MAK M20 Marine Diesel Engine Manuals

Manuals and User Guides for MAK M20 Marine Diesel Engine. We have 2 MAK M20 Marine Diesel Engine manuals available for free PDF download: Operating Instructions Manual, Maintenance Manual

MAK M20 Operating Instructions Manual (457 pages)

Brand: MAK | Category: Engine | Size: 8 MB

Total Index
2
Table of Contents
2
Safety Instructions
4
Working Pressures of Auxiliary Equipment
7
Temperatures of Operating Media
8
Viscosity/Temperature Dependence
8
Table of Contents
12
Introduction A3.02
16
Safety Instructions A3.03
17
Safety Measures for Local Control of the Engine
18
Instructions for Heavy Fuel Operation A3.04
19
Instructions for Heavy Fuel Operation Fuel System
20
Instructions for Heavy Fuel Operation Care and Supervision / Engine Fuel
21
Storage Tank
22
Settling Tank HT5, HT6
22
Separator HSD1, HSD2
22
Self Cleaning Fuel Filter HF4
23
Day Tank HT 1
23
Fuel Pressure Pump HP1, HP2
23
Fuel Pressure-Regulating Valve HR1
23
Final Preheater HH1
24
Fine Filter HF1
24
Viscosity Measurement and Control Equipment HR2
24
Instructions for Heavy Fuel Operation Lubricating Oil System
25
Oil Level Control
26
Instructions for Heavy Fuel Operation Care and Supervision / Lubricating Oil
26
Lubricating Oil Circulatory System Diagram
27
Prelubrication LP2 (Standby or Prelubrication Pump)
28
Check the Operation of the Engine-Driven Force Pump LP1
28
Lube Oil Automatic Filter LF2 (Flushing with Oil or Compressed Air)
28
Lube Oil Automatic Filter LF2 (with Permanent Oil Flushing)
29
Duplex Lube Oil Filter LF1 (with Indicator)
29
Strainer Filter (for Pumps)
29
Initial Operation Engine
30
Additional Preparation Work for Heavy Fuel Operation
31
Initial Operation Fuel System
31
Lubricating Oil System Maintenance
32
Plants with Lubricating Oil Separator
32
Turbocharger with Independent Lubricating Oil Supply
32
Initial Operation Lubricating Oil System
32
Initial Operation Cooling Water System
33
Initial Operation Starting Air System
34
Initial Operation General Performance Testing
35
Commissioning
36
Putting into Operation/Starting
36
Direct Start at the Main Engine
36
Normal Start (Control Panel in Manometer Board)
36
Emergency Start
38
Direct Start at the Generator Engine
39
Initial Operation Putting into Service/Starting
39
Putting into Service/Loading
40
Loading During the Warming up of a Main Engine
40
Normal Loading
40
Cold Starting, below the above Preheating Temperature
40
Loading During the Warming up of a Generator Motor
41
Normal Working Conditions
41
Severe Working Conditions
41
Increasing the Load of a Warmed-Up Engine (Generator Engine)
42
Accelerated Load Increase
43
Operational Supervision Engine
44
Monitoring
45
Operation in the Case of Low Intake Air Temperatures
45
Intake Air Temperature A3.06.05.00
45
Exhaust-Gas Temperature Monitoring
46
Operational Supervision Exhaust System/Supercharging
46
Assessment of the Engine Behaviour
47
Turbocharger: Compressor/Turbine
48
Charge Air Cooler
48
Monitoring of Operation Exhaust System/Firing Pressure
49
Exhaust Temperatures
50
Operational Supervision Exhaust System/Supercharging
50
Note for Exhaust Temperature Monitors
51
Indication of the Firing Pressure
52
Turbocharger: Compressor
53
Air Charge Cooler
53
Operational Supervison
54
Exhaust Gas Temperatures
54
Fuel System Supervision
58
Alarm - Leakage Fuel Injection Pipe
58
Changing the Type of Fuel
59
Fuel Pressure System (Only Within Heavy Oil Circle)
59
Lubricating Oil System Supervision
60
Cooling Water System Supervision
61
Partial Load Operation with Heavy Fuel
62
Removal from Operation
64
Placing out of Service/Stopping
65
Operation Directly at the Generator Engine
65
Engine Stop/Engine Emergency Stop
65
Cooling
65
If the Engine Is to be Started Again after a Short Interval
66
Direct Operation at the Main Engine
67
Engine Stop (Control Panel in Manometer Board)
67
Decommissioning/Stopping
68
Aftercooling
69
Resumption of Engine Operation after Short Operating Stop
69
Danger of Frost
71
Danger of Frost
72
Antifreeze Protection
72
Preservation - Engine
73
Light Preservation (Short Term Preservation)
75
Heavy Preservation (Long Term Preservation)
78
Starting System and Starting Air Distributor Storage
79
Mechanic-Hydraulic Governor Storage
79
Turbocharger Storage
79
External Preservation
80
Preservation Measures Fittings and Tools
80
Depreservation
81
Running-In
83
Running-In
84
Fault Tracing
85
Fault Tracing
86
Engine Starts Poorly or Does Not Start at All
87
Engine Reaches Ignition Speed but Does Not Fire
87
Filter Differential Pressure too High During Starting/Pre-Lubrication
88
Engine Does Not Reach Full Speed And/Or Full Power
88
Engine Speed Is Not Steady
89
Opaque Exhaust Gas - Engine Is Emitting Soot
89
Exhaust Gases Are Blue
90
Exhaust Gases Are White
90
Emergency Operation
91
Defective Turbocharger
92
Determination of the Maximum Permissible Fuel Rack Position
92
Emergency Operation of the Generator Engine
93
Monitoring the Engine While the Turbocharger Is Defective
93
Charge Air Temperature While the Turbocharger Is Defective
93
Finishing with Emergency Operation
93
Emergency Operation of the Main Engine
94
Fixed Propellers
94
CP Propellers
94
Multi-Engine Plants with One Propeller
94
Operational Misﬁre - Protection of the Flexible Coupling
98
Single-Engine Installations with Fixed or CP Propeller
98
Twin Engine Installations
99
Misﬁre
100
Total Misﬁre
101
Operating Media A4
102
Introduction A4.02
103
Safety Instructions A4.03
105
Regulations and Care
106
Regulations and Care
108
Distillate Fuel
108
Heavy Fuels
111
ISO-Speciﬁcation
111
CIMAC-Specifications
112
BSI-Specification
112
Notes to the Speciﬁcation of the Permissible Limits
114
Fuel Additives
115
CCAI-Limit Curves
116
Admissible Limit Speciﬁcation for the Operation with Heavy Fuel
117
Heavy Fuel Specification
118
Viscosity Temperature Sheet
119
