M20+ M20 C MAINTENANCE

8/12/2019 M20+ M20 C MAINTENANCE

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Maintenance

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Maintenance A0

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Total Index A0.01

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Maintenance A0

Total Index A0.01

Introduction A0.02

Emergency Stop Safety System A0.04

Maintenance A5

Table of Contents A5.01

Introduction A5.02


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Introduction A0.02

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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 fueloil operation, in order to ensure an expert retrofit of the engine plant and to exchange the necessary docu-mentation. When changing over from heavy fuel oil operation to destillate operation, the Caterpillar after-sales service should also be consulted for a longer period of time so that a documentation with extendedmaintenance intervals can be made available.

With regard to operation and maintenance of the engine including the necessary work to be carried out, the

operating instructions are subdivided into the following chapters:

Operating Instructions

Maintenance

Technical Engine Data

Operating Media

Control/Regulation

Tool Catalogue

With the respective information contained in the individual chapters, the technical personnel is able to

maintain the engine in such a manner that regarding its output, reliability, economy and service life opti-

mum operating results can be achieved.

If you need further information or if you have any other questions, we kindly ask you to contact our respon-

sible service organization.

The operating instructions do not release the personnel in charge of this engine plant from their duty to take

care. The recognized rules of technology are to be observed, taking into account overriding regulations,

observance of the general safety measures and locally applicable accident prevention regulations. Data or

explanations assumed to be the basic knowledge of trained technical and engine room personnel, are not

contained.

Caterpillar Motoren GmbH Co. KG is not responsible for damage caused by improper operation andmaintenance.

These operating instructions are only intended for our customers. All rights reserved for this docu-ment. All technical data contained in these operating instructions must neither be reproduced, dis-

tributed nor utilized for competitive purposes or disclosed to third parties without our expressapproval.

Postal address: Caterpillar Motoren GmbH & Co. KG, P.O. Box 9009, D-24157 Kiel

Telephone: +49(0)431- 3995-01(chief operator)

Telefax: +49(0)431-3995-2010(after-sales service only)

http://www.marine.cat.com


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Emergency StopSafety System

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Actions that must be performed after a safety/emergency stop* occurred:

- Identify the reason for emergency stop based on the points listed below.

- Work through list of corresponding sub-points.

- Contact your Caterpillar Service.

Type of emergency stop:

1. Overspeed condition

2. Lubrication oil (pressure and temperature)

3. Engine room monitoring

4. Cooling water - fresh water - HT (pressure and temperature)

5. Exhaust gas

6. Check pneumatic emergency stop system on engine after every emergency stop

7. Fault messages and measuring points

WARNINGDo not perform further starting attempts for a while after the safety/emergency stopdevice has triggered!

Note and observe the following points and actions.

If these actions are not observed, severe personal injuries as well as damage to theengine can occur, which may void the warranty.

NOTE*

With some engine assemblies, in particular in marine applications, an alarm or a po-wer reduction may be triggered before a safety/emergency stop is performed. If thereare no safety concerns, the engine must also be shut down, if an alarm occurs or en-gine power is reduced and the causes have to be eliminated.


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1. Overspeed condition

Emergency stop due to excessive rpm.

1.1 How high was the maximum rpm before emergency stop was triggered?

1.2 Why did engine go into an overspeed condition?

Check:

Check if emergency stop safety device is operational.

Check free operation of adjustment shaft and joint

Check every single regulator rack of fuel pumps in both directions for proper operation bypulling and pressing.

Checking governor drive.

Verification of possible out of calibration of actuator (if fitted).

1.3 Contact your Caterpillar Service.

2. Lube oil (lube oil pressure, lube oil temperature)

2.1 Emergency stop due to lack of lube oil

Checks:

Visual inspection of engine.

Lube oil pump drive:- Check gears for damage or loss.

Check lube oil pressure switch.

Check lube oil filter for metal chips.

Check oil sump and piping for leaks and cracks.

2.2 Contact the Caterpillar Service.

NOTEThe following checks may be of assistance during troubleshooting and permit identi-fication of root causes of an emergency stop. However, they cannot cover the entirespectrum of possible causes.


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2.3 Emergency stop due to high lube oil temperature

Checks:

Check temperature sensor.

Check oil cooler.

Check cooling water circuit.

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.

2.4 Contact the Caterpillar/ MaKService.

3. Engine room monitoring

Emergency Stop due to excessive oil mist concentrationsee engine documentation, chap-

ter "Operating Instructions".

Checks:

Check engine room monitoring device (operational test),see"engine documentation, chapter "External Documentation"C5.05.11.02.03. nn.

Visual inspection of engine and gear train,

of cam shaft trough,

of combustion chamber,

of turbo charger.

3.1 Contact your Caterpillar Service.

4. Cooling water (fresh water - HT, pressure and temperature)

Emergency stop due to excessively high cooling water temperature

Checks:

Visual inspection of engine

Check temperature sensors

Check fresh water cooler

Operational test of LT - Cooling water circuit with cooling water pump.

4.1 Contact your CaterpillarService.
http://k%20c5.pdf/http://k%20c5.pdf/


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5. 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.

Injection valves (refer to A5.05.07.08.01.nn).

Turbocharger

5.1 Contact your CaterpillarService.

6. Check pneumatic emergency stop system on engine after every emergencystop

Checks:

Check emergency stop pneumatic system on the engine for leaks.

Stop valve to main start line upstream from start valve must constantly be open duringoperation, see engine documentation, chapter "Operating Instructions".

NOTE

In order for emergency stop safety device to operate properly, 7,5 bar pneumaticsupply has to be available continuously.


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7. Fault messages and measuring points

7.1 General fault messages:

Fault message: Description:(Measuring point number)

6105 * Low shutdown air pressure

9631 * Oil mist detector failure

9601 * Terminal set X1 voltage failure

9717 * Terminal set X3 voltage failure

* see also List of Measuring Points, see"engine documentation, chapter "Control/Regulati-on". C5.05.02.01.nn.nn.

