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MAK M 20 Maintenance Manual

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Maintenance
A0
Maintenance
M 20 / M 20 C
en / 26.01.2011
AA047781
1/1

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  • Page 1 Maintenance Maintenance M 20 / M 20 C en / 26.01.2011 AA047781...

  • Page 2: Total Index

    Total Index A0.01 Maintenance Total Index A0.01 Introduction A0.02 Emergency Stop Safety System A0.04 Maintenance Table of Contents A5.01 Introduction A5.02 en / 26.01.2011 AA047652...
  • Page 3 Introduction A0.02 M20/M25/M32/M43 The present operating instructions include notes and guidelines for proper handling of the engine plant. It is matched with the equipment condition and the type of fuel sold. Since the type of fuel used considerably influences the service life of the components, the Caterpillar 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 docu- mentation.
  • Page 4 Emergency Stop A0.04 Safety System M20/M25/M32/M43 WARNING Do not perform further starting attempts for a while after the safety/emergency stop device has triggered! Note and observe the following points and actions. If these actions are not observed, severe personal injuries as well as damage to the engine can occur, which may void the warranty.
  • Page 5 Emergency Stop A0.04 Safety System M20/M25/M32/M43 NOTE The following checks may be of assistance during troubleshooting and permit identi- fication of root causes of an emergency stop. However, they cannot cover the entire spectrum of possible causes. Overspeed condition Emergency stop due to excessive rpm. How high was the maximum rpm before emergency stop was triggered? Why did engine go into an overspeed condition? Check:...
  • Page 6 Pressurize each cylinder through opened indexing valves with shop air. If there is a rapid pressure drop or if no pressure builds up the cause must be investigated. Contact the Caterpillar/ MaK Service. Engine room monitoring Emergency Stop due to excessive oil mist concentrationsee engine documentation, chap- ter "Operating Instructions".

  • Page 7: Exhaust Gas

    Emergency Stop A0.04 Safety System M20/M25/M32/M43 Exhaust gas Emergency stop due to excessively high exhaust temperature Checks: • Check exhaust gas temperature sensors. • Aftercooler (differential pressure) (refer to A5.05.06.04.02.nn). • Fuel pumps and fill level scale on each fuel pump. •...
  • Page 8 Emergency Stop A0.04 Safety System M20/M25/M32/M43 Fault messages and measuring points CAUTION The fault messages listed below do not directly lead to an emergency stop, but they considerably affect reliable engine operation. If such a fault message appears on the monitoring display of the alarm system, the engine plant may only be operated for a short time and under permanent observati- At any rate, the cause of the fault message must be remedied immediately.
  • Page 9 Maintenance Maintenance en / 26.01.2011 AA000026...
  • Page 10 Table of Contents A5.01 Maintenance Table of Contents A5.01 Introduction A5.02 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 clearance A5.05.01.01.01.02 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 A5.05.01.05.01.01...
  • Page 11 Table of Contents A5.01 Piston A5.05.02.06.01.02 Piston Rings and Grooves A5.05.02.07.01.01 Piston Rings and Grooves A5.05.02.07.01.03 Piston A5.05.02.10.01.01 Engine, housing A5.05.03 Crankcase Explosion Relief Valves A5.05.03.01.01.00 Explosion Relief Valve A5.05.03.01.01.02 Explosion relief valve A5.05.03.01.01.03 Zylinderbuchse A5.05.03.03.01.02 Cylinder Liner A5.05.03.04.01.00 Cylinder Liner A5.05.03.04.02.00 Engine Bolting and Unions A5.05.03.07.01.00...
  • Page 12 Table of Contents A5.01 Engine, exhaust gas system/supercharging A5.05.06 Exhaust Manifold A5.05.06.01.01.00 Exhaust Manifold A5.05.06.01.01.01 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 Charge Air Cooler A5.05.06.04.02.04 Exhaust gas turbocharger A5.05.06.05.00.01 Exhaust gas turbocharger A5.05.06.05.01.01 Exhaust gas turbocharger A5.05.06.05.01.02...
  • Page 13 Table of Contents A5.01 Fuel Injector A5.05.07.08.01.01 Fuel Injector A5.05.07.08.01.02 Fuel Injector A5.05.07.09.01.00 Fuel Injector A5.05.07.09.01.01 Duplex Fuel Filter A5.05.07.12.01.00 Duplex Fuel Preliminary Filter A5.05.07.12.02.02 Duplex Fuel Preliminary Filter A5.05.07.12.02.04 Fuel Feed Pump A5.05.07.13.01.00 Fuel Distributor Line/Manifold Line A5.05.07.15.01.00 Fuel / Fuel collector rail A5.05.07.15.01.01 Engine, lubricating oil system A5.05.08...
  • Page 14 Introduction A5.02 M20/M25/M32/M43 General It is assumed that the engine room personnel has the necessary knowledge and experi- ence required for the proper maintenance and servicing of diesel engines. For this rea- son and in the interest of clearness we did not go too much into details in the maintenance documents.

  • Page 15: Maintenance System

    Introduction A5.02 M20/M25/M32/M43 Therefore the present interval schedule shall not be considered stringent in the long run, but it is left to the user to modify the maintenance schedule in accordance with own experiences. But in any case a sufficient safety margin - even if the mean wearing levels are well- known - is to be calculated in order to cover the always occurring variations.
  • Page 16 Introduction A5.02 M20/M25/M32/M43 2.2.1 Work interval schedule The work interval schedule shall provide for a quick summary of all intended inspection, maintenance and repair work occurring up to 90,000 operating hours. The interval schedule is subdivided into the following four areas: •...

  • Page 17: Job Cards

    Introduction A5.02 M20/M25/M32/M43 2.2.2 Job cards The job cards are instructions for inspection, maintenance, repair and safety chec ¬ Title of the job card Activity Maintenance work Discharge valve A5.05.01.04.01.03 Inspection / Dismounting and mounting Operating hours/maintenance deadline M20/M25/M32/M43 6,000 / 12,000 Engine type Register Main maintenance group...
  • Page 18 Introduction A5.02 M20/M25/M32/M43 • The first pair of digits indicates the engine main maintenance group: Cylinder head Lube oil system Driving mechanism Cooling water system Engine housing Starting air system Engine control Monitors Regulation Auxiliary generator sets and tools Exhaust gas system/ Additional installation supercharging Fuel system...
  • Page 19 Introduction A5.02 M20/M25/M32/M43 • Under the designation "tools (W)" only special and additional tools are listed with the 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 20: Safety Instructions

    Introduction A5.02 M20/M25/M32/M43 Safety instructions Safety symbols In the present operating instructions the following warning notices are used: DANGER A warning notice of this risk level signals the threat of a dangerous situation. If the dangerous situation is not prevented, it will lead to death or serious injury. Follow the instructions in this warning notice to prevent the risk of death or serious injury to persons.
  • Page 21 Introduction A5.02 M20/M25/M32/M43 CAUTION A warning notice of this risk level signals possible damage to property. If the situation is not prevented, this could lead to damage to property. Follow the instructions in this warning notice to prevent damage to property. NOTE A note identifies additional information that facilitates the handling of the engine.

