covers at the gear housing...
  • Page 313 Governor Drive A5.05. 04.08.03.00 Inspection / Disassembly and reassembly 15000 See also: Spare parts list: B1.05.04.2.4111 Time requirement: 1 Pers./ 2,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: Contact reflection at helical gear wheels every 15,000 h Tools:...
  • Page 314 Governor Drive A5.05. 04.08.03.00 Inspection / Disassembly and reassembly 15000 Loosen and remove the cover (Fig. 2/11) at the gear housing, taking care of the dowel pin (12). Check the oil lubricating hole. Loosen the hexagon screws at the helical gear wheel (13) and remove the helical gear wheel (13) from the camshaft gear (14).
  • Page 315 Governor Drive A5.05. 04.08.03.00 Inspection / Disassembly and reassembly 15000 Reassembly The reassembly is to be carried out in reverse order. Grease the governor drive shaft (Fig. 2/17) and slide it into the cylinder block and crankcase with washer (21) from above. Slide the helical gear wheel (18) with the conical spring washer (16) onto the governor drive shaft (17) and tighten and secure it with a castellated nut (15).
  • Page 316 Vibration damper on camshaft A5.05. 04.09.01.00 Repair / Disassembly and reassembly 15000 See also: Spare parts list: B1.05.04.2.3140 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: 20 - 90 Nm 1/2" torque wrench W1 * 1.9454-020 12mm Allan key insert...
  • Page 317 Vibration damper on camshaft A5.05. 04.09.01.01 Repair / Disassembly and reassembly 15000 See also: Spare parts list: B1.05.04.2.3140 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: 20 - 90 Nm 1/2" torque wrench W1 * 1.9454-020 12mm Allan key insert...
  • Page 318 Vibration Damper on Camshaft A5.05. 04.09.01.02 Repair / Disassembly and reassembly 15000 See also: Spare parts list: B1.05.04.2.3140 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 20 - 90 Nm 1/2" W1 * 1.9454-020 Hex cap screw drive A/F12...
  • Page 319 Vibration Damper on Camshaft A5.05. 04.09.01.02 Repair / Disassembly and reassembly 15000 Reassembly Clean contact faces of dampers (1and 2), washers (4 and 5) and cover disk (6). Check bores (9) of cover disk (6) and bore (8) of washer (5) for free flow and clean, if neces- sary.
  • Page 320 Control shaft bedding A5.05. 05.01.02.00 Maintenance / Checking 1500 See also: Spare parts list: B1.05.04.2.4110, B1.05.05.2.4210, B1.05.05.2.4521, B1.05.05.2.4523 Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Oil control shaft after 1.200 h Auxiliary material:...
  • Page 321 Fuel Limiter A5.05. 05.04.01.00 Inspection / Adjust M20/M282/M332C/M452/M453C/M551/M552C 3750 See also: 05.04.02.nn Spare parts list: B1.05.05.1.4337 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: of fuel limiter every...
  • Page 322 Fuel Limiter A5.05. 05.04.01.00 Inspection / Adjust M20/M282/M332C/M452/M453C/M551/M552C 3750 Check whether the piston follows the charge air pressure change continuously and without hesitation. Overhaul the fuel limiter if piston operation is not satisfactory. Piston travel = 26 mm If the exhaust gas becomes black turn adjusting screw (2) 1 to 1.5 turns clockwise to increase the spring load.
  • Page 323 Fuel Limiter A5.05. 05.04.01.01 Inspection / Adjust 3750 See also: 05.04.02.nn Spare parts list: B1.05.05.1.4337 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: of fuel limiter every 3,750 h Note: This unit limits the fuel injection depending on the carge air pressure so as to avoid a smoky exhaust.
  • Page 324 Fuel Limiter A5.05. 05.04.01.01 Inspection / Adjust 3750 Check whether the piston follows the charge air pressure change continuously and without hesitation. Overhaul the fuel limiter if piston operation is not satisfactory. Piston travel = 26 mm If the exhaust gas becomes black turn adjusting screw (2) 1 to 1.5 turns clockwise to increase the spring load.
  • Page 325 Servo-Actuator A5.05. 05.04.02.00 Maintenance / Disassembly and reassembly M20/M282/M332C/M452/M453C/M551/M552C See also: 05.04.01.nn Spare parts list: B1.05.05.1.4337 Time requirement: 1 Pers./ 2,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Auxiliary material: Liquid seal “Loctite 221” *...
  • Page 326 Servo-Actuator A5.05. 05.04.02.01 Maintenance / Disassembly and reassembly See also: 05.04.01.nn Spare parts list: B1.05.05.1.4337 Time requirement: 1 Pers./ 2,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Auxiliary material: Liquid seal “Loctite 221” * * or a product of equal standard Attention: Note:The fuel limiter must not be removed when there is pressure on the lubricating oil...
  • Page 327 Starting Fuel Limiter A5.05. 05.05.01.00 Inspection / Disassembly and reassembly M20-M601C 3750 See also: Spare parts list: B1.05.05.1.4337 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 20 - 90 Nm W1 * 1.9454-020...