7.2 Plant-specific fault messages:

- Safety system failure

- RPM switch unit failure (overspeed)

7.3 Please contact the CaterpillarCustomer Service.

CAUTION

The fault messages listed below do not directly lead to an emergency stop, but theyconsiderably affect reliable engine operation.

If such a fault message appears on the monitoring display of the alarm system, theengine plant may only be operated for a short time and under permanent observati-on.

At any rate, the cause of the fault message must be remedied immediately.
http://k%20c5.pdf/http://k%20c5.pdf/


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Maintenance A5

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Maintenance


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Maintenance A5


Introduction A5.02

Periodical scheduleDistillate fuel A5.04.01

Periodical scheduleHeavy 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

Media line A5.05.01.05.50.00

Cylinder Head A5.05.01.06.01.00

Nozzle Sleeve A5.05.01.06.50.00

Inlet and Exhaust Valve Cones A5.05.01.07.01.01

Valve Cones A5.05.01.08.01.00Inlet Valve Cones A5.05.01.08.01.01

Exhaust Valve Cones A5.05.01.08.01.03

Inlet Valve Cones A5.05.01.08.01.04

Valve Seat Ring A5.05.01.08.02.00

Valve Seat Ring A5.05.01.08.02.01




Engine, gear A5.05.02

Running Gear/Engine Timing A5.05.02.01.01.00

Crank Web Deflection A5.05.02.02.01.00

Bearing Shells A5.05.02.03.07.01

Al-Grooved Bearings A5.05.02.03.09.01

Big-End Bearings A5.05.02.04.01.01

Big-End Bearings A5.05.02.04.02.00

Main Bearings A5.05.02.05.01.01

Main Bearings A5.05.02.05.02.00

Piston A5.05.02.06.01.01


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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 A5.05.03.04.01.00Cylinder Liner A5.05.03.04.02.00

Engine Bolting and Unions A5.05.03.07.01.00

Engine, control A5.05.04

Camshaft Bearing A5.05.04.01.01.00

Camshaft A5.05.04.04.01.00

Camshaft A5.05.04.04.01.01

Camshaft A5.05.04.04.01.02

Timing Gear Train A5.05.04.08.01.00

Governor Drive A5.05.04.08.03.00

Vibration damper on camshaft A5.05.04.09.01.00

Vibration damper on camshaft A5.05.04.09.01.01

Vibration Damper on Camshaft A5.05.04.09.01.02

Engine, regulation A5.05.05

Control shaft bedding A5.05.05.01.02.00

Fuel Limiter A5.05.05.04.01.00Fuel Limiter A5.05.05.04.01.01

Servo-Actuator A5.05.05.04.02.00

Servo-Actuator A5.05.05.04.02.01

Starting Fuel Limiter A5.05.05.05.01.00

Control Valves A5.05.05.09.05.00

Compressed-Air Filter A5.05.05.09.06.00

Compressed-Air Filter A5.05.05.09.06.01

Reglerl A5.05.05.25.00.01


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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





Exhaust gas turbocharger A5.05.06.05.00.01



Exhaust gas turbochargerTurbine cleaning A5.05.06.05.02.03

Exhaust gas turbochargerTurbine cleaning A5.05.06.05.02.04

Turbocharger A5.05.06.13.01.00







Abgasturbolader A5.05.06.13.01.07


Exhaust gas turbocharger - HPR 5000 -(KBB) A5.05.06.13.02.11

Exhaust gas turbocharger - HPR 4000 -(KBB) A5.05.06.13.02.12

Engine, fuel system A5.05.07

Injection Pump A5.05.07.02.01.00







Fuel Injector A5.05.07.07.01.00



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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

Lubricating Oil System A5.05.08.02.01.00

Lube Oil Pump A5.05.08.03.01.00

Lube Oil Pump A5.05.08.03.02.00

Lubricating Oil Duplex Filter A5.05.08.04.01.00

Oil pressure control valve A5.05.08.05.01.00

Oil pressure control valve A5.05.08.05.01.01

Prelubricating pump/Prelubrication A5.05.08.10.00.00

Engine, cooling water system A5.05.09

Centrifugal Cooling Water Pump A5.05.09.07.01.00



Engine control equipment A5.05.11

Pressure Switches A5.05.11.01.02.01

Pressure Switches A5.05.11.01.03.00RPM Switch A5.05.11.05.01.02

Lubricating Oil/Cooling Water Thermostat A5.05.11.06.01.00

Lubricating Oil/Cooling Water Thermostat A5.05.11.06.01.01

Pressure Switch A5.05.11.06.05.02

Pressure Switch A5.05.11.06.06.02

Crankcase Monitoring Device A5.05.11.09.01.03

Engine auxiliary units A5.05.12

Vibration Damper A5.05.12.04.01.03


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Introduction A5.02

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1. 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 themaintenance documents.

No claims can be raised owing to missing instructions in the maintenance documents, ifdamage is caused by improper handling.

All information refers to the date of printing.

2. Explanation of the maintenance system

2.1 Scheduled maintenance

Without Scheduled maintenance the economicoperation of supercharged engine is inthe long run not possible at today's state of art.

The explanations are used to make the user of this engine plant familiar with the existingmaintenance system of Caterpillar Motoren GmbH & Co. KG and to interest and deepenthe understanding of the user for the problems and importance of the Scheduledmaintenance.

It is the purpose of the maintenance to replace parts subject to wear and tear or to repair

these parts before they are damaged.

The Scheduled maintenance is thereby supported by inspections according to fixeddeadlines. These inspections are decision criteria for the need and extend of mainte-nance and servicing.

The following is used as parameter:

data on wear and tear

evaluation criterion and

performance checks

Most of the work to be carried out does not have a fixed deadline since the service life ofindividual components is highly influenced by environmental and operating conditions,fuel qualities and their care.