  • Page 22: General Safety Instructions

    Introduction A5.02 M20/M25/M32/M43 General safety instructions Our engine is equipped with a monitoring system and an emergency stop system to prevent da- mage caused to the operators' health as well as damages to the engine. Within the scope of commissioning all mechanical, electric and pneumatic equipment and sy- stems allowing the engine to be stopped for safety reasons will be demonstrated and explained by our commissioning personnel.
  • Page 23 Introduction A5.02 M20/M25/M32/M43 WARNING Keep all handles, steps, handrails, platforms, ladders free from dirt, e.g. oil, grease, fuel! Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity! Never work or stand under suspended loads! During replacement work, individual parts and large assemblies are to be ca- refully fastened and secured on hoists to avoid risks of accidents! Re-install removed guards and protecting devices on completion of work.
  • Page 24 Introduction A5.02 M20/M25/M32/M43 CAUTION Seals made of VITONR have been used at various locations in the engine. With normal engine operation this material is completely harmless, however it should not be exposed to temperatures above 300 °C, since above 325 °C a thermal decomposition and the formation of hydrofluoric acid can occur.

  • Page 25: Working On Electrical Equipment

    Introduction A5.02 M20/M25/M32/M43 Working on electrical equipment CAUTION 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! Use only original fuses with the specified current raiting! Switch off the engi- ne/plant immediately if trouble occurs in the electrical system!
  • Page 26 Introduction A5.02 M20/M25/M32/M43 Working with hydraulic devices WARNING Do not place parts of your body above/below pressurized hydraulic tools! Replace hydraulic hose lines at regular intervals, even if no safety relevant defects are detectable! Operating instructions, tightening torques and setting dimensions specified in the appropriate job card are to be carefully observed! The minimum bending radius of the high-pressure hoses are to be strictly ob- served!
  • Page 27 Introduction A5.02 M20/M25/M32/M43 Handling of liquid nitrogen or carbon dioxide snow WARNING 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! CAUTION Parts of the skin which have come into contact with liquid nitrogen or carbon dioxide snow must not be rubbed but covered with sterile surgical bandage...
  • Page 28 Introduction A5.02 M20/M25/M32/M43 Proposition 65 Warning NOTE California / USA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. en / 14.12.2010 AA047605 15/15...
  • Page 29 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 Chapter 3 Compare with acceptance test records: Technical engine data Speed, rating Acceptance test record Chapter 3...
  • Page 30 Periodical schedule A5.04.01 Distillate fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks Chapter 1 Lube oil Lube oil circulation tank system Check of the lube oil level Operating instructions Lube oil Lubricating oil duplex filter A5.05.08.04.01.00 system Maintenance/Cleaning at 50 % differential pressure Chapter 1...
  • Page 31 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 32 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.nn 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 33 Periodical schedule A5.04.01 Distillate fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks 3.750 h Actuator A5.05.05.04.01.nn Inspection/Adjust 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...
  • Page 34 Periodical schedule A5.04.01 Distillate fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks 15.000 h Inlet and exhaust valves A5.05.01.07.01.01 Inspection/Disassembly and reassembly of all inlet and exhaust valves 15.000 h Big-end bearings A5.05.02.04.01.01 Inspection/Disassembly of one big-endbearing 15.000 h Main bearings A5.05.02.05.01.01...
  • Page 35 Periodical schedule A5.04.01 Distillate fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks 30.000 h Piston rings and grooves A5.05.02.07.01.nn Inspection/Checking all cylinder units 30.000 h Cylinder liner A5.05.03.04.01.00 Maintenance/Disassembly at all cylinder units 30.000 h Control valves A5.05.05.09.05.00 Inspection/Checking 30.000 h...
  • Page 36 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.nn Repair/Checking Valve seat ring...
  • Page 37 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.nn Repair/Disassembly and reassembly Injection pump A5.05.07.03.01.nn Maintenance/Disassembly and reassembly Fuel injector A5.05.07.07.01.nn Maintenance/Disassembly and reassembly Fuel injector A5.05.07.08.01.nn Maintenance/Adjust Duplex fuel filter...
  • Page 38 Periodical schedule A5.04.02 Heavy 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 Chapter 3 Compare with acceptance test records: Technical engine data Speed, rating Acceptance test record Temperature...
  • Page 39 Periodical schedule A5.04.02 Heavy fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks Chapter 1 Lube oil Lube oil circulation tank system Check of the lube oil level Operating instructions Lube oil Lubricating oil duplex filter A5.05.08.04.01.00 system Maintenance/Cleaning at 50 % differential pressure Chapter 1...
  • Page 40 Periodical schedule A5.04.02 Heavy 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 41 Periodical schedule A5.04.02 Heavy fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks Periodical maintenance procedures -------------------------------------------------------------------------------------------------------------------------------- 24 h Compressed air strainer A5.05.05.09.06.nn Maintenance/Cleaning 24 h 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 42 Periodical schedule A5.04.02 Heavy fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks 3.750 h Timing gear train A5.05.04.08.01.00 Inspection/Checking 3.750 h Actuator A5.05.05.04.01.nn Inspection/Adjust 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...
  • Page 43 Periodical schedule A5.04.02 Heavy fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks 15,000 h Nozzle sleeve A5.05.01.06.50.00 Maintenance/Disassesmbly and reassembly 15.000 h Inlet and exhaust valves A5.05.01.07.01.01 Inspection/Disassembly and reassembly of all inlet and exhaust valves 15.000 h Cylinder head A5.05.01.10.01.01 Maintenance/Cleaning...
  • Page 44 Periodical schedule A5.04.02 Heavy fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks 30.000 h Control valves A5.05.05.09.05.00 Inspection/Checking 30.000 h Exhaust manifold A5.05.06.01.01.nn Maintenance/Disassembly and reassembly 30.000 h Vibration damper A5.05.12.04.01.03 Maintenance/Disassembly and reassembly en / 26.01.2011 AA021679...
  • Page 45 Periodical schedule A5.04.02 Heavy 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.nn Repair/Checking Valve seat ring...
  • Page 46 Periodical schedule A5.04.02 Heavy fuel Intervall Designation / Doc-Nr. Work to be carried out Remarks Injection pump A5.05.07.02.01.nn Repair/Disassembly and reassembly Injection pump A5.05.07.02.01.nn Repair/Disassembly and reassembly Injection pump A5.05.07.03.01.nn Maintenance/Disassembly and reassembly Injection valve A5.05.07.07.01.nn Maintenance/Disassembly and reassembly Injection valve A5.05.07.08.01.nn Maintenance/Adjust Duplex fuel filter...

  • Page 47: Valve Clearance

    Valve Clearance A5.05. 01.01.01.00 Inspection / Adjust 1500 See also: 02.01.01.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 -------------------------------------------------------------------------------------------------------------------------------- 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 48 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 rotation “a”.
  • Page 49 Valve clearance A5.05. 01.01.01.02 Inspection / Adjust 1500 See also: 02.01.01.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 -------------------------------------------------------------------------------------------------------------------------------- Inspection: Check valve clearance, adjust if necessary every 1.500 h Tools:...
  • Page 50 Valve clearance A5.05. 01.01.01.02 Inspection / Adjust 1500 Release locknut (6) and unsrew setting bolt (7) until a contact in „X” without clearance is reached. At this position of the valve bridge screw in setting bolt (7) until contact at „Y” without any clearance is reached.
  • Page 51 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 52 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 53: Maintenance