  • Page 328 Starting Fuel Limiter A5.05. 05.05.01.00 Inspection / Disassembly and reassembly M20-M601C 3750 Check whether full fuel is admitted within 15 seconds after starting the engine. Adjust by throttle screw (Fig. 1/10). Venting Slip a transparent hose over vent screw (12) and put the other end into a an oil reservoir arranged at a lower level.
  • Page 329 Starting Fuel Limiter A5.05. 05.05.01.00 Inspection / Disassembly and reassembly M20-M601C 3750 Reassembly Renew all gaskets and seals (Fig. 2/1 - 9). Assemble the unit observing the following: 4.2.1 Tighten the socket head cap screws (17) with a torque M = 20 Nm.
  • Page 330 After four years carry out a random test of the low pressure valves. In case of deficiencies recondition all control valves. Special grease for all control units see MaK Lubricant Recommendations in A4.05.08.nn The use of other lubricants may have a detrimental effect on the functioning of the fittings.
  • Page 331 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...
  • Page 332 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.
  • Page 333 Exhaust Manifold A5.05. 06.01.01.00 Maintenance / Disassembly and reassembly 7500, 30000 See also: Spare parts list: B1.05.06.2.72n0 Time requirement: 1 Pers./ 3,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: Exhaust manifolds must be examined for leakages after 7,500 h Maintenance: Remove and clean exhaust manifold after...
  • Page 334 Exhaust Manifold A5.05. 06.01.01.00 Maintenance / Disassembly and reassembly 7500, 30000 Note: Soot and soot deposits indicate a leak of the system. Renew the gaskets if no cracks in the pipes or slack bolts are the cause of the leak. Replace expansion joints that have cracks in the bellows.
  • Page 335 Charge Air Cooler A5.05. 06.04.02.00 Maintenance / Disassembly and reassembly See also: Spare parts list: B1.05.06.2.7280 Time requirement: 2 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: The charge air cooler is to be disassembled and cleaned at the air side if the differential pressure before/after radiator reaches more than 1.5 times test bed value (see acceptance brake certificate A1.10).
  • Page 336 Charge Air Cooler A5.05. 06.04.02.00 Maintenance / Disassembly and reassembly Safety note: Observe regulations of the manufacturer for cleansing agent to be used, protect skin against contact with cleansing agent, wear safety glasses. Ensure good ventilation. Reassembly Carry out reassembly in reverse order to disassembly. Note: Ensure proper fit of the sealing plates in the housing.
  • Page 337 Charge Air Cooler A5.05. 06.04.02.01 Maintenance / Disassembly and reassembly See also: Spare parts list: B1.05.06.2.7240 Time requirement: 2 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: The charge air cooler is to be disassembled and cleaned at the air side if the differential pressure before/after radiator reaches more than 1.5 times test bed value (see acceptance brake certificate A1.10).
  • Page 338 Charge Air Cooler A5.05. 06.04.02.01 Maintenance / Disassembly and reassembly Safety note: Observe regulations of the manufacturer for cleansing agent to be used, protect skin against contact with cleansing agent, wear safety glasses. Ensure good ventilation. Reassembly Carry out reassembly in reverse order to disassembly. Note: Ensure proper fit of the sealing plates in the housing.
  • Page 339 Charge Air Cooler A5.05. 06.04.02.02 Maintenance / Disassembly and reassembly See also: Spare parts list: B1.05.06.2.7240 Time requirement: 2 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: The charge air cooler is to be disassembled and cleaned on the air side, if the differential pressure upstream/downstream cooler exceeds 1.5 times the test bed value (see accep- tance test record A1.10).
  • Page 340 Charge Air Cooler A5.05. 06.04.02.02 Maintenance / Disassembly and reassembly Safety note: Strictly observe the supplier’s handling instructions for the used cleaning agent! Protect your skin against contact with the cleaning agent, wear rubber gloves, safety glasses and evtl. respiratory mask! Ensure good ventilation! Reassembly Renew all gaskets Grease hexagon screws (1,2 and 3) with Molykote paste „G-Rapid Plus“.
  • Page 341 Charge Air Cooler A5.05. 06.04.02.03 Maintenance / Disassembly and reassembly See also: Spare parts list: B1.05.06.2.7240 Time requirement: 2 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: The charge air cooler is to be disassembled and cleaned on the air side, if the differential pressure upstream/downstream cooler exceeds 1.5 times the test bed value (see accep- tance test record A1.10).
  • Page 342 Charge Air Cooler A5.05. 06.04.02.03 Maintenance / Disassembly and reassembly Safety note: Strictly observe the supplier’s handling instructions for the used cleaning agent! Protect your skin against contact with the cleaning agent, wear rubber gloves, safety glasses and evtl. respiratory mask! Ensure good ventilation! Reassembly Renew all gaskets Grease hexagon screws (1,2 and 3) with Molykote paste „G-Rapid Plus“.
  • Page 343 Turbocharger A5.05. 06.05.00.01 Maintenance / Cleaning 24, 300 See also: 06.13.01.nn Spare parts list: B1.05.06.2.725n Time requirement: 0 Pers./ 0,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: a) Washing of the compressor every 24 h b) Wash of the turbine every 300 h...