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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.

It is recommended to consult Caterpillar Motoren GmbH & Co. KG with regard to exten-ded intervals in order to maintain the guarantee.

The information given by us gives no rise to legal claims.

2.2 Maintenance system

The maintenance system consists of:

work interval schedule

job cards

maintenance schedule (large-scale plan) *

While the work interval schedule indicates the date when inspection, maintenance orrepair shall be carried out, the job cards indicate the manner in whichthe work is to becarried out.

* will be handed during commissioning of the engine


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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:

Daily inspection and control work

Initial inspection and maintenance work

Work which has to be carried out after first commissioning or commissioning after

major repair work.

Periodic maintenance work

A list of all recurrent inspection, maintenance and repair work to be carried out at thescheduled date.

The indicated intervals are statistical mean values. Other values may be obtained,depending on equipment condition, operating and maintenance conditions.

Maintenance work to be carried out independent of deadlines

List of work which may be required in the scope of scheduled work which cannot beallocated to a deadline.


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2.2.2 Job cards

The job cards are instructions for inspection, maintenance, repair and safety check.

The job card number consists of the index breakdown (A5.05) and the maintenance

number (bold) subdivided into four pairs of digits.

Discharge valveInspection / Dismounting and mounting

A5.05.01.04.01.03

6,000 / 12,000

M20/M25/M32/M43

01Engine type

Operating hours/maintenance deadline

RegisterMain maintenance group

Title of the job card

ActivityMaintenance work

en / 30.01.10 IB000003 1/1

Language

Date of issue

Registration number Page/number of pages

See also: 01.01.01.nn, 01.02.01.nn, 01.08.01.nn

Spare parts list: B1.05.01.7.2104, B1.05.01.7.2220

Time requirement: 1 Pers. / 3 h

Personnel qualification: skilled engine hand

Operating medium: Heavy fuel and destillate fuel

Job cardsDocument number

Operating Instructions

Chapter maintenance Subchapter

Job cards

Main maintenance group

Maintenance group

Subgroup

Breakdown

A5.05.01.04.01.03

Variant


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Under the designation "tools(W)" only special and additional tools are listed with thetool 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.

The indicated personnel and time requirement does not define theworking time ofthe individual person.

The indicated time is based on estimated mean values which may deviate accordingto the equipment of the plant and its maintenance conditions. Wherever the requiredworking time depends on the number of cylinders the indicated time of the mainte-nance sheets refers to one cylinder unit only.

2.2.3 Maintenance schedule (Periodic maintenance work)

A large-scale plan showing all maintenance work up to the largest maintenance intervalclearly indicating all occurrences and the future work expenditure for the individualcomponents.

It would be useful to mount the plan on a wall; when this is not possible for space rea-sons, it has to be folded and filed in the map maintenance forms *.

We cannot and will not give instructions for handling this plan but we will only give you

some guidelines how to use this plan as an aid for the maintenance system.

The work already carried out will be countersigned in fields intended for this purpose.Different colours can be used to differentiate between the results, e.g.: green = nodefects/o.k.; yellow = readjustment/correction (e.g. clearances); red = damage/replace-ment of parts.

Typical consumption parts which are replaced routinely or any time mounting is carriedout (O-ring seals, O-rings etc.) are not considered defective parts.

* The map will be handed during commissioning of the engine


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3. Safety instructions

3.1 Safety symbols

In the present operating instructions the following warning notices are used:

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 topersons.

A warning notice of this risk level signals a potentially dangerous situation.

If the dangerous situation is not prevented, this could lead to death or serious injury to persons.

Follow the instructions in this warning notice to prevent the possible risk of death or serious injuryto persons.

A warning notice of this risk level signals a potentially dangerous situation.

If the dangerous situation is not prevented, this could lead to minor or moderate injury.

Follow the instructions in this warning notice to prevent injury to persons.

DANGER

WARNING

CAUTION


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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.

A note identifies additional information that facilitates the handling of the engine.

CAUTION

NOTE


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3.2 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.

Participants in this acceptance procedure are the authorized personnel of Caterpillar Motoren

GmbH & Co. KG, the managing and operating personnel of the operator and also representatives

of the insurance companies.

This important system is subject to recurrent inspections and tests in order to ensure proper

function of its individual components.

In the section "Scheduled Maintenance" you will find the respective test frequencies and related

job instructions that should be followed to protect the personnel from injuries and prevent material

damages.

NOTE

The provisions of the relevant accident prevention regulations of the appro-priate employer's liability insurance association are to be observed any timeoperation and repair work is carried out.


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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 systemswith 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.

When carrying out overhead assembly work, the specially designed or safe-ty-oriented climbing aids are to be used only!

Do not use engine/plant parts for climbing on!

Use personal protective equipment as far as necessary or as required by theregulations!

Pressurized plant components (lube oil, hydraulic oil, fuel, cooling water, star-ting and control air) must be depressurized. Shut-off valves are to be securedby a plate Do not open!

When work is being carried out on engines and systems, the switch-on de-vices have to be switched off and protected. In order to prevent reconnection,the engines and systems have to be marked with a plate Do not switch oran appropriate pictogram plate!

Mounting openings are to be protected!

Replaced seals should be disposed of immediately, and above all, it shouldbe taken care that this material is not overheated even by accident e.g. du-ring combustion and welding operations. If this should however has happen-ed, the gases emitted must not be inhaled. Skin contact with decomposedVITONR is to be avoided at all times. After a fire with VITONR, it is essentialthat neoprene gloves are worn during the clearing up operations.


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CAUTION

Seals made of VITONR have been used at various locations in the engine.With normal engine operation this material is completely harmless, however itshould not be exposed to temperatures above 300 C, since above 325 C athermal decomposition and the formation of hydrofluoric acid can occur.