    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 54 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. Re- new 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 55 Valve Rocker A5.05. 01.02.02.00 Maintenance / Disassembly and reassembly 30000 Reassembly NOTE Valve rocker axle must be un- damaged and free of burrs. Oil surfaces of the bushes of the inlet val- ve rocker (Fig. 1/3) and exhaust valve rok- ker (4) and rocker axle and carefully move the valve rocker onto the axle.
  • Page 56 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 CAUTION Heavy fuel operation:=4 valve rotatorsinlet and exhaust valves...
  • Page 57 CAUTION 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 position.
  • Page 58 Replacement of the valve guide NOTE If possible replace the valve guide in the workshop of a MaK dealer during the over- haul of cylinder head. There is a risk that the cylinder cover may be damaged when the old valve guide is knocked out.
  • Page 59 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 -------------------------------------------------------------------------------------------------------------------------------- CAUTION Depressurize system before commencing work. Auxiliary material: soft green soap* * or product of equal standard...
  • Page 60 Media line A5.05. 01.05.50.00 Maintenance / Disassembly and reassembly Remove flange (3a and 3b) together with sleeves (4). 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.
  • Page 61 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 62: Cylinder Head

    Cylinder Head A5.05. 01.06.01.00 Maintenance / Disassembly See also: Spare parts list: 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) 0.9205-B High-pressure hose...
  • Page 63 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. CAUTION Screw off pressure gage line from end flange (lube oil jet cooling) during disassembly of the last cylinder head at counter-coupling side.
  • Page 64 Cylinder Head A5.05. 01.06.01.00 Maintenance / Disassembly Loosen the four cylinder head screws together with the hydraulic tightening device. CAUTION 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 65 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 2.5 mm (approx.

  • Page 66: Maintenance

    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 67 Nozzle Sleeve A5.05. 01.06.50.00 Maintenance / Disassembly and reassembly 15000 Remove the O-rings (3 and 4). 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.
  • Page 68 Inlet and Exhaust Valve Cones A5.05. 01.07.01.01 Inspection / Disassembly and reassembly 15000, 7500 See also: 01.02.01.nn, 01.05.01.nn, 01.06.01.nn, 01.08.01.nn Spare parts list: B1.05.01.2.2107 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 69 Inlet and Exhaust Valve Cones A5.05. 01.07.01.01 Inspection / Disassembly and reassembly 15000, 7500 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 70 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 *...
  • Page 71 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: Valves cannot be reused when •...
  • Page 72 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 73 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. 4). Therafter the seat ring surface is to be sprayed with a thinner (F25) belonging to the diamond paste, for dilution and in...
  • Page 74 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 75 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 76 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: Valves cannot be reused when •...
  • Page 77 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 78 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. 4). Therafter the seat ring surface is to be sprayed with a thinner (F25) belonging to the diamond paste, for dilution and in...
  • Page 79 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 80 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 81 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: Valves cannot be reused when •...
  • Page 82 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 83 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. 4). Therafter the seat ring surface is to be sprayed with a thinner (F25) belonging to the diamond paste, for dilution and in...
  • Page 84 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 85 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 86 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: Valves cannot be reused when •...
  • Page 87 NOTE Refinishing should always be carried out professionally on precision spindle grinding machines. 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 88 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. 4). Therafter the seat ring surface is to be sprayed with a thinner (F25) belonging to the diamond paste, for dilution and in...
  • Page 89 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 90 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 91 Valve Seat Ring A5.05. 01.08.02.00 Repair / Checking Sequence of operations: Check of valve condition The hardness of the valve seats is designed in such a manner that a certain adaptability is pre- sent with regard to the valve face. Carbon deposits are therefore a normal indication and not ha- zardous if good cooling is present (Fig.
  • Page 92 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 93 The dimension for "z" must not drop be- low the minimum dimension of 1 mm due to the reworking. 3.1.7 If the milling cutters are blunt, the cutter head is to be sent to MaK for refinishing. en / 31.05.2010 IB001438...
  • Page 94 Valve Seat Ring A5.05. 01.08.02.00 Repair / Checking 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 the new or refinished vlave spindle and distribute the paste uniformly.
  • Page 95 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 96 Valve Seat Ring A5.05. 01.08.02.01 Repair / Checking Sequence of operations: Check of valve condition The hardness of the valve seats is designed in such a manner that a certain adaptability is pre- sent with regard to the valve face. Carbon deposits are therefore a normal indication and not ha- zardous if good cooling is present (Fig.
  • Page 97 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 98 Valve Seat Ring A5.05. 01.08.02.01 Repair / Checking 3.1.3 Place cutter head (Fig. 6/2) on greased 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 99 A5.05. 01.08.02.01 Repair / Checking 3.1.7 If the milling cutters are blunt, the cutter head is to be sent to MaK for refinishing. 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 the...

  • Page 100: Cylinder Head

    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 head,...
  • Page 101 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 102 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 103 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 104 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 105 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 106 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 107 Running Gear/Engine Timing A5.05. 02.01.01.00 Inspection / Checking 1500, 3750 See also: 03.01.01.nn, 04.08.01.nn, 01.01.01.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 The temperature check for the bearings must be carried out with the engine at opera-...
  • Page 108 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 dan- ger of foundation deformation, e.
  • Page 109 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 110 A high load admits less deflection than a low one. 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 111 Crank Web Deflection A5.05. 02.02.01.00 Inspection / Measuring en / 14.10.2010 IB001439...

  • Page 112: Bearing Shells

    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 113 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. Fig.
  • Page 114 Bearing Shells A5.05. 02.03.07.01 Inspection / Evaluate en / 30.09.2010 IB001449...
  • Page 115 Bearing Shells A5.05. 02.03.07.01 Inspection / Evaluate en / 30.09.2010 IB001449...
  • Page 116 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate M20/M25 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 con- sists of approx.
  • Page 117 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate M20/M25 Should more than one of the conditions described appear together, the respectively lowest limits apply. Reuse possible 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 118 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate M20/M25 Reuse possible Condition: Small foreign particles spread over the entire running surface. No significant alteration of the alu- minium allow ridges (Fig. 4). Assessment: Reuse of the bearing shell is possible, since foreign particles are embedded in the grooves. Condition: The overlay has been locally “dragged”...
  • Page 119 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate M20/M25 Wear Overlay-groove Bearing metal ridge 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 120 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate M20/M25 Wear and levelling of the ridges (borderline case) Condition: Bearing metal ridges are worn locally. Wear limits: a) max. 20 % of width b) max. 5 % of circumference = Bearing metal ridges worn c) max.
  • Page 121 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate M20/M25 Overlay fatigue ruptures Conditions: Rupture of electroplated overlay in the grooves as a result of overloading at certain points Wear limits: a) max. 25 % of circumference = Overlay fatigue ruptures b) max. 70 % of width c) max.
  • Page 122 Al-Grooved Bearings A5.05. 02.03.09.01 Inspection / Evaluate M20/M25 Overlay fatique ruptures and empty grooves Condition: In certain areas empty grooves are visible after washing out the ruptured overlay. Wear limits: a) max. 40 % of width b) max. 10 % of circumferende = Overlay fatique ruptures c) max.

  • Page 123: Sequence Of Operations

    Big-End Bearings A5.05. 02.04.01.01 Inspection / Disassembly 30000, 15000 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 124 Big-End Bearings A5.05. 02.04.01.01 Inspection / Disassembly 30000, 15000 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 125 Big-End Bearings A5.05. 02.04.01.01 Inspection / Disassembly 30000, 15000 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 126 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 127 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 128 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 129 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° ° ° ° . 3.7.2 Lower bolts 3 and 4: The maximum pointer must have passed the angle marking or the bolts must have turned through 17°...