  • Page 344 Turbocharger A5.05. 06.05.00.02 Maintenance / Cleaning See also: Spare parts list: B1.05.06.2.725n Time requirement: 0 Pers./ 0,00 h Personnel qualification: skilled engine hand Operating medium: Distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: The maintenance of the turbocharger is always to be carried out according to the “maintenance, repair and spare part documents”...
  • Page 345 Turbo Charger Sound Absorber A5.05. 06.05.01.00 Inspection / Cleaning 7500 See also: Spare parts list: B1.05.06.2.725n Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Distillate fuel ---------------------------------------------------------------------------------------------------------------------- Inspection: Check the sound absorber of the turbo charger (perforated plate) for dirt accumulation every 7,500 operating hours.
  • Page 346 Turbocharger A5.05. 06.13.01.00 Maintenance / Cleaning See also: Spare parts list: B1.05.06.n.7259 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Cleaning of the turbocharger every 300 h Note: Particulary if the engine is running on the heavy fuel, deposits will form on the turbine blades decreasing the charger efficiency and increasing the bearing loads by unbalance.
  • Page 347 Turbocharger A5.05. 06.13.01.00 Maintenance / Cleaning Close stop valves and corner valves and remove hose clip (Fig. 1/1). Run the turbocharger dry with a written engine load approx. 30 min., then increase engine load slowly. Note: Repeat washing procedure if vibrations and sounds appear at the turbocharger which were previously not present.
  • Page 348 Turbocharger A5.05. 06.13.01.01 Maintenance / Cleaning See also: Spare parts list: B1.05.06.n.7259 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Cleaning of the turbocharger every 300 h Note: Particulary if the engine is running on the heavy fuel, deposits will form on the turbine blades decreasing the charger efficiency and increasing the bearing loads by unbalance.
  • Page 349 Turbocharger A5.05. 06.13.01.01 Maintenance / Cleaning Close stop valves and corner valves and remove hose clip (1). Run the turbocharger dry with a written engine load approx. 30 min., then increase engine load slowly. Note: Repeat washing procedure if vibrations and sounds appear at the turbocharger which were previously not present.
  • Page 350 Turbocharger A5.05. 06.13.01.02 Maintenance / Cleaning See also: Spare parts list: B1.05.06.n.7259 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Cleaning of the turbocharger every 300 h Note: Particulary if the engine is running on the heavy fuel, deposits will form on the turbine blades decreasing the charger efficiency and increasing the bearing loads by unbalance.
  • Page 351 Turbocharger A5.05. 06.13.01.02 Maintenance / Cleaning Close stop valves and corner valves and remove hose clip (1). Run the turbocharger dry with a written engine load approx. 30 min., then increase engine load slowly. Note: Repeat washing procedure if vibrations and sounds appear at the turbocharger which were previously not present.
  • Page 352 Turbocharger A5.05. 06.13.01.03 Maintenance / Cleaning See also: Spare parts list: B1.05.06.n.7259 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Cleaning of the turbocharger every 300 h Note: Particulary if the engine is running on the heavy fuel, deposits will form on the turbine blades decreasing the charger efficiency and increasing the bearing loads by unbalance.
  • Page 353 Turbocharger A5.05. 06.13.01.03 Maintenance / Cleaning Close stop valves and corner valves and remove hose clip (1). Run the turbocharger dry with a written engine load approx. 30 min., then increase engine load slowly. Note: Repeat washing procedure if vibrations and sounds appear at the turbocharger which were previously not present.
  • Page 354 Turbocharger A5.05. 06.13.01.04 Maintenance / Cleaning See also: Spare parts list: B1.05.06.n.7259 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Cleaning of the turbocharger every 300 h Note: Particulary if the engine is running on the heavy fuel, deposits will form on the turbine blades decreasing the charger efficiency and increasing the bearing loads by unbalance.
  • Page 355 Turbocharger A5.05. 06.13.01.04 Maintenance / Cleaning Close stop valves and corner valves and remove hose clip (1). Run the turbocharger dry with a written engine load approx. 30 min., then increase engine load slowly. Note: Repeat washing procedure if vibrations and sounds appear at the turbocharger which were previously not present.
  • Page 356 Turbocharger A5.05. 06.13.01.05 Maintenance / Cleaning See also: Spare parts list: B1.05.06.n.7259 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Cleaning of the turbocharger every 300 h Note: Particulary if the engine is running on the heavy fuel, deposits will form on the turbine blades decreasing the charger efficiency and increasing the bearing loads by unbalance.
  • Page 357 Turbocharger A5.05. 06.13.01.05 Maintenance / Cleaning Close stop valves and corner valves and remove hose clip (1). Run the turbocharger dry with a written engine load approx. 30 min., then increase engine load slowly. Note: Repeat washing procedure if vibrations and sounds appear at the turbocharger which were previously not present.
  • Page 358 Abgasturbolader A5.05. 06.13.01.06 Maintenance / Cleaning See also: Spare parts list: B1.05.06.n.7259 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Cleaning of the turbocharger every 300 h Note: Particularly if the engine is running on heavy fuel, deposits will settle down on the turbine blades decreasing the charger efficiency and increasing the bearing loads by unbalance.