CAUTION

Maintenance and repair work must only be carried out by skilled and autho-rized personnel!

NOTE

Any residues have to be neutralized before their disposal, i.e. saturated withcalcium hydroxide.

Clean the engine parts, especially connections and threaded unions of anytraces of oil, fuel or preservatives before carrying out maintenance/repair (di-

sassembly, assembly)!

Never use aggresive detergents and preservatives!

Use non-fuzzy cleaning rags!

Observe all indicating labels attached to the engine!


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3.3 Working on electrical equipment

CAUTION

Work on the electrical equipment of the engine/plant must be carried out onlyby a skilled electrician or by instructed persons under the supervision andguidance of a skilled electrician in accordance with the electrical engineeringrules 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!

The electrical equipment is to be inspected/checked at regular intervals.Defects such as loose connections or scorched cables must be rectified imme-diately!

DANGER

Engine or plant parts on which inspection and maintenance work is being car-

ried out have to be - if prescribed - shut off at the power supply and providedwith the notice Do not switch on or the corresponding warning sign!


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3.4 Working with hydraulic devices

3.5 Checking and adjustment of injection valve

WARNING

Do not place parts of your body above/below pressurized hydraulic tools!

Replace hydraulic hose lines at regular intervals, even if no safety relevantdefects are detectable!

Operating instructions, tightening torques and setting dimensions specified inthe appropriate job card are to be carefully observed!

The minimum bending radius of the high-pressure hoses are to be strictly ob-served!

The hose lines are to be protected against damage caused by externalmechanical, thermal or chemical influences!

CAUTION

During testing make sure that no parts of your body are positioned in the area of the

fuel jet!

Do not inhale the fuel mist - respiratory mask!


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3.6 Handling of liquid nitrogen or carbon dioxide snow

3.7 Cleansing agents/chemicals

WARNING

When handling liquid nitrogen or carbon dioxide snow, safety shoes, safetygloves and safety glasses are to be worn in order to avoid injuries. Observeprotection against cold!

CAUTIONParts of the skin which have come into contact with liquid nitrogen or carbondioxide snow must not be rubbed but covered with sterile surgical bandage

NOTE

Use only cleansing agents with a flash point above 65 C!

Observe instructions for use in accordance with DIN safety data sheet of the regulati-ons for dangerous substances!

Observe the specialist disposal of all cleansing agents and chemicals in accordancewith the regulations for dangerous substances!

In case of accident, observe the accident leaflets including first-aid actions fordangerous substances in accordance with the regulations for dangerous substances!


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3.8 Proposition 65 Warning

NOTE

California / USA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the state ofCalifornia to cause cancer, birth defects, and other reproductive harm.


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Periodical scheduleDistillate fuel

A5.04.01

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Intervall Designation / Doc-Nr.Work to be carried outRemarks

Daily inspection and monitoring procedures

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

(if it is not automated)

General Engine operating data Chapter 3Compare with acceptance test records: Technical engine dataSpeed, rating Acceptance test record

Temperature Lubricating oil Chapter 3Engine inlet; Temperature rise at rated output Technical engine data

see also acceptance test record Temp. of operating medias

Temperature Cooling water Chapter 3Engine outlet; Temperature rise at rated output Technical engine datasee also acceptance test record Temp. of operating medias

Temperature Nozzle cooling oil Chapter 3 Chapter 3Upstream nozzles Technical engine data

Temp. of operating medias

Temperature Cooling water A1.10Upstream charge air cooler; downstream charge air cooler

Temperature Cooling water Chapter 3

Upstream charge air cooler; Technical engine datadownstream charge air cooler Acceptance test record

Temperature Exhaust gas Chapter 3After cylinder; downstream turbocharger Technical engine data

Acceptance test record

Pressure Lubricating oil Chapter 3At the main bearing or at the camshaft bearing Technical engine datasee also acceptance test record Press. of operating medias

Pressure Cooling water Chapter 3Upstream engine Technical engine datasee also acceptance test record Press. of operating medias

Pressure Fuel Chapter 3Upstream pumps Technical engine data

Press. of operating medias

Pressure Control air Chapter 3Technical engine dataPress. of operating medias

Pressure Starting air Chapter 3Technical engine dataPress. of operating medias

Pressure Charge air Chapter 3Upstream charge air cooler; Technical engine datadownstream charge air cooler Acceptance test record


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Lube oil Lube oil circulation tank Chapter 1system Check of the lube oil level Operating instructions

Lube oil Lubricating oil duplex filter A5.05.08.04.01.00system Maintenance/Cleaning

at 50 % differential pressure

Cooling Expansion tank Chapter 1water system Check of the cooling water level Operating instructions

Fuel Day tank Chapter 1system Check of the fuel level Operating instructions

Fuel Fuel duplex filter A5.05.07.12.01.00system Maintenance/Cleaning


Pressure air Air bottles Chapter1Drain Operating instructions


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First inspection and maintenance procedures

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Work to be carried out after the first commissioning or after major repairs.