Engine Lubricating Oil
120
Base Oil
120
Additives
120
Care of Lubricating Oil
121
Lubricating Oil Brand Recommendations
121
Lubricating Oil Filtering (By-Pass)
121
Lubricating Oil Filtering (Full Flow)
121
List of Brands of Lubricating Oil for Operation with Distillate Fuel
122
List of Brands of Lubricating Oil for Heavy Oil Operation
123
Lubricating Oil Changing
124
Limits
125
Lubricating Oil Dilution by Fuel
125
Alkalinity (TBN)
125
Water Content/Contamination
125
Lubricating Oil for Exhaust Turbocharger and Change-Over Controls
126
Multi-Purpose Grease – Lithium Saponified – Consistency Number 2
127
Recirculating Cooling Water
128
Requirements for the Cooling Water
128
Treatment of Cooling Water with Corrosion Inhibitors
130
Anti-Corrosion Oil
130
Chemical Corrosion Inhibitors
131
Checking and Care of the Treated Water
132
Changing the Cooling Water
133
Anti-Corrosion Oil Emulsion
133
Cleaning the Cooling Water Chambers before Changing the Emulsion
133
Cooling Water with Anti-Freeze Agent
134
Cleaning the Cooling Water Chambers
134
Determining the Cooling Water Mixture for 10 Degrees Dgh
135
Emulsion Freshening for Weak Concentration
136
Maintenance A5
137
Explanation of the Maintenance System
142
Scheduled Maintenance
142
Introduction A5.02
142
Maintenance System
143
Work Interval Schedule
143
Job Cards
144
Maintenance Schedule (Periodic Maintenance Work)
146
General Safety Instructions
147
Safety Instructions A5.03
147
Working on Electrical Equipment
149
Working with Hydraulic Devices
149
Checking and Adjustment of Injection Valve
149
Handling of Liquid Nitrogen or Carbon Dioxide Snow
150
Cleansing Agents/Chemicals
150
Periodical Schedule - Distillate Fuel
151
Lubricating Oil System A5.05.08.02.01.00
158
Lubricating Oil Duplex Filter A5.05.08.04.01.00
158
Periodical Schedule - Heavy Fuel
159
Prelubricating Pump/Prelubrication A5.05.08.10.00.00
161
Pressure Switches A5.05.11.01.02.01
162
Pressure Switches A5.05.11.01.03.00
162
RPM Switch A5.05.11.05.01.01
162
Lubricating Oil/Cooling Water Thermostat A5.05.11.06.01.00
162
Vibration Damper A5.05.12.04.01.03
163
Valve Clarance Inspection/Adjust
167
Tools A6
167
Valve Rocker Brackets Maintenance/Disassembly and Reassembly
169
Valve Rotator Inspection/Evaluate
174
Valve Guide / Oil Scraper Ring Inspection/Replace
175
Media Line Maintenance/Disassembly and Assembly
179
Cylinder Head Maintenance/Disassembly
182
Nozzle Sleeve Maintenance/Disassembly and Reassembly
186
Inlet and Exhaust Valves Inspection/Disassembly and Reassembly
188
Valve Cones Repair/Checking
192
Inlet Valve Cones Repair/Checking
197
Refinishing of the Valve Cone Face
199
Check of Contact Reflection/Grinding
200
Exhaust Valve Cones Repair/Checking
202
Valve Seat Ring Repair/Checking
218
Cylinder Head Inspection/Checking
227
Cylinder Head Maintenance/Cleaning
228
Cylinder Head Repair/Reassembly
230
Running Gear/Engine Timing Inspection/Checking
235
Crank Web Deflection Inspection/Measuring
236
Bearing Shells Inspection/Evaluate
240
Bearing Shells Replacement
241
Ai-Grooved Bearings Inspection/Evaluate
244
Criteria for Replacement of the Grooved Bearings
244
Wear and Levelling of the Ridges (Borderline Case)
248
Overlay Fatigue Ruptures
249
Overlay Fatique Ruptures and Empty Grooves
250
Big-End Bearings Inspection/Disassembly
251
Removing the Big-End Bearing Cap
253
Removing the Bearing Shells
253
Big-End Bearings Inspection/Reassembly
260
Fitting the Bearing Shells
260
Fitting the Bearing Cap
261
Tightening the Big-End Bolts
262
Main Bearings Inspection/Disassembly
264
Main Bearings - Measure Clearance
267
Main Bearings Maintenance/Reassembly
274
Piston Maintenance/Disassembly
278
Piston Rings and Grooves Inspection/Checking
284
Piston Maintenance/Reassembly
293
Crankcase Explosion Relief Valves Inspection/Checking
296
Cylinder Liner Inspection/Measuring
297
Cylinder Liner Maintenance/Disassembly
299
Cylinder Liner Maintenance/Reassembly
300
Engine Bolting and Unions Inspection/Checking
302
Camshaft Repair/Disassembly and Reassembly
303
Timing Gear Train Inspection/Checking
312
Governor Drive Inspection/Disassembly and Reassembly
313
Vibration Damper on Camshaft Repair/Disassembly and Reassembly
316
Control Shaft Bedding Maintenance/Checking
320
Fuel Limiter Inspection/Adjust
321
Servo-Actuator Maintenance/Disassembly and Reassembly
325
Starting Fuel Limiter Inspection/Disassembly and Reassembly
327
Control Valves Inspection/Checking
330
Compressed-Air Filter Maintenance/Cleaning
331
Exhaust Manifold Maintenance/Disassembly and Reassembly
333
Charge Air Cooler Maintenance/Disassembly and Reassembly
335
Turbocharger Maintenance/Cleaning
343
Turbocharger Sound Absorber
345
Turbocharger Maintenance/Cleaning
346
Injection Pump Repair/Disassembly and Reassembly
364
Injection Pump Maintenance/Disassembly and Reassembly
370
Fuel Injector Maintenance/Disassembly and Reassembly
380
Fuel Injector Maintenance/Adjust
383
Fuel Injector Repair/Disassembly and Reassembly
385
Duplex Fuel Filter Maintenance/Cleaning
389
Duplex Fuel Preliminary Filter Maintenance/Cleaning
392
Fuel Feed Pump Maintenance/Disassembly and Reassembly
396
Fuel Distributor Line/Manifold Line Repair/Disassembly and Reassembly
399
Fuel/Fuel Collector Rail Repair/Disassembly and Reassembly
401
Lubricating Oil System Maintenance/Oil Change
403
Lube Oil Pump Inspection/Checking
405
Lube Oil Pump Maintenance/Disassembly and Reassembly
406
Lubricating Oil Duplex Filter Maintenance/Cleaning
408
Prelubricating Pump/Prelubrication Maintenance/Checking
412
Centrifugal Cooling Water Pump Maintenance/Disassembly/Reassembly
413
Pressure Switches Inspection/Adjust
420
RPM Switch Inspection/Adjust
426
Lubricating Oil/Cooling Water Thermostat Maintenance/Checking
428
Crankcase Monitoring Device Inspection/Checking
432
Vibration Damper Maintenance/Disassembly and Reassembly
433
Summary of Tools
436