  • Page 359 Abgasturbolader A5.05. 06.13.01.06 Maintenance / Cleaning Open corner valves (Fig.1/4) and stop valve (3) and set water pressure on pressure gauge (5) to 1,2 - 1,5 bar Duration of washing: 5 minutes Attention: Check drain valve (Fig. 2/4) and pipe (2) during the washing process perma- nently for free passage.
  • Page 360 Abgasturbolader A5.05. 06.13.01.07 Maintenance / Cleaning See also: Spare parts list: B1.05.06.n.7259 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Cleaning of the turbocharger every 300 h Note: Particularly if the engine is running on heavy fuel, deposits will settle down on the turbine blades decreasing the charger efficiency and increasing the bearing loads by unbalance.
  • Page 361 Abgasturbolader A5.05. 06.13.01.07 Maintenance / Cleaning Open corner valves (Fig.1/4) and stop valve (3) and set water pressure on pressure gauge (5) to 1,2 - 1,5 bar Duration of washing: 5 minutes Attention: Check drain valve (Fig. 2/4) and pipe (2) during the washing process perma- nently for free passage.
  • Page 362 Turbocharger A5.05. 06.13.01.08 Maintenance / Cleaning See also: Spare parts list: B1.05.06.n.7259 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Cleaning of the turbocharger every 300 h Note: Particularly if the engine is running on heavy fuel, deposits will settle down on the turbine blades decreasing the charger efficiency and increasing the bearing loads by unbalance.
  • Page 363 Turbocharger A5.05. 06.13.01.08 Maintenance / Cleaning Open corner valve (Fig.1/4) and stop valve (3) and set water pressure on pressure gauge (5) to 1,2 - 1,5 bar Duration of washing: 5 minutes Attention: Check drain valve (Fig. 2/4) and pipe (2) during the washing process perma- nently for free passage.
  • Page 364 Injection Pump A5.05. 07.02.01.00 Repair / Disassembly and reassembly See also: Spare parts list: B1.05.07.2.3580 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 40 - 180 Nm W1 * 1.9454-40 * not available as figure...
  • Page 365 Injection Pump A5.05. 07.02.01.00 Repair / Disassembly and reassembly Disconnect connection of the injection pump control rack (Fig. 1/2) to the regulating shaft and slide control rack completely into the injection pump. Disconnect holder for stop cylinder (3) at the injection pump. Loosen thrust screws (Fig.
  • Page 366 Injection Pump A5.05. 07.02.01.00 Repair / Disassembly and reassembly Renew O-ring (Fig. 3/22) at the injection pump and at the distributor housing of the fuel collecting pipe and place the injection pump over the fastening screws. Lubricate threads and contact surfaces of nuts (Fig. 2/14) with Molykote paste “G-Rapid Plus”...
  • Page 367 Injection Pump A5.05. 07.02.01.01 Repair / Disassembly and reassembly See also: A5.05.07.15.01.nn Spare parts list: B1.05.04.2.3580 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 40 - 180 Nm W1 * 1.9454-40 * not available as figure...
  • Page 368 Injection Pump A5.05. 07.02.01.01 Repair / Disassembly and reassembly Disconnect connection of the injection pump control rack (Fig. 1/2) to the regulating shaft and slide control rack completely into the injection pump. Disconnect holder for stop cylinder (3) at the injection pump. Loosen thrust screws (Fig.
  • Page 369 Injection Pump A5.05. 07.02.01.01 Repair / Disassembly and reassembly Replace the O-rings on the lower spring plate (Fig. 3/22) and the connections for the fuel manifold and collector (24). Place the injection pump above the fastening screws. Lubricate threads and contact surfaces of nuts (Fig. 2/14) with Molykote paste “G-Rapid Plus”...
  • Page 370 Injection Pump A5.05. 07.03.01.00 Maintenance / Disassembly and reassembly See also: Spare parts list: B1.05.07.2.3597 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Disassemble injection pump if required, clean all parts and replace if necessary. Observe note! Tools: Torque wrench 20 - 90 Nm 1/2"...
  • Page 371 Injection Pump A5.05. 07.03.01.00 Maintenance / Disassembly and reassembly Safety note: Caution spring tension! Loosen fillister head screws (Fig. 1/4) uniformly. Remove injection pump bottom part (3) with lower spring seat from injection pump housing (5). Take care of fixing pin.
  • Page 372 Injection Pump A5.05. 07.03.01.00 Maintenance / Disassembly and reassembly Note: Insert O-rings with vaseline untwisted into slots, do not pull across sharp edges of the components. During visual inspection pay special attention to the following wear phenomena: • plunger, scores marks on the running surface. Control helix worn by cavitation or erosion •...
  • Page 373 Injection Pump A5.05. 07.03.01.01 Maintenance / Disassembly and reassembly See also: Spare parts list: B1.05.07.2.3597 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Disassemble injection pump if required, clean all parts and replace if necessary. Observe note! Tools: Torque wrench 20 - 90 Nm 1/2"...
  • Page 374 Injection Pump A5.05. 07.03.01.01 Maintenance / Disassembly and reassembly Safety note: Caution spring tension! Loosen fillister head screws (Fig. 1/4) uniformly. Remove injection pump bottom part (3) with lower spring seat from injection pump housing (5). Take care of fixing pin.