24 h Duplex fuel filter A5.05.07.12.01.00Maintenance/Cleaningat 50 % differential pressure clean strainer

24 h Lubricating oil system A5.05.08.02.01.00Maintenance/Oil change

24 h Lubricating oil duplex filter A5.05.08.04.01.00Maintenance/Cleaningat 50 % differential pressure clean cartridges

150 h Valve clearance A5.05.01.01.01.nnInspection/Adjust

150 h Engine bolting and unions A5.05.03.07.01.00Inspection/CheckingTight fit and leaks

150 h Compressed air strainer A5.05.05.09.06.nnMaintenance/Cleaning
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Periodical maintenance procedures


24 h Turbocharger A5.05.06.05.00.01Maintenance/Cleaningsee book C

150 h Valve rotor A5.05.01.03.01.00Inspection/Evaluate

150 h Cylinder head A5.05.01.10.00.00Inspection/Checkingof all cylinder units

150 h Vorschmierpumpe/Vorschmierung A5.05.08.10.00.00Wartung/Prfen


300 h Turbocharger A5.05.06.13.01.nn

Maintenance/Cleaningsee book C

750 h Cooling water system A4.05.09.01Inspection/Anti-corrosion oil

750 h Duplex Fuel Filter A5.05.07.12.01.00Maintenance/Cleaning

1.500 h Valve clearance A5.05.01.01.01.nnInspection/Adjust

1.500 h Running gear/Engine timing A5.05.02.01.01.00Inspection/Checking

1.500 h Crankcase explosion safety valve A5.05.03.01.01.nnInspection/Checking

1.500 h Control shaft bedding A5.05.05.01.02.00Maintenance/Checking

1.500 h GovernorGovernor behaviour/Governor control rodsee book C


3.750 h Timing gear train A5.05.04.08.01.00Inspection/Checking
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3.750 h Actuator A5.05.05.04.01.nnInspection/Adjust

3.750 h Starting fuel limiter A5.05.05.05.01.00Inspection/Disassembly and reassembly

3.750 h Pressure switch A5.05.11.01.02.01Inspection/Adjust


3.750 h GovernorOil changesee book C

7.500 h Anti-corrosion oil emulsion A4.05.09.02Changing

7.500 h Inlet and exhaust valves A5.05.01.07.01.01Inspection/Disassembly and reassemblyof one cylinder unit

7.500 h Piston rings and grooves A5.05.02.07.01.nnInspection/Checking

of one cylinder unit

7.500 h Compressed air filter A5.05.05.09.06.nnMaintenance/Cleaning

7.500 h Exhaust manifold A5.05.06.01.01.nnMaintenance/Disassembly and reassembly

7.500 h Turbo Charger Sound Absorber A5.05.06.05.01.nnInspection/Cleaning

7,500 h Injection pump A5.05.07.03.01.nnInspection/Disassembly and reassemblyof one pump

7.500 h Fuel injector A5.05.07.09.01.nnRepair/Disassembly and reassembly

7.500 h RPM-switch A5.05.11.05.01.02Inspection/Adjust

7.500 h Lubricating Oil/Cooling Water Thermostat A5.05.11.06.01.nnMaintenance/Checking

7.500 h Oil mist detector A5.05.11.09.01.03Inspection/Checking

15.000 h Nozzle sleeve A5.05.01.06.50.00Maintenance/Disassesmbly and reassembly
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15.000 h Inlet and exhaust valves A5.05.01.07.01.01Inspection/Disassembly and reassemblyof all inlet and exhaust valves

15.000 h Big-end bearings A5.05.02.04.01.01Inspection/Disassemblyof one big-endbearing

15.000 h Main bearings A5.05.02.05.01.01Inspection/Disassemblyof two main bearings

15.000 h Governor drive A5.05.04.08.03.00Inspection/Disassembly and reassembly

15.000 h Vibration damper on camshaft A5.05.04.09.01.nnRepair/Disassembly and reassembly

15.000 h Exhaust gas turbocharger A5.05.06.05.00.01Maintenance/Cleaning resp. revision of turbochargersee book C

15,000 h Injection pump A5.05.07.03.01.nnInspection/Disassembly and reassemblyof all pumps

15.000 h Fuel feed pump A5.05.07.13.01.00Maintenance/Disassembly and reassembly

15.000 h Lub oil pump A5.05.08.03.01.00Inspection/Checking

15,000 h Oil pressure regulating valve A5.05.08.05.01.nnMaintenance/Adjust

15.000 h Centrifugal cooling water pump A5.05.09.07.01.nnMaintenance/Disassembly and reassembly

30.000 h Valve rocker A5.05.01.02.02.00

Maintenance/Disassembly and reassembly

30.000 h Valve guide/Oil scraper ring A5.05.01.05.01.01Inspection/Replaceat all valves

30.000 h Cylinder head A5.05.01.10.01.01

Maintenance/Cleaning

30.000 h Big-end bearings A5.05.02.04.01.01Inspection/Disassemblyexchange all big-end bearings

30.000 h Main bearings A5.05.02.05.01.01Inspection/Disassemblyexchange of all bearings


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30.000 h Piston rings and grooves A5.05.02.07.01.nnInspection/Checkingall cylinder units

30.000 h Cylinder liner A5.05.03.04.01.00Maintenance/Disassemblyat all cylinder units

30.000 h Control valves A5.05.05.09.05.00Inspection/Checking


30.000 h Vibration damper A5.05.12.04.01.03Maintenance/Disassembly and reassembly
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Non-interval dependent maintenance procedures

Valve rocker brackets A5.05.01.02.01.00Maintenance/Disassembly and reassembly

Media guiding system A5.05.01.05.50.00Maintenance/Disassembly and reassembly

Cylinder head A5.05.01.06.01.00Maintenance/Disassembly

Inlet and exhaust valve cones A5.05.01.08.01.nnRepair/Checking

Valve seat ring A5.05.01.08.02.nnRepair/Checking

Cylinder head A5.05.01.11.01.00Repair/Reassembly

Crank web deflection A5.05.02.02.01.00Inspection/Measuring

Bearing shells A5.05.02.03.07.01

Inspection/Evaluate

Al-grooved bearings A5.05.02.03.09.01Inspection/Evaluate

Big-end bearings A5.05.02.04.02.00Inspection/Reassembly

Main bearings A5.05.02.05.02.00Maintenance/Reassembly

Piston A5.05.02.06.01.nnMaintenance/Disassembly

Piston A5.05.02.10.01.01Maintenance/Reassembly

Cylinder liner A5.05.03.04.02.00Maintenance/Reassembly

Engine bolting and unions A5.05.03.07.01.00Inspection/Checking

Camshaft A5.05.04.04.01.nnRepair/Disassembly and reassembly

Charge air cooler A5.05.06.04.02.nn

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Turbocharger A5.05.06.05.00.01Maintenance/Cleaningsee book C