MAK M20 Maintenance Manual (350 pages)

Brand: MAK | Category: Engine | Size: 6 MB

Total Index
2
Exhaust Gas
7
Maintenance System
15
Job Cards
17
Discharge Valve
17
Safety Instructions
20
Safety Symbols
20
General Safety Instructions
22
Working on Electrical Equipment
25
Valve Clearance
47
Sequence of Operations
47
Maintenance
53
Cylinder Head
62
Maintenance
66
Cylinder Head
100
Bearing Shells
112
Sequence of Operations
123
Main Bearings
130
Maintenance
145
Auxiliary Materials
157
Sequence of Operation
159
Cylinder Liner
161
Maintenance
161
Camshaft Bearing
165
Timing Gear Train
175
Auxiliary Tools
179
Maintenance
185
Safety Note
192
Control Valves
195
Compressed-Air Filter
196
Maintenance & Cleaning
196
Exhaust Manifold
200
Maintenance
200
Charge Air Cooler
213
Washing Procedure
217
Cleaning Procedure
225
Sequence of Operations
231
Injection Pump
253
Maintenance
262
Fuel Injector
276
Maintenance
293
Fuel Feed Pump
297
Lubricating Oil System
304
Lube Oil Pump
306
Oil Pressure Control Valve
313
Maintenance
313
Pressure Switches
331
Maintenance
339
Pressure Switch
343
Vibration Damper
349

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