  • Page 375 Injection Pump A5.05. 07.03.01.01 Maintenance / Disassembly and reassembly Note: Insert O-rings with vaseline untwisted into slots, do not pull across sharp edges of the components. During visual inspection pay special attention to the following wear phenomena: • plunger, scores marks on the running surface. Control helix worn by cavitation or erosion •...
  • Page 376 Injection Pump A5.05. 07.03.01.02 Maintenance / Disassembly and reassembly See also: Spare parts list: B1.05.07.2.3597 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Disassemble injection pump if required, clean all parts and replace if necessary. Observe note! Tools: Torque wrench 20 - 90 Nm 1/2"...
  • Page 377 Injection Pump A5.05. 07.03.01.02 Maintenance / Disassembly and reassembly Safety note: Caution spring tension! Loosen fillister head screws (Fig. 2/32) uniformly. Remove injection pump bottom part (33) with lower spring seat from injec- tion pump housing (Fig. 1/5). Take care of fixing pin.
  • Page 378 Injection Pump A5.05. 07.03.01.02 Maintenance / Disassembly and reassembly 1.10 Dismantle the fuel outlet throttle screw (Fig.2/30) and the fuel inlet throttle screw (31). 1.11 Clean all parts with gas oil and a hard brush and blow through with compressed air. Check lube oil bores for free passage.
  • Page 379 Injection Pump A5.05. 07.03.01.02 Maintenance / Disassembly and reassembly Reassembly The reassembly is carried out in reverse order to the disassembly procedure. Attention: During reassembly see that the barrel is locked and that the marking of control rack - control sleeve and control sleeve - plunger coincide. Grease contact surfaces between constant pressure release (Fig.
  • Page 380 Fuel Injector A5.05. 07.07.01.00 Maintenance / Disassembly and reassembly See also: 07.08.01.nn Spare parts list: B1.05.01.2.2107, B1.05.07.2.2267 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Removal tool for fuel injector 2.9122-A Auxiliary material: Molykote paste “G-Rapid Plus”...
  • Page 381 (07.08.01 nn). 1.10 Renew the soft iron sealing ring (17) and all of the O-rings (18). Attention: Only use original MaK spare parts. Reassembly Apply a thin film of Molykote paste on the threads of gudgeons (Fig. 2/11), O-rings.
  • Page 382 Fuel Injector A5.05. 07.07.01.00 Maintenance / Disassembly and reassembly Tighteen the thrust bolts (1 and 2) manually in alternating order, becauce of tapered seat of the transverse thrust piece (3) on the injection pump. First tighten thrust bolt (2) and then thrust bolt (1) with a torque of M = 85 Nm.
  • Page 383 Fuel Injector A5.05. 07.08.01.00 Maintenance / Adjust See also: 07.07.01.nn, 07.09.01.nn Spare parts list: B1.05.07.2.2267 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Nozzle tester 1.9470 B Adapter/Nozzle holder - nozzle tester 2.9208 A Pressure pipe 1.9470-51...
  • Page 384 Fuel Injector A5.05. 07.08.01.00 Maintenance / Adjust Sequence of operations: Remove carbon deposits from the nozzle with a hard brush (no wire brush). Check the nozzle holes for sharp edges, ovalization, corrosion and damage. Place the injector with adapter (Fig. 1/ W2) in the nozzle tester (W1) and con- nect the pressure pipe (W3).
  • Page 385 Fuel Injector A5.05. 07.09.01.00 Repair / Disassembly and reassembly See also: 07.07.01.nn, 07.08.01.nn Spare parts list: B1.05.07.2.2267 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 60 - 420 Nm W1 * 1.9454-60 * not available as figure...
  • Page 386 Fuel Injector A5.05. 07.09.01.00 Repair / Disassembly and reassembly Sequence of operations: Disassembly Loosen nut (Fig. 1/1) and relieve pressure spring (2) by unscrewing setting spindle (3). Loosen and screw off nozzle nut (4) by turning to the left. Remove nozzle element (5) with needle, without damaging the lapped surfaces or coming into contact with the fingers.
  • Page 387 Einspritzventil A5.05. 07.09.01.01 Repair / Disassembly and reassembly 7500 See also: 07.07.01.nn, 07.08.01.nn Spare parts list: B1.05.07.2.2267 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 388 Einspritzventil A5.05. 07.09.01.01 Repair / Disassembly and reassembly 7500 Sequence of operations: Disassembly Loosen nut (Fig. 1/1) and relieve pressure spring (2) by unscrewing setting spindle (3). Loosen and screw off nozzle nut (4) by turning to the left. Remove nozzle element (5) with needle, without damaging the lapped surfaces or coming into contact with the fingers.
  • Page 389 Duplex Fuel Filter A5.05. 07.12.01.00 Maintenance / Cleaning See also: Spare parts list: B1.05.07.2.7667 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 Auxiliary material: Cleaning fluid “Filterclean” from Vecom * * or a product of equal standard Note: Operation and maintenance of the filter have to be carried out with utmost care to avoid...