Injection pump A5.05.07.02.01.nnRepair/Disassembly and reassembly

Injection pump A5.05.07.03.01.nnMaintenance/Disassembly and reassembly

Fuel injector A5.05.07.07.01.nnMaintenance/Disassembly and reassembly

Fuel injector A5.05.07.08.01.nnMaintenance/Adjust

Duplex fuel filter A5.05.07.12.01.00Maintenance/Cleaning

Fuel Distributor Line/Manifold Line A5.05.07.15.01.nnRepair/Disassembly and reassembly

Lubricating oil system A5.05.08.02.01.00Maintenance/oil change

Lub oil pump A5.05.08.03.02.00Maintenance/Disassembly and reassembly

Lubricating oil duplex filter A5.05.08.04.01.00Maintenance/Cleaning


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Periodical scheduleHeavy fuel

A5.04.02

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Daily inspection and monitoring procedures

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(if it is not automated)

General Engine operating data Chapter 3Compare with acceptance test records: Technical engine dataSpeed, rating Acceptance test record

Temperature Lubricating oil Chapter 3Engine inlet; Temperature rise at rated output Technical engine datasee also acceptance test record Temp. of operating medias

Temperature Cooling water Chapter 3Engine outlet; Temperature rise at rated output Technical engine datasee also acceptance test record Temp. of operating medias

Temperature Fuel Chapter 3Upstream pumps Technical engine data


Temperature Cooling water Chapter 3Upstream charge air cooler; Technical engine datadownstream charge air cooler Acceptance test record

Temperature Charge air Chapter 3

Upstream charge air cooler; Technical engine datadownstream charge air cooler Acceptance test record

Temperature Exhaust gas Chapter 3After cylinder; downstream turbocharger Technical engine data

Acceptance test record

Pressure Lubricating oil Chapter 3At the main bearing or at the camshaft bearing Technical engine datasee also acceptance test record Press. of operating medias

Pressure Cooling water Chapter 3Upstream engine Technical engine datasee also acceptance test record Press. of operating medias

Pressure Fuel Chapter 3Upstream pumps Technical engine data


Pressure Control air Chapter 3Technical engine dataPress. of operating medias

Pressure Starting air Chapter 3Technical engine dataPress. of operating medias

Pressure Charge air Chapter 3Upstream charge air cooler; Technical engine datadownstream charge air cooler Acceptance test record


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Lube oil Lube oil circulation tank Chapter 1system Check of the lube oil level Operating instructions

Lube oil Lubricating oil duplex filter A5.05.08.04.01.00system Maintenance/Cleaning


Cooling Expansion tank Chapter 1water system Check of the cooling water level Operating instructions

Fuel Day tank Chapter 1system Check of the fuel level Operating instructions

Fuel Fuel duplex filter A5.05.07.12.01.00system Maintenance/Cleaning


Pressure air Air bottles Chapter1Drain Operating instructions


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First inspection and maintenance procedures

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

Work to be carried out after the first commissioning or after major repairs

24 h Duplex fuel filter A5.05.07.12.01.00Maintenance/Cleaningat 50 % differential pressure clean strainer

24 h Lubricating oil system A5.05.08.02.01.00Maintenance/Oil change

24 h Lubricating oil duplex filter A5.05.08.04.01.00Maintenance/Cleaningat 50 % differential pressure clean cartridges

150 h Valve clearance A5.05.01.01.01.nnInspection/Adjust

150 h Engine bolting and unions A5.05.03.07.01.00

Inspection/CheckingTight fit and leaks
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Periodical maintenance procedures



150 h Valve rotor A5.05.01.03.01.00

Inspection/Evaluate150 h Cylinder head A5.05.01.10.00.00

Inspection/Checkingof all cylinder units

150 h Prelubricating pump/Prelubrication A5.05.08.10.00.00

Maintenance/Checking

300 h Turbocharger A5.05.06.05.00.01

Maintenance/Cleaningsee book C

300 h Turbocharger A5.05.06.13.01.nn


750 h Cooling water system A4.05.09.01Inspection/Anti-corrosion oil

750 h Duplex fuel prefilter A5.05.07.12.02.nnMaintenance/Cleaning

750 h Oil mist detector A5.05.11.09.01.03Inspection/Checking

1.500 h Valve clearance A5.05.01.01.01.nnInspection/Adjust


1.500 h Crankcase explosion safety valve A5.05.03.01.01.nnInspection/Checking

1.500 h Control shaft bedding A5.05.05.01.02.00

Maintenance/Checking

1.500 h Kurbelraumberwachungsgert A5.05.11.09.01.03Kontrolle/Prfen

1.500 h Governor

Governor behaviour/Governor control rod

see book C

3.750h Running gear/Engine timing A5.05.02.01.01.00Inspection/Checking


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3.750 h Timing gear train A5.05.04.08.01.00Inspection/Checking

3.750 h Actuator A5.05.05.04.01.nnInspection/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 GovernorOil changesee book C

7.500 h Anti-corrosion oil emulsion A4.05.09.02Changing

7.500 h Inlet and exhaust valves A5.05.01.07.01.01Inspection/Disassembly and reassemblyof one cylinder unit

7.500h Piston rings and grooves A5.05.02.07.01.nnInspection/Checkingof one cylinder unit

7.500 h Compressed air strainer A5.05.05.09.06.nnMaintenance/Cleaning

7.500 h Exhaust manifold A5.05.06.01.01.nn


7,500 h Injection pump A5.05.07.03.01.nnInspection/Disassembly and reassemblyof one pump