  • Page 130: Main Bearings

    Main Bearings A5.05. 02.05.01.01 Inspection / Disassembly 30000, 15000 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 131 Main Bearings A5.05. 02.05.01.01 Inspection / Disassembly 30000, 15000 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...
  • Page 132 Main Bearings A5.05. 02.05.01.01 Inspection / Disassembly 30000, 15000 Loosen bearing bolts with hydraulic tightening equipment. 1.3.1 Remove hexagon screws (Fig. 2/11) of the main bearing which is to be removed. 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 133 Main Bearings A5.05. 02.05.01.01 Inspection / Disassembly 30000, 15000 Measure clearance. 1.4.1 Remove hexagon screws (Fig. 4/11) of 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 134 Main Bearings A5.05. 02.05.01.01 Inspection / Disassembly 30000, 15000 Wear = new dimension - actual dimension New dimension: 4.927 -0.015 In the case of a wear of > 0.05 mm the bearing shells are to be changed. Further rating criteria, 02.03.07.nn. CAUTION If a bearing shell has to be changed during inspection, the...
  • Page 135 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 1.9454-500 Square-driven 1.9459-006 Socket wrench 1.9024-036 See job chart 02.05.01.nn.
  • Page 136 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. Twist in top bearing shell.
  • Page 137 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 (W6) with torque 1st stage: M = 100 Nm 2nd stage: M = 300 Nm...
  • Page 138 Main Bearings A5.05. 02.05.02.00 Maintenance / Reassembly CAUTION 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 139 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 140 Piston A5.05. 02.06.01.01 Maintenance / Disassembly CAUTION 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 141 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 insert con-rod foot into the liner and remove big- end bearing shells.
  • Page 142 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 143 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 si- 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 144 Piston A5.05. 02.06.01.02 Maintenance / Disassembly CAUTION 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 145: Maintenance

    Piston Rings and Grooves A5.05. 02.07.01.01 Inspection / Checking 30000, 7500 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:...
  • Page 146 Renew the piston in case of heavy damage or deep scores. 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.
  • Page 147 Piston Rings and Grooves A5.05. 02.07.01.01 Inspection / Checking 30000, 7500 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 148 Piston Rings and Grooves A5.05. 02.07.01.03 Inspection / Checking 30000, 7500 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:...
  • Page 149 Renew the piston in case of heavy damage or deep scores. 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.
  • Page 150 Piston Rings and Grooves A5.05. 02.07.01.03 Inspection / Checking 30000, 7500 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 151 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 152 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 153 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. 1/W4), piston assembly ring (fig.
  • Page 154 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. Auxiliary material: Glue “Hymir 1000”...
  • Page 155 Explosion relief valve A5.05. 03.01.01.02 Inspection / Checking 1500 See also: 02.01.01.nn Spare parts list: B1.05.03.2.1633 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Inspection: freedom of movement of the explosion relief valve. NOTE Disassembly of the explosion relief valve is only required when the prescribed spring tension can not be reached or abnormal fouling by oil or a leakage can be recognized.
  • Page 156 Explosion relief valve A5.05. 03.01.01.02 Inspection / Checking 1500 Reassembly Reassembly is done in reverse order of disassembly. Tighten connecting bolts (9) using a torque of M = 24,5 Nm Check the explosion relief valve for proper function by manual operation after assembly. When mounting the explosion relief valve to the crankcase door be sure that the sealing between seat ring and crankcase door is in proper condition.

  • Page 157: Auxiliary Materials

    Explosion relief valve A5.05. 03.01.01.03 Inspection / Checking 1500 See also: 02.01.01.nn Spare parts list: B1.05.03.2.1633 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Check: Ease of movement of the explosion relief valve every 1,500 h Auxiliary materials: Molykote Paste "G Rapid Plus“...
  • Page 158 Explosion relief valve A5.05. 03.01.01.03 Inspection / Checking 1500 Tighten screws (8) to a torque of M = 15 Nm. After assembly check the explosion relief valve for proper operation by actuating it by hand. When mounting the explosion relief valve on the crankcase door care has to be taken to ensure proper sealing between seat and crankcase door.

  • Page 159: Sequence Of Operation

    Zylinderbuchse A5.05. 03.03.01.02 Inspection / Measuring 30000, 15000 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 160 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...

  • Page 161: Cylinder Liner

    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 162 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 163 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.
  • Page 164 Check the monitoring and control equipment for good fitting. Cables and signal lines must not scrape against any part. 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 / 10.08.2010 IB001402...

  • Page 165: Camshaft Bearing

    0,22 NOTE With reaching the clearance limit the camshaft bearing is to be replaced (MaK customer support) and the clearance of all camshaft bearings are to be checked. Check running surface of the bearing necks of the corresponding camshaft bearings.
  • Page 166 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 167 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 168 Camshaft A5.05. 04.04.01.00 Repair / Disassembly and reassembly CAUTION 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...
  • Page 169 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 170 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 171 Camshaft A5.05. 04.04.01.01 Repair / Disassembly and reassembly CAUTION 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 accor- ding to the cylinder and positi- on in accordance with the firing order (32) and provided with a...
  • Page 172 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 173 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 174 Camshaft A5.05. 04.04.01.02 Repair / Disassembly and reassembly CAUTION 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 accor- ding to the cylinder and positi- on in accordance with the firing order (32) and provided with a...

  • Page 175: Timing Gear Train

    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 on...
  • Page 176 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 177 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 do- wel 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 178 Governor Drive A5.05. 04.08.03.00 Inspection / Disassembly and reassembly 15000 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). Put the helical gear wheel (13) in the recess of the crankshaft gear (14). Grease the threads and contact surfaces of the hexagon screws with Molykote paste “G-Rapid Plus”...

  • Page 179: Auxiliary Tools

    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 180 Vibration damper on camshaft A5.05. 04.09.01.00 Repair / Disassembly and reassembly 15000 Assemble the cover disc (3), the damper (1), sleeves (6) and cheese head screws (5) according to the illustration. Tighten the cheese head screws (5) with a torque of M = 60 Nm.
  • Page 181 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 182 Vibration damper on camshaft A5.05. 04.09.01.01 Repair / Disassembly and reassembly 15000 Assemble the cover disc, both dampers (1) and disc (3), cheese head screws (5) and sleeves (6) according to the illustration. Tighten the cheese head screws (5) with a torque of M = 60 Nm.
  • Page 183 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 184 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 necessary. Lubricate thread and contact face of cylinder head screws (3 and 7) with Molykote paste „G-Ra- pid“.

  • Page 185: Maintenance

    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 1.500 h Auxiliary material:...
  • Page 186 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 3,750 h Note: This unit limits the fuel injection depending on the carge air pressure so as to avoid a smoky ex-...
  • Page 187 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 hesi- tation. 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 188 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 189 Fuel Limiter A5.05. 05.04.01.01 Inspection / Adjust 3750 Check whether the piston follows the charge air pressure change continuously and without hesi- tation. 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 190 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” * * or a product of equal standard Note: The fuel limiter must not be removed when...
  • Page 191 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 CAUTION The fuel limiter must not be removed when there is pressure on the lubricating oil...

  • Page 192: Safety Note

    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 * not available as figure...
  • Page 193 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 194 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. 4.2.2 Before fitting vent screw (12), plug (13), spring (14), piston (15) and throttle screw...