  • Page 390 Duplex Fuel Filter A5.05. 07.12.01.00 Maintenance / Cleaning Safety note: Depressurize chamber! Open the sludge drain and let the fuel run out. Loosen self-locking nut (Fig. 1/2) on tie rod (3) and lift out strainers (X) one by one. Place the individual strainers into containers with cleansing agent and clean them with a soft brush.
  • Page 391 Duplex Fuel Filter A5.05. 07.12.01.00 Maintenance / Cleaning 2.11 Inspect the gauze of all strainers on the inside and outside for damage and replace if required. Attention: The individual strainers are connected in parallel, and damage on only one filter element means malfunction of the entire element.
  • Page 392 Duplex Fuel Preliminary Filter A5.05. 07.12.02.02 Maintenance / Cleaning M20/M32/M282/M332C/M452/M453C/M551/M552C/M601/M601C See also: Spare parts list: B1.05.07.1.7668 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Cleaning of the filter every...
  • Page 393 Duplex Fuel Preliminary Filter A5.05. 07.12.02.02 Maintenance / Cleaning M20/M32/M282/M332C/M452/M453C/M551/M552C/M601/M601C Put the filter element in a suitable cleansing liquid (e. g. “Filterclean” from Vecom). The cleansing liquid must only reach up to the bottom edge of the top frame of the filter element so that no contaminated liquid can enter into the clean space of the element.
  • Page 394 Duplex Fuel Preliminary Filter A5.05. 07.12.02.04 Maintenance / Cleaning M20-M601C See also: Spare parts list: B1.05.07.1.7668 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: Cleaning of the filter every...
  • Page 395 Duplex Fuel Preliminary Filter A5.05. 07.12.02.04 Maintenance / Cleaning M20-M601C Sequence of operations: Cleaning Change over to operable filter chamber. Open the vent screw (1) of the filter chamber which has been cut off in order to vent the system.
  • Page 396 Fuel Feed Pump A5.05. 07.13.01.00 Maintenance / Disassembly and reassembly 15000 See also: Spare parts list: B1.05.07.2.6480 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: The fuel feed pump is to be disassembled every 15,000 hours of operation and the drive checked for wear.
  • Page 397 Fuel Feed Pump A5.05. 07.13.01.00 Maintenance / Disassembly and reassembly 15000 Check tooth profiles for wear (pittings, crooked running, breakage). Remove circlip (Fig. 2/13) and pull drive shaft (5) with deep groove ball bearings (14 and 15) to the toothed wheel side out of the drive housing (2).
  • Page 398 Fuel Feed Pump A5.05. 07.13.01.00 Maintenance / Disassembly and reassembly 15000 Inspect contact reflection between toothed wheel cone and drive shaft cone by spot- grinding. A uniformly distributed contact reflection must be offset to the thicker end. Heat up toothed wheel (Fig. 1/3) to approx. 150 °C and fit onto the corresponding drive shaft cone up to stop (conical surfaces of the cones free from grease and dry) and immediately lubricate thread and contact surface of the hexagon screw (4) and washer with Molykote paste “G-Rapid Plus”...
  • Page 399 Fuel Distributor Line/Manifold Line A5.05. 07.15.01.00 Repair / Disassembly and reassembly See also: Spare parts list: B1.05.07.2.8510 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 20 - 90 Nm W1 * 1.9454-20 * not available as figure...
  • Page 400 Fuel Distributor Line/Manifold Line A5.05. 07.15.01.00 Repair / Disassembly and reassembly Reassembly Clean faces at distributor housing (3). Insert new O-rings (5). Check bore (6) in equalizer for passage. Insert and reassemble equalizer (4) in distributor housing (3). Insert screws (1) with Molykote paste “G-Rapid Plus”...
  • Page 401 Fuel / Fuel collector rail A5.05. 07.15.01.01 Repair / Disassembly and reassembly See also: A5.05.07.02.01.nn Spare parts list: B1.05.07.2.8510 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Helpful resource: Green soft soap** ** or a similar quality product Sequence of work:...
  • Page 402 Fuel / Fuel collector rail A5.05. 07.15.01.01 Repair / Disassembly and reassembly Assembly Insert new O-rings (4) with green soft soap in both injection pumps. Push fuel pipe ends into the fuel pump without retaining rings until they stop. Assemble fuel pump (3). Push fuel pipes (2) into fuel pump (3) until they stop.
  • Page 403 Lubricating Oil System A5.05. 08.02.01.00 Maintenance / Oil change See also: A4.05.08.nn, A5.05.08.04.01.nn Spare parts list: B1.05.08.2.64n0, B1.05.08.2.7810 Time requirement: 1 Pers./ 2,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Note: The strainer on the suction side of the lubricating oil pumps must be checked and cleaned, if necessary, 24 to 48 hours of operation after the start- up of a new installation or working on the suction side of the lubricating oil piping system.
  • Page 404 Lubricating Oil System A5.05. 08.02.01.00 Maintenance / Oil change Refill new lubricating oil up to the respective mark on the sump tank (lubricating oil quality, see A4.05.08.nn). Refill lubricating oil system and start the stand-by pump. en / 20.09.1995 IB001483...