7.500 h Injection valve A5.05.07.09.01.nnRepair/Disassembly and reassembly

7.500 h RPM-switch A5.05.11.05.01.02

Inspection/Adjust

7.500 h Lubricating Oil/Cooling Water Thermostat A5.05.11.06.01.nnMaintenance/Checking

7.500 h Oil mist detector A5.05.11.09.01.03Inspection/Checking

15.000 h Valve guide/Oil scraper ring A5.05.01.05.01.01

Inspection/Replaceat all valves
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15,000 h Nozzle sleeve A5.05.01.06.50.00Maintenance/Disassesmbly and reassembly

15.000h Inlet and exhaust valves A5.05.01.07.01.01Inspection/Disassembly and reassemblyof all inlet and exhaust valves

15.000 h Cylinder head A5.05.01.10.01.01


15.000h Big-end bearings A5.05.02.04.01.01

Inspection/Disassemblyof one big-end bearing

15.000 h Main bearings A5.05.02.05.01.01Inspection/Disassemblyof two main bearings

15.000 h Governor drive A5.05.04.08.03.00Inspection/Disassembly and reassembly

15.000 h Vibration damper on camshaft A5.05.04.09.01.nnRepair/Disassembly and reassembly

15,000 h Injection pump A5.05.07.03.01.nn

Inspection/Disassembly and reassemblyof all pumps

15.000 h Fuel feed pump A5.05.07.13.01.00Maintenance disassembly and reassembly

15.000h Lub oil pump A5.05.08.03.01.00Inspection/Checking

15.000h Centrifugal cooling water pump A5.05.09.07.01.nn


30.000 h Valve rocker A5.05.01.02.02.00Maintenance/Disassembly and reassembly

30.000 h Big-end bearings A5.05.02.04.01.01Inspection/Disassemblyexchange of all big-endbearings

30.000 h Main bearings A5.05.02.05.01.01

Inspection/Disassemblyexchange of all bearings

30.000 h Piston rings and grooves A5.05.02.07.01.nnInspection/Checkingall cylinder units

30.000 h Cylinder liner A5.05.03.04.01.00

Maintenance/Disassemblyat all cylinder units


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30.000 h Control valves A5.05.05.09.05.00Inspection/Checking


30.000 h Vibration damper A5.05.12.04.01.03

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Non-interval dependent maintenance procedures

Valve rocker brackets A5.05.01.02.01.00Maintenance/Disassembly and reassembly

Media guiding system A5.05.01.05.50.00Maintenance/Disassembly and reassembly

Cylinder head A5.05.01.06.01.00Maintenance/Disassembly

Inlet and exhaust valve cones A5.05.01.08.01.nnRepair/Checking

Valve seat ring A5.05.01.08.02.nnRepair/Checking

Cylinder head A5.05.01.11.01.00Repair/Reassembly

Crank web deflection A5.05.02.02.01.00Inspection/Measuring

Bearing shells A5.05.02.03.07.01

Inspection/Evaluate

Al-grooved bearings A5.05.02.03.09.01Inspection/Evaluate

Big-end bearings A5.05.02.04.02.00Inspection/Reassembly

Main bearings A5.05.02.05.02.00Maintenance/Reassembly

Piston A5.05.02.06.01.nnMaintenance/Disassembly

Piston A5.05.02.10.01.01Wartung/Montage

Cylinder liner A5.05.03.04.02.00Maintenance/Reassembly

Engine bolting and unions A5.05.03.07.01.00Inspection/Checking

Camshaft A5.05.04.04.01.nnRepair/Disassembly and reassembly

Actuator A5.05.05.04.01.nn


Charge air cooler A5.05.06.04.02.nnMaintenance/disassembly and reassembly
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Injection pump A5.05.07.03.01.nnMaintenance/Disassembly and reassembly

Injection valve A5.05.07.07.01.nnMaintenance/Disassembly and reassembly

Injection valve A5.05.07.08.01.nnMaintenance/Adjust

Duplex fuel filter A5.05.07.12.01.00


Fuel Distributor Line/Manifold Line A5.05.07.15.01.nnRepair/Disassembly and reassembly

Lubricating oil system A5.05.08.02.01.00Maintenance/oil change

Lub oil pump A5.05.08.03.02.00

Maintenance/Disassembly and reassemblyLubricating oil duplex filter A5.05.08.04.01.00Maintenance/Cleaning
http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/


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Valve ClearanceInspection / Adjust

A5.05. 01.01.01.00

1500M20

en / 30.09.2010 IB021028 1/2

01See also: 02.01.01.nn

Spare parts list: B1.05.01.2.2107

Time requirement: 1 Pers./ 0,50 h


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Operating medium: Heavy fuel and distillate fuel

Inspection:

150 operating hoursafter first commissioning or after basic overhaul, the valve clearance is tobe checked and readjusted, followed by a check after 1,500 operating hours.

Tools:

Turning rod W1 * 2.9100-380Feeler gauge W2 * 1.9075-3

* not available as figure

Valve clearance (Fig. 1/S):

Inlet0.6 mm

Exhaust:0.8 mm

Readjust the valve bridge position to the valve spindles before each valve clearance adjustment, du-ring inspections at intervals or due to works at the valve drive components

Sequence of operations:

1. Adjust valve bridge.

1.1 Open decompression valves.

1.2 Remove the hoods without damaging the packing.

1.3 Turn the crank shaft in such a manner that the piston of the cylinder to be adjusted is moved tothe ignition dead center position.

NOTE

The valve clearance shall only be measured with warm engine, i.e. 15 min after theengine is shut down.
http://k%20a6.pdf/http://k%20a6.pdf/


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Valve ClearanceInspection / Adjust

A5.05. 01.01.01.00

1500M20

en / 30.09.2010 IB021028 2/2

011.4 Adjust a sufficiently large clearance sbetween the valve rocker (Fig. 1/1) and/orvalve bridge by folding back the valverocker (1) and/or by adjusting the valveadjusting screw (2).