  • Page 195: Control Valves

    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 196: Compressed-Air Filter

    Compressed-Air Filter A5.05. 05.09.06.00 Maintenance / Cleaning M20/M25/M32/M43/M453C/M552C/M601C 24, 150, 7500 See also: Spare parts list: B1.05.05.1.4900 Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance/cleaning: Drain compressed-air filter: every 24 h Disassemble and clean compressed-air filter:...
  • Page 197 Compressed-Air Filter A5.05. 05.09.06.00 Maintenance / Cleaning M20/M25/M32/M43/M453C/M552C/M601C 24, 150, 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 198 Compressed-Air Filter A5.05. 05.09.06.01 Maintenance / Cleaning M20/M25/M32/M43 24, 7500 See also: C5.05.05.45.23.nn Spare parts list: B1.05.05.9.4523 Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance/cleaning: Drain compressed-air filter: every 24 h Disassemble and clean compressed-air filter:...
  • Page 199 Regleröl A5.05. 05.25.00.01 Inspection / Oil change M20/M25/M32/M43 See also: C5.05.04.20.27.nn Spare parts list: Time requirement: 1 Pers./ 0,05 h Personnel qualification: skilled engine hand Operating medium: Every fuel -------------------------------------------------------------------------------------------------------------------------------- Check: Visual check of the governor oil every 24 h Attention: A visual check of the governor oil must be carried out every 24 hours on the oil level sight glass of the governor.

  • Page 200: Exhaust Manifold

    Exhaust Manifold A5.05. 06.01.01.00 Maintenance / Disassembly and reassembly 30000, 7500 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 201 Exhaust Manifold A5.05. 06.01.01.00 Maintenance / Disassembly and reassembly 30000, 7500 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 202 Exhaust Manifold A5.05. 06.01.01.01 Maintenance / Disassembly and reassembly 7500 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 -------------------------------------------------------------------------------------------------------------------------------- Checks: Check exhaust pipe for leaks after 7,500 hrs Auxiliary material: High temperature bolt lubricant "Rivolta G.W.F“...
  • Page 203 Exhaust Manifold A5.05. 06.01.01.01 Maintenance / Disassembly and reassembly 7500 Carry out visual inspections on flanges and expansion joints. NOTE Soot buildup and/or bubbles can be a sign of leaks. Replace any expansion joints that show cracks in the bellows. Observe indicated direction of flow when installing expansion joints before the turbine.
  • Page 204 Exhaust Manifold A5.05. 06.01.01.01 Maintenance / Disassembly and reassembly 7500 Install exhaust pipe (3) with expansion joint (4) and new seal (5). Coat threads and washer face of bolts (2) with "Rivolta G.W.F". Insert bolts with extension slee- ves in cylinder head and tighten alternately in 2 steps with a tightening torque of M = 60 and 110 Nm Coat mounting surfaces of clamps with "Rivolta G.W.F".
  • Page 205 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 206 Charge Air Cooler A5.05. 06.04.02.00 Maintenance / Disassembly and reassembly WARNING 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 207 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 208 Charge Air Cooler A5.05. 06.04.02.01 Maintenance / Disassembly and reassembly WARNING 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 209 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 pressu- re upstream/downstream cooler exceeds 1.5 times the test bed value (see acceptance test record A1.10).
  • Page 210 Charge Air Cooler A5.05. 06.04.02.02 Maintenance / Disassembly and reassembly Reassembly Renew all gaskets Grease hexagon screws (1,2 and 3) with Molykote paste „G-Rapid Plus“. Secure charge air cooler on hoist and push cooler into casing Strictly observe the tightening instructions for hexagon screws (1, 2 and 3). Mount hexagon screws (1 and 3) and slightly tighten them crosswise to provide for uniform contact of the charge air cooler on front and sides.
  • Page 211 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 pressu- re upstream/downstream cooler exceeds 1.5 times the test bed value (see acceptance test record A1.10).
  • Page 212 Charge Air Cooler A5.05. 06.04.02.03 Maintenance / Disassembly and reassembly Reassembly Renew all gaskets Grease hexagon screws (1,2 and 3) with Molykote paste „G-Rapid Plus“. Secure charge air cooler on hoist and push cooler into casing Strictly observe the tightening instructions for hexagon screws (1, 2 and 3). Mount hexagon screws (1 and 3) and slightly tighten them crosswise to provide for uniform contact of the charge air cooler on front and sides.

  • Page 213: Charge Air Cooler

    Charge Air Cooler A5.05. 06.04.02.04 Maintenance / Disassembly and reassembly See also: Spare parts list: B1.05.06.2.7250 Time requirement: 2 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: The charge air cooler must be removed and cleaned on the air side when the differential pressure before/after the cooler exceeds 1.5 times the test bench value (see acceptance brake certificate A1.10).
  • Page 214 Charge Air Cooler A5.05. 06.04.02.04 Maintenance / Disassembly and reassembly Remove hexagon screws (Fig. 2/28) with washers (37). Pull the charge air cooler (9) out of the housing (3), suspend with hoist and lower into suitable container for cleaning. Clean the charge air cooler in accordance with the manufacturer's instructions (see Book C). Inspect the housing, drain all condensation by opening the drain line.
  • Page 215 Charge Air Cooler A5.05. 06.04.02.04 Maintenance / Disassembly and reassembly Assembly Install charge air cooler in the reverse order as disassembly. Insert new O-ring (8) into O-ring sheet (9). Slide charge air cooler (2) into the housing (3) carefully. NOTE Apply a light coat of Molykote paste “G-Rapid Plus”...
  • Page 216 Exhaust gas turbocharger A5.05. 06.05.00.01 Maintenance / Cleaning 24, 300 See also: Spare parts list: B1.05.06.25725n Time requirement: 0 Pers./ 0,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: a) Wash the compressor every 24 h b) Wash the turbine...

  • Page 217: Washing Procedure

    Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Compressor cleaning M 20 every 24 h Prerequisites: -The compressor stage must be cleaned with the engine at operating temperature and under full load (> 85% load ), if possible; i.e., at high turbocharger rpm.
  • Page 218 Exhaust gas turbocharger A5.05. 06.05.01.01 Maintenance / Cleaning Open ballcock (4) for about 20 seconds until the entire water volume has been injected. NOTE After the air-side has been cleaned, the engine must be operated at least another 5 minutes under load. When the compressor impeller was contaminated, the success of a cleaning can be told by the charge air pressure after the turbocharger.
  • Page 219 Exhaust gas turbocharger A5.05. 06.05.01.01 Maintenance / Cleaning CAUTION Because of the increased risk of corrosion, only clear water (drinking water) - never salt water - must be used for cleaning. This water should not contain any coolant treatments or other chemicals that may form deposits in the air ducts. CAUTION The injection tube must never be connected directly to a water line, a different or larger metering container or to a larger washing water containerother than the...
  • Page 220 Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Compressor cleaning M 20 every 24 h Prerequisites: -The compressor stage must be cleaned with the engine at operating temperature and under full load (> 85% load ), if possible; i.e., at high turbocharger rpm.
  • Page 221 Exhaust gas turbocharger A5.05. 06.05.01.02 Maintenance / Cleaning Open ballcock (4) for about 20 seconds until the entire water volume has been injected. NOTE After the air-side has been cleaned, the engine must be operated at least another 5 minutes under load. When the compressor impeller was contaminated, the success of a cleaning can be told by the charge air pressure after the turbocharger.
  • Page 222 Exhaust gas turbocharger A5.05. 06.05.01.02 Maintenance / Cleaning CAUTION Because of the increased risk of corrosion, only clear water (drinking water) - never salt water - must be used for cleaning. This water should not contain any coolant treatments or other chemicals that may form deposits in the air ducts. CAUTION The injection tube must never be connected directly to a water line, a different or larger metering container or to a larger washing water containerother than the...
  • Page 223 1 Pers./ 0,40 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Turbine cleaning M 20 every 150 h Prerequisite: - Wet cleaning wet cleaning of turbine and nozzle ring require lower exhaust gas temperatures or lower engine load NOTE The cleaning effect during turbine washing is caused by the mechanical impact of the water droplets as well as by the water solubility of the deposits.
  • Page 224 Exhaust gas turbocharger A5.05. 06.05.02.03 Maintenance / Cleaning Quality requirements for water for washing turbine and nozzle ring: NOTE Water flow is controlled by a diaphragm located in the needle valve (Fig.2/1). The cleaning parameters for the turbocharger models KBB - HPR 5000 are as follows: exhaust gas temperature before turbine intake: <...