  • Page 405 Lube Oil Pump A5.05. 08.03.01.00 Inspection / Checking 15000 See also: 08.03.02.nn Spare parts list: B1.05.08.1.6417 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Control: Check safety valve for function every 15,000 hours of operation. Sequence of operations: Screw off valve cover (Fig.
  • Page 406 Lube Oil Pump A5.05. 08.03.02.00 Maintenance / Disassembly and reassembly See also: 08.03.01.nn Spare parts list: B1.05.08.1.6417 Time requirement: 0 Pers./ 0,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Auxiliary material: Molykote paste “G-Rapid Plus” * Silicon sealing compound “Dirco Gray”...
  • Page 407 Maintenance / Disassembly and reassembly Check the bearing bushes (Fig. 2/15 and 16), driving wheel shaft ends and impeller axle ends for wear and renew them if required with original MaK spare parts. Note: Undercool new bushes before the installation.
  • Page 408 Lubricating Oil Duplex Filter A5.05. 08.04.01.00 Maintenance / Cleaning See also: Spare parts list: B1.05.08.2.7657 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 liquid “Filterclean”...
  • Page 409 Lubricating Oil Duplex Filter A5.05. 08.04.01.00 Maintenance / Cleaning Filter cleaning with mounted filter candles. Safety note: Depressurize the filter chamber! 2.2.1 Remove the cover from the filter chamber that has been cut out. Open the sludge drain and drain the contaminated liquid.
  • Page 410 Lubricating Oil Duplex Filter A5.05. 08.04.01.00 Maintenance / Cleaning Put the filter element in a suitable cleansing liquid. The cleansing liquid must only reach up 2.3.4 to the bottom edge of the element plate (Fig. 3/2) so that no contaminated liquid can enter into the filter candles (14) from the top.
  • Page 411 Lubricating Oil Duplex Filter A5.05. 08.04.01.00 Maintenance / Cleaning 2.4.6 Introduce the pistol into the cartridge, pull the trigger and move down to the bottom of each filter candles. 2.4.7 Remove sticking dirt with a soft brush. Note: If possible, clean the filter elements from the ouside with a high-pressure cleaner. Working pressure of the high-pressure cleaner max.
  • Page 412 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...
  • Page 413 Centrifugal Cooling Water Pump A5.05. 09.07.01.00 Maintenance / Disassembly and reassembly 15000 See also: Spare parts list: B1.05.09.2.6437 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: The centrifugal cooling water pump is to be removed and checked for wear every 15,000 hours of operation.
  • Page 414 Centrifugal Cooling Water Pump A5.05. 09.07.01.00 Maintenance / Disassembly and reassembly 15000 Loosen the hexagon screws (Fig. 2/18) and remove the housing cover (12) from the bearing carrier (19). 1.10 Loosen flat head screw (28). 1.11 Remove cover (26) with sealing ring (27). 1.12 Remove “Nilos“...
  • Page 415 Centrifugal Cooling Water Pump A5.05. 09.07.01.00 Maintenance / Disassembly and reassembly 15000 Before mounting the gear wheel (2) (Fig. 1/X), check contact reflection between gear wheel cone and shaft cone by spot-grinding. A uniformly distributed contact reflection must be offset to the thicker end. Heat up the gear wheel (2) to approx.
  • Page 416 Centrifugal Cooling Water Pump A5.05. 09.07.01.01 Maintenance / Disassembly and reassembly 15000 See also: Spare parts list: B1.05.09.2.6437 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: The centrifugal cooling water pump is to be removed and checked for wear every 15,000 hours of operation.
  • Page 417 Centrifugal Cooling Water Pump A5.05. 09.07.01.01 Maintenance / Disassembly and reassembly 15000 Loosen the hexagon screws (Fig. 2/18) and remove the housing cover (12) from the bearing carrier (19). 1.10 Loosen flat head screw (28). 1.11 Remove cover (26) with sealing ring (27). 1.12 Remove circlip (21) and “Nilos“...
  • Page 418 Centrifugal Cooling Water Pump A5.05. 09.07.01.01 Maintenance / Disassembly and reassembly 15000 Fig. 2 Before mounting the gear wheel (2) (Fig. 1/X), check contact reflection between gear wheel cone and shaft cone by spot-grinding. A uniformly distributed contact reflection must be offset to the thicker end.
  • Page 419 Centrifugal Cooling Water Pump A5.05. 09.07.01.02 Maintenance / Disassembly and reassembly 15000 Sehr geehrter Kunde! Zum Zeitpunkt der Auslieferung war dieses Dokument leider nicht verfügbar bzw. in der geforderten Sprache nicht lieferbar. Sie bekommen das entsprechende Dokument in Kürze nachgeliefert. Dear customers ! At the time of delivery this document was unfortunatly not available / not available in the required language.
  • Page 420 Pressure Switches A5.05. 11.01.02.01 Inspection / Adjust M20-M601C 3750 See also: Spare parts list: B1.05.11.9.4843 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 421 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).
  • Page 422 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 423 Pressure Switches A5.05. 11.01.03.00 Inspection / Adjust 3750 See also: Spare parts list: B1.05.11.2.4842 Time requirement: 1 Pers./ 0,50 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Tools: Adjusting device, electric measuring instrument Inspection: Check the set operating values of the pressure switch every 3,750 operation hours.
  • Page 424 Pressure Switches A5.05. 11.01.03.00 Inspection / Adjust 3750 Pneumatic connection (Fig. 2) Fig. 2 10 Compressed air flange > 16 bar 11 Pressure reducer 12 Stop valve 13 One-way restrictor 14 Volume 1 l 15 Precision manometer 16 Pressure switch Electric connection (Fig.
  • Page 425 Pressure Switches A5.05. 11.01.03.00 Inspection / Adjust 3750 Correction of setting Note: In case of deviations from the set value (see measuring point list in Book C) correct the setting in accordance with sequence of operations 3. Pressure switch is set in the case of falling pressure.
  • Page 426 RPM Switch A5.05. 11.05.01.01 Inspection / Adjust M20/M25/M32/M453C/M552C 7500 See also: 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.
  • Page 427 RPM Switch A5.05. 11.05.01.01 Inspection / Adjust M20/M25/M32/M453C/M552C 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.
  • Page 428 Lubricating Oil/Cooling Water Thermostat A5.05. 11.06.01.00 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 and functional check of the thermostatic...
  • Page 429 Lubricating Oil/Cooling Water Thermostat A5.05. 11.06.01.00 Maintenance / Checking M20-M601C 7500 Check lower seat and sealing faces of thermostatic element for damage. Wipe clean thermostat housing with a lint-free rag and check for corrosion and deposits. Check upper plate for erosion.
  • Page 430 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,...
  • Page 431 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).
  • Page 432 Crankcase Monitoring Device A5.05. 11.09.01.03 Inspection / Checking M20/M25/M32/M43/M453C/M552C/M601C 750, 1500, 7500 See also: Spare parts list: B1.05.11.1.4877 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...
  • Page 433 Vibration Damper A5.05. 12.04.01.03 Maintenance / Disassembly and reassembly 30000 See also: Spare parts list: B1.05.12.1.6347 Time requirement: 0 Pers./ 0,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel ---------------------------------------------------------------------------------------------------------------------- Maintenance: every 30,000 h Auxiliary material: Molykote paste “G-Rapid Plus”...
  • Page 434 Vibration Damper A5.05. 12.04.01.03 Maintenance / Disassembly and reassembly 30000 Telescope out spring assemblies (Fig. 1/9). 1.4.2 • Inspect springs for grooves and cracks. • If individual springs show grooves or are broken, replace spring assembly (9) completely. Clean the vibration damper thoroughly, check oil bores for free passage with wire. Inspect the flywheel rim (7) on carrier (8) for easy turning.
  • Page 435 Table of contents A6.01 Tools Table of contents A6.01 en / 31.10.2001 AA020050...
  • Page 436 Werkzeug-Zusammenstellung Summary of tools Sommaira d`outillage Somario de las herramientas Lista de ferramentas Verktory-oversikt M 20...
  • Page 437 Zylinderkopf A6.05.01 Cylinder head Benennung Stück Werkzeug-Nr. Bild Tool-No. Description Figur Qty.
  • Page 438 Zylinderkopf A6.05.01 Cylinder head Benennung Stück Werkzeug-Nr. Bild Tool-No. Description Figur Qty.
  • Page 439 Zylinderkopf A6.05.01 Cylinder head Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur...
  • Page 440 Zylinderkopf A6.05.01 Cylinder head Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur...
  • Page 441 Zylinderkopf A6.05.01 Cylinder head Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur...
  • Page 442 Triebwerk A6.05.02 Running gear Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur 1x 2.9180-001 1x 2.9180-002...
  • Page 443 Triebwerk A6.05.02 Running gear Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur...
  • Page 444 Triebwerk A6.05.02 Running gear Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur...
  • Page 445 Motorgehäuse A6.05.03 Motor casing Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur...
  • Page 446 Motorgehäuse A6.05.03 Motor casing Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur 1x 2.9214-022 1x 2.9214-011 2x 2.9216-001 1x 2.9216-002...
  • Page 447 Abgasanlage/Aufladung A6.05.06 Exhaust system/supercharging Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur...
  • Page 448 Kraftstoffsystem A6.05.07 Fuel system Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur 1x 2.9208-002 1x 2.9208-001...
  • Page 449 Kraftstoffsystem A6.05.07 Fuel system Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur 1x 1.9124-001 1.9124-025...
  • Page 450 Kraftstoffsystem A6.05.07 Fuel system Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur 1x 1.9470-040 1x 1.9470-030 1x 1.9470-051 1x 1.9470-010 1x 1.9470-020...
  • Page 451 Schmierölsystem A6.05.08 Lubricating oil system Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur...
  • Page 452 Zusatzinstallation A6.05.13 Additional installation Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur...
  • Page 453 Zusatzinstallation A6.05.13 Additional installation Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur...
  • Page 454 DIN-Werkzeuge A6.05.19 DIN Standard Tools Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur...
  • Page 455 DIN-Werkzeuge A6.05.19 DIN Standard Tools Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur...
  • Page 456 DIN-Werkzeuge A6.05.19 DIN Standard Tools Benennung Stück Werkzeug-Nr. Bild Description Qty. Tool-No. Figur...

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