  • Page 225: Cleaning Procedure

    Exhaust gas turbocharger A5.05. 06.05.02.03 Maintenance / Cleaning Cleaning procedure: For standard operation: - Needle valve (Fig.2/1) is closed. - Hose (3) has been disconnected and removed from the water supply. For washing operation: - Needle valve (Fig.2/1) is closed. - Shut-off valve (4) is closed.
  • Page 226 Exhaust gas turbocharger A5.05. 06.05.02.03 Maintenance / Cleaning Open drain valve (Fig.2/4); pressure gauge (8) must indicate a pressure of: p ~ 2 bar (on-board supply) . Close shut-off valve (4). Open needle valve (1). Open shut-off valve (4) for 30 secs. Check if exhaust gas temperature after turbocharger decreases.
  • Page 227 1 Pers./ 0,40 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Turbine cleaning M 20 every 150 h Prerequisite: - Wet cleaning wet cleaning of turbine and nozzle ring require lower exhaust gas temperatures or lower engine load NOTE The cleaning effect during turbine washing is caused by the mechanical impact of the water droplets as well as by the water solubility of the deposits.
  • Page 228 Exhaust gas turbocharger A5.05. 06.05.02.04 Maintenance / Cleaning Quality requirements for water for washing turbine and nozzle ring: NOTE Water flow is controlled by a diaphragm located in the needle valve (Fig.2/1). The cleaning parameters for the turbocharger models KBB - HPR 4000 are as follows: exhaust gas temperature before turbine intake: <...
  • Page 229 Exhaust gas turbocharger A5.05. 06.05.02.04 Maintenance / Cleaning Cleaning procedure: For standard operation: - Needle valve (Fig.2/1) is closed. - Hose (3) has been disconnected and removed from the water supply. For washing operation: - Needle valve (Fig.2/1) is closed. - Shut-off valve (4) is closed.
  • Page 230 Exhaust gas turbocharger A5.05. 06.05.02.04 Maintenance / Cleaning Open drain valve (Fig.2/4); pressure gauge (8) must indicate a pressure of: p ~ 2 bar (on-board supply) . Close shut-off valve (4). Open needle valve (1). Open shut-off valve (4) for 30 secs. Check if exhaust gas temperature after turbocharger decreases.

  • Page 231: Sequence Of Operations

    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 unba- lance.
  • Page 232 Turbocharger A5.05. 06.13.01.00 Maintenance / Cleaning slowly. NOTE Repeat washing procedure if vibrations and sounds appear at the turbocharger which were previously not present. en / 31.05.2010 IB001462...
  • Page 233 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 unba- lance.
  • Page 234 Turbocharger A5.05. 06.13.01.01 Maintenance / Cleaning NOTE Repeat washing procedure if vibrations and sounds appear at the turbocharger which were previously not present. en / 31.05.2010 IB002154...
  • Page 235 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 unba- lance.
  • Page 236 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 237 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 unba- lance.
  • Page 238 Turbocharger A5.05. 06.13.01.03 Maintenance / Cleaning slowly. NOTE Repeat washing procedure if vibrations and sounds appear at the turbocharger which were previously not present. en / 31.05.2010 IB003041...
  • Page 239 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 unba- lance.
  • Page 240 Turbocharger A5.05. 06.13.01.04 Maintenance / Cleaning NOTE Repeat washing procedure if vibrations and sounds appear at the turbocharger which were previously not present. en / 31.05.2010 IB003046...
  • Page 241 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 unba- lance.
  • Page 242 Turbocharger A5.05. 06.13.01.05 Maintenance / Cleaning NOTE Repeat washing procedure if vibrations and sounds appear at the turbocharger which were previously not present. en / 31.05.2010 IB003054...
  • Page 243 Exhaust gas turbocharger 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 tur- bine blades decreasing the charger efficiency and increasing the bearing loads by...
  • Page 244 Exhaust gas turbocharger 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 CAUTION Check drain valve (Fig. 2/4) and pipe (2) during the washing process permanently for free passage.
  • Page 245 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 tur- bine blades decreasing the charger efficiency and increasing the bearing loads by unbalance.
  • Page 246 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 CAUTION Check drain valve (Fig. 2/4) and pipe (2) during the washing process permanently for free passage.
  • Page 247 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 tur- bine blades decreasing the charger efficiency and increasing the bearing loads by unbalance.
  • Page 248 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 CAUTION Check drain valve (Fig. 2/4) and pipe (2) during the washing process permanently for free passage.
  • Page 249 Exhaust gas turbocharger - HPR 5000 - A5.05. 06.13.02.11 Repair / Replacement 12000, 24000, 48000, 250, 1000 See also: A3.06.06.nn Spare parts list: B1.05.06.nn725n nn Time requirement: 1 Pers./ 0,40 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------- NOTE The exhaust gas turbocharger must generally be maintained according to the main-...
  • Page 250 Exhaust gas turbocharger - HPR 5000 - A5.05. 06.13.02.11 Repair / Replacement 12000, 24000, 48000, 250, 1000 Rotor --> ( 2000 ) Seal set --> ( 9910 ) Bearing set --> Fasteners --> ( 4000 ) ( 9920 ) Fasteners -->...
  • Page 251 Exhaust gas turbocharger - HPR 4000 - A5.05. 06.13.02.12 Repair / Replacement 12000, 24000, 48000, 250, 1000 See also: A3.06.06.nn Spare parts list: B1.05.06.nn725n nn Time requirement: 1 Pers./ 0,40 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------- NOTE The exhaust gas turbocharger must generally be maintained according to the main-...
  • Page 252 Exhaust gas turbocharger - HPR 4000 - A5.05. 06.13.02.12 Repair / Replacement 12000, 24000, 48000, 250, 1000 Rotor --> ( 2000 ) Seal set --> ( 9910 ) Bearing set --> Fasteners --> ( 4000 ) ( 9920 ) Fasteners -->...

  • Page 253: Injection Pump

    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 254 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 255 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 256 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 257 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 258 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 259 Injection Pump A5.05. 07.02.01.02 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 260 Injection Pump A5.05. 07.02.01.02 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 261 Injection Pump A5.05. 07.02.01.02 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 262: Maintenance

    Injection Pump A5.05. 07.03.01.00 Maintenance / Disassembly and reassembly 15000, 7500 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 263 Injection Pump A5.05. 07.03.01.00 Maintenance / Disassembly and reassembly 15000, 7500 WARNING Caution spring tension! Loosen fillister head screws (Fig. 1/4) uni- formly. Remove injection pump bottom part (3) with lower spring seat from injection pump housing (5). Take care of fixing pin. Remove the following single components from injection pump housing (6): Cam follower body (7), pressure plate (8),...
  • Page 264 Injection Pump A5.05. 07.03.01.00 Maintenance / Disassembly and reassembly 15000, 7500 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.
  • Page 265 Injection Pump A5.05. 07.03.01.01 Maintenance / Disassembly and reassembly 15000, 7500 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 266 Injection Pump A5.05. 07.03.01.01 Maintenance / Disassembly and reassembly 15000, 7500 WARNING Caution spring tension! Loosen fillister head screws (Fig. 1/4) uni- formly. Remove injection pump bottom part (3) with lower spring seat from injection pump housing (5). Take care of fixing pin. Remove the following single components from injection pump housing (6): Cam follower body (7), pressure plate (8),...
  • Page 267 Injection Pump A5.05. 07.03.01.01 Maintenance / Disassembly and reassembly 15000, 7500 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.
  • Page 268 Injection Pump A5.05. 07.03.01.02 Maintenance / Disassembly and reassembly 15000, 7500 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 269 Injection Pump A5.05. 07.03.01.02 Maintenance / Disassembly and reassembly 15000, 7500 WARNING Caution spring tension! Loosen fillister head screws (Fig. 2/32) uniformly. Remove injection pump bottom part (33) with lower spring seat from injection pump housing (Fig. 1/5). Take care of fixing pin. Remove the following single components from injection pump housing (6): Cam follower body (7), pressure plate (8),...
  • Page 270 Injection Pump A5.05. 07.03.01.02 Maintenance / Disassembly and reassembly 15000, 7500 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.
  • Page 271 Injection Pump A5.05. 07.03.01.02 Maintenance / Disassembly and reassembly 15000, 7500 Reassembly The reassembly is carried out in reverse order to the disassembly procedure. CAUTION During reassembly see that the barrel is locked and that the marking of control rack - control sleeve and control sleeve - plunger coincide.
  • Page 272 Injection Pump A5.05. 07.03.01.03 Maintenance / Disassembly and reassembly 15000, 7500 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 273 Injection Pump A5.05. 07.03.01.03 Maintenance / Disassembly and reassembly 15000, 7500 WARNING Caution spring tension! Loosen fillister head screws (Fig. 2/32) uniformly. Remove injection pump bottom part (33) with lower spring seat from injection pump housing (Fig. 1/5). Take care of fixing pin (34).
  • Page 274 Injection Pump A5.05. 07.03.01.03 Maintenance / Disassembly and reassembly 15000, 7500 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.
  • Page 275 Injection Pump A5.05. 07.03.01.03 Maintenance / Disassembly and reassembly 15000, 7500 Reassembly The reassembly is carried out in reverse order to the disassembly procedure. CAUTION During reassembly see that the barrel is locked and that the marking of control rack - control sleeve and control sleeve - plunger coincide.

  • Page 276: Fuel Injector

    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 277 (07.08.01 nn). 1.10 Renew the soft iron sealing ring (17) and all of the O-rings (18). CAUTION 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 278 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 279 Fuel Injector A5.05. 07.07.01.02 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 280 (07.08.01 nn). 1.10 Renew the soft iron sealing ring (17) and all of the O-rings (18). CAUTION 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 281 Fuel Injector A5.05. 07.07.01.02 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 282 Fuel Injector A5.05. 07.08.01.01 Maintenance / Adjust See also: 07.07.01.nn, 07.09.01.nn Spare parts list: B1.05.07.2.2267, B1.05.07.2.2260 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...
  • Page 283 Fuel Injector A5.05. 07.08.01.01 Maintenance / Adjust Sequence of operations: Remove carbon deposits from the nozzle with a hard brush (no wire brush). Check the nozzle hole for sharp edges, ovalization, corrosion and damage. Place the injector with the adapter (W2) in the tester (W1).
  • Page 284 Fuel Injector A5.05. 07.08.01.02 Maintenance / Adjust See also: 07.07.01.nn, 07.09.01.nn Spare parts list: B1.05.07.2.2267, B1.05.07.2.2260 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...
  • Page 285 Fuel Injector A5.05. 07.08.01.02 Maintenance / Adjust Sequence of operations: Remove carbon deposits from the nozzle with a hard brush (no wire brush). Check the nozzle hole for sharp edges, ovalization, corrosion and damage. Place the injector with the adapter (W2) in the tester (W1).
  • Page 286 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 287 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 288 Fuel Injector 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 -------------------------------------------------------------------------------------------------------------------------------- Tools: Torque wrench 60 - 420 Nm W1 * 1.9454-60 * not available as figure...
  • Page 289 Fuel Injector 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 290 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...
  • Page 291 Duplex Fuel Filter A5.05. 07.12.01.00 Maintenance / Cleaning WARNING 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 292 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 CAUTION The individual strainers are connected in parallel, and damage on only one filter ele- ment means malfunction of the entire element.

  • Page 293: Maintenance

    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 750 h Tools: Cleaning pistol...
  • Page 294 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 295 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 750 h Auxiliary material: Cleaner “Filterclean”...
  • Page 296 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 cham- ber which has been cut off in order to vent the system. Remove the drain plug (2) of the filter chamber which has been cut off.

  • Page 297: Fuel Feed Pump

    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 298 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 299 Fuel Feed Pump A5.05. 07.13.01.00 Maintenance / Disassembly and reassembly 15000 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 300 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 301 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 dis- tributor housing (3). Insert screws (1) with Molykote paste “G- Rapid Plus”...
  • Page 302 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 303 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 304: Lubricating Oil System

    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 installa- tion or working on the suction side of the lubricating oil piping system.
  • Page 305 Lubricating Oil System A5.05. 08.02.01.00 Maintenance / Oil change A4.05.08.nn). Refill lubricating oil system and start the stand-by pump. en / 31.05.2010 IB001483...

  • Page 306: Lube Oil Pump

    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 307 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 308 Check the tooth surfaces for wear (pitting, cross bearing, disintegrations). 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 309 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 310 Lubricating Oil Duplex Filter A5.05. 08.04.01.00 Maintenance / Cleaning Filter cleaning with mounted filter candles. WARNING 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. 2.2.2 Remove the filter element.
  • Page 311 Lubricating Oil Duplex Filter A5.05. 08.04.01.00 Maintenance / Cleaning 2.3.4 Put the filter element in a suitable cleansing liquid. The cleansing liquid must only reach up 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 312 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 313: Oil Pressure Control Valve

    Oil pressure control valve A5.05. 08.05.01.00 Maintenance / Adjust 15000 See also: 08.03.02.nn Spare parts list: B1.05.08.2.6417 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Disassembly and adjustment of the oil pressure control valve every 15,000 h...
  • Page 314 Oil pressure control valve A5.05. 08.05.01.00 Maintenance / Adjust 15000 1.2.5 Remove the screw plug (26) of the pilot control unit (A-A) with the sealing ring (25), pressure spring (28) and ball (29). Clean all parts with gas oil and check them. Check the free passage of the control oil bore (12) in the pressure control valve and in the set screw (5) and remove any deposits.
  • Page 315 Oil pressure control valve A5.05. 08.05.01.00 Maintenance / Adjust 15000 Reassembly Check the O-ring (7) and sealing ring (14) and replace them if necessary. Assembly is effected in the reverse sequence of disassembly. Pay attention to the free movement of the pistons (4 and 11)! Check the lubricating oil pressure at the pressure gauge on the control panel and adjust it if ne- cessary.
  • Page 316 Oil pressure control valve A5.05. 08.05.01.01 Maintenance / Adjust M20/M25/M32/M43 15000 See also: Spare parts list: B1.05.08.n.7810 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Disassembly and adjustment of the oil pressure control valve every 15,000 h...
  • Page 317 Oil pressure control valve A5.05. 08.05.01.01 Maintenance / Adjust M20/M25/M32/M43 15000 1.2.2 Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush (10). 1.2.3 Remove the locking ring (9) and take out the piston (11) with washer (15) and pressure spring (13).
  • Page 318 Oil pressure control valve A5.05. 08.05.01.01 Maintenance / Adjust M20/M25/M32/M43 15000 Clean all parts with gas oil and check them. Check the free passage of the control oil bore (12) in the pressure control valve and in the set screw (5) and remove any deposits. Check the valve seats, balls, piston seating as well as the slide faces and grind them if necessary.
  • Page 319 Prelubricating pump/Prelubrication A5.05. 08.10.00.00 Maintenance / Checking M20/M25/M32/M43/M453C/M552C/M601C See also: C5.05.08.10.00.nn Spare parts list: Time requirement: 1 Pers./ 0,20 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Prelubrication and turning approximately every 150 h NOTE When multi-engine systems run on rigid bearings, the bearings might be damaged by vibration when individual engines are shut down for more than 3 days.
  • Page 320 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 321 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 car- rier (19). 1.10 Loosen flat head screw (28). 1.11 Remove cover (26) with sealing ring (27). 1.12 Remove “Nilos“...
  • Page 322 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.
  • Page 323 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 324 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 car- rier (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 325 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 326 Centrifugal Cooling Water Pump A5.05. 09.07.01.04 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 327 Centrifugal Cooling Water Pump A5.05. 09.07.01.04 Maintenance / Disassembly and reassembly 15000 Mark the position of the volute (Fig. 2/11) with respect to the housing cover (12) and bearing carrier (13). Loosen hexagon nut (14) and remove volute (11). Loosen impeller nut (32) and impeller nut (15), remove shim (16). Remove impeller (18) by means of an extractor.
  • Page 328 Centrifugal Cooling Water Pump A5.05. 09.07.01.04 Maintenance / Disassembly and reassembly 15000 1.13 Loosen screws (Fig. 2/23) and remove cover (24). 1.14 Remove slinger ring(25) from the shaft by means of an extractor. CAUTION Drive screw M12x45 into the shaft (20) and put the extractor on it. 1.15 Clamp bearing carrier (13) in a bench vice and heat inner ring of the ball bearing (26) up.
  • Page 329 Centrifugal Cooling Water Pump A5.05. 09.07.01.04 Maintenance / Disassembly and reassembly 15000 Heat new slinger ring (Fig. 2/27) up to 150° C and mount it on the shaft (20) at the impeller end. The slinger ring must fit closely to the ball bearing. 3.10 Insert new split ring (30) in the housing cover (12).
  • Page 330 Centrifugal Cooling Water Pump A5.05. 09.07.01.04 Maintenance / Disassembly and reassembly 15000 3.24 Heat gear wheel (2) up to 150°C and place it on the shaft cone up to the limit stop. (Cone surface grease-free and dry). 3.25 Coat thread and contact surface of the hexagon screw (3) and washer (4) with Molykote paste "G-Rapid Plus"...

  • Page 331: Pressure Switches

    Pressure Switches A5.05. 11.01.02.01 Inspection / Adjust M20-M601C 3750 See also: Spare parts list: B1.05.11.nn.4843 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Adjusting device, electro test instrument Inspection: Inspect the pressure switch for the set operating values every 3,750 working hours.
  • Page 332 Pressure Switches A5.05. 11.01.02.01 Inspection / Adjust M20-M601C 3750 CAUTION When loosen/thighten the union nut directly located at the pressure joint of the pres- sure switch, it should be simultaneously counter acted at the key faces of the pressu- re joint. Connect the hose (with union nut and cutting) with the adju- sting device (Fig.
  • Page 333 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 in- dividually calibrated (1 - 2 on) so that no gauge inspection is necessary.
  • Page 334 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 335 Pressure Switches A5.05. 11.01.03.00 Inspection / Adjust 3750 Pneumatic connection (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. 3) Connect terminals 1, 2, 3 in the appliance plug.
  • Page 336 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 337 RPM Switch A5.05. 11.05.01.02 Inspection / Adjust M20/M25/M32/M43 7500 See also: C5.05.05.70.06.43 Spare parts list: Time requirement: 1 Pers./ 1,00 h Personnel qualification: E-specialist Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Inspection: Check the function of the rpm switches every 7,500 operating hours. NOTE The engine speed must be constant whilst testing.
  • Page 338 RPM Switch A5.05. 11.05.01.02 Inspection / Adjust M20/M25/M32/M43 7500 Supply (24 V DC at contact z16 and z20, contact z20 positive). 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.The engine speed must be constant whilst testing.

  • Page 339: Maintenance

    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 element of the lubricating oil/cooling water thermostat every 7,500 h...
  • Page 340 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. Functional Check of the Thermostatic Element Put thermostatic element (1) into a water bath of a termpature of approx.
  • Page 341 Lubricating Oil/Cooling Water Thermostat A5.05. 11.06.01.01 Maintenance / Checking M20-M601C 7500 See also: Spare parts list: B1.05.11.1.7837 Time requirement: 1 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Disassembly of lubricating oil/cooling water thermostat, making a funcional check of thermostatic element every 7,500 h NOTE...
  • Page 342 Lubricating Oil/Cooling Water Thermostat A5.05. 11.06.01.01 Maintenance / Checking M20-M601C 7500 Wash parts in gas oil and blow them clean. Wipe clean thermostat housing with lint-free cloth and check for corrosion and deposits. 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 343: Pressure Switch

    Pressure Switch A5.05. 11.06.05.02 Inspection / Replacement M20/M25 22500 See also: 11.06.06.nn Spare parts list: Time requirement: 1 Pers./ 2,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Replacement of all pressure switches after 22,500 h Tools:...
  • Page 344 Pressure Switch A5.05. 11.06.05.02 Inspection / Replacement M20/M25 22500 Procedure: Put the engine and the related safety systems out of operation. - > Notify the engine to be ’’unserviceable’’ < -. CAUTION Prior to replacing the pressure switches the shut-off cocks of the media must be closed.
  • Page 345 Pressure Switch A5.05. 11.06.05.02 Inspection / Replacement M20/M25 22500 3.1.9 Put the engine and the safety system into normal operating condition again. -> Notify the engine to be "ready for operation" <-. en / 20.10.2010 IB026248...
  • Page 346 Pressure Switch A5.05. 11.06.06.02 Maintenance / Adjust M20/M25/M32/M43 See also: 11.06.05.nn Spare parts list: Time requirement: 1 Pers./ 0,25 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Tools: Pressure calibrating device Electric continuity tester (multimeter) * no picture Procedure: Mount new pressure switch, see A5.05.11.06.05.nn.
  • Page 347 Pressure Switch A5.05. 11.06.06.02 Maintenance / Adjust M20/M25/M32/M43 Adjustment of switching point Remove cover (Fig. 2/4). By turning the hexagon socket screw (5) the switching point can be adjusted correspondingly. Assembly: Mount cover (4). Remove pressure calibrating device (W1). Clip on plug to the pressure switch. Open shut-off valve (Fig.
  • Page 348 Crankcase Monitoring Device A5.05. 11.09.01.03 Inspection / Checking M20/M25/M32/M43/M453C/M552C/M601C 1500, 750, 7500 See also: Spare parts list: B1.05.11.nn4810 Time requirement: 2 Pers./ 1,00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: a) Check the underpressure in the measuring chamber every 750 h b) Clean the infrared filter and replace the sintered bronze filter in the measuring attachment every...

  • Page 349: Vibration Damper

    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 350 Vibration Damper A5.05. 12.04.01.03 Maintenance / Disassembly and reassembly 30000 1.4.2 Telescope out spring assemblies (Fig. 1/9). • 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.

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