1.5 Loosen counternut (Fig. 2/3) and unscrewthe adjusting screw (4) until there issufficient clearance when the valve bridgeis tipped in the direction of rotation a.

1.6 Tilt the valve bridge in the direction ofrotation b and screw the adjusting screw(Fig. 3/4) into the valve bridge until thevalve bridge has contact at both valves.

Tighten counternut (3).

2. Adjust the valve clearance.

2.1 Measure the clearance (Fig. 1/S) bymeans of a feeler gauge. Thereby, pressthe pushrod down.

2.2 Correct clearance s.

2.2.1 Loosen counternut.

2.2.2 Turn the square of the valve adjustingscrew (2) until the prescribed clearance isobtained.

2.2.3 Retighten the counternut to fix the positionof the adjusting screw.

2.2.4 Recheck the clearance after thecounternut is tightened.

NOTE

During tightening of the coun-ternut, the adjusting screw (4)turns back so far that an equalgap between valve bridge andboth valves is obtained.


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Valve clearanceInspection / Adjust

A5.05. 01.01.01.02

1500M20

en / 30.09.2010 IB025384 1/2

01See also: 02.01.01.nn




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Inspection:

Check valve clearance,adjust if necessary every 1.500 h

Tools:

Feeler gauge W1 * 1.9075-003Turning rod W2 * 2.9100-380* not illustrated


1. Adjust valve bridge.

1.1 Open the decompression valve.

1.2 Remove the cylinder head covers.

1.3 Move the cylinder to be adjusted to firingTDC. Inlet and exhaust valves are closed, rocker armrelieved.

1.4 Release valve bridge (1) of rocker arm (5).Enlarge clearance s and/or flap back rocker arm (5).

NOTE

The valve clearance should only be measured when the engine is warm, i.e. 15 min.after the engine is shut down.

The position of the valve bridge must be readjustedbefore adjusting the valveclearance during scheduled inspections or due to work being carried out on the valvedrive components.

NOTEThe adjustment is necessary so that the clearance s of the valve bridge (Fig.1/1) isdistributed evenly onto the corresponding valve cones (2,3).There must be a sufficient clearance s between the valve adjusting screw (4) andthe valve bridge (1) when adjusting the valve bridge.


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Valve clearanceInspection / Adjust

A5.05. 01.01.01.02

1500M20

en / 30.09.2010 IB025384 2/2

011.5 Release locknut (6) and unsrew settingbolt (7) until a contact in Xwithout clearance is reached.

1.6 At this position of the valve bridge screw insetting bolt (7) until contact at Ywithoutany clearance is reached.Valve bridge must not be tited.

1.7 Hold tight setting bolt (7) and tighten lock-nut (6) with

M = 30 Nm.

1.8 Check absence of clearance at Xand

Ywith feeler gauge of 0.02 mm(W1).Afterwards adjust valve clearance sasper instruction.

2. Adjust valve clearance

2.1 Press the rocker arm (5) onto the push rodand measure the clearance swith thefeeler gauge.

2.2 Correct the clearance s:

2.2.1 Loosen counter nut (8).

2.2.2 Turn the valve adjusting screws (4) until the specified clearance s has been attained.

Valve clearance s:

Inlet: 0.6 mm

Outlet: 0.8 mm

2.2.3 Tighten counter nut (8) with

M = 90 Nm

2.2.4 Check the clearance s again.

2.3 Check the gaskets for the cylinder cover hoods and mount the cylinder cover hood.

2.4 Remove turning rod

2.5 Close decompression valves.


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Valve Rocker BracketsMaintenance / Disassembly and reassembly

A5.05. 01.02.01.00

M20

en / 30.09.2010 IB001341 1/2

01See also: 01.01.01.nn




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Tools:

Torque wrench 40 - 180 Nm 1/2" W1 * 1.9454-40Turning rod W2 * 2.9100-380


Auxiliary material:

Molykote paste G-Rapid Plus **

** or a product of equal standard


1. Disassembly

1.1 Remove the cylinder head cover.

1.2 Move the piston to firing TDC. Inlet valves and exhaust valves are closed, valve rocker isrelieved.

1.3 Unscrew the nuts (Fig. 1/1 and 2).

1.4 Remove the valve rocker bracket with inlet rocker and exhaust rocker.

2. Reassembly

2.1 Clean the surface for the valve rocker bracket on the cylinder head.

2.2 Blow through the oil transition hole with compressed air.

2.3 Fit the valve rocker bracket via studs on the cylinder head and adjust in such a way that theadjusting screws rest on the center of the valve bridges.


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012.4 Grease the thread and nut contact face with Molykote paste G-Rapid Plus and tighten the nutsgradually (1) with a

Torque of 120 Nm

and nuts (2) with a

Torque of 60 Nm.

2.5 Set the valve clearance (01.01.01 nn).

2.6 Perform the oil flow control.

2.7 Fit the cylinder head cover (inspect the gasket).


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Valve RockerMaintenance / Disassembly and reassembly

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30000M20

en / 30.09.2010 IB021075 1/3

01See also: 01.02.01.nn




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Maintenance:

Disassemble inlet and exhaust valve rockerand inspect the bearing clearances 30,000 h


1. Disassembly

1.1 Disassemble valve rocker bracket(01.02.01.nn).

1.2 Remove circlip (Fig. 1/1) and supportingdisc (2) from inlet valve rocker (3) andexhaust valve rocker (4) and pull valverocker from rocker axle (5).

2. Clean all parts and check for damage.Blow through oil holes with compressed airand check for free passage.

NOTE

The bushes must be lubricated with oil only.

Molykote paste must not be used even on assembly.

NOTE

Further remedial measures areidentical in the case of inlet andexhaust valve rocker.


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013. 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. Observethe marking (x) of the ball pin.

4. Measure valve rocker bush (Fig. 2/13) and axle (Fig. 1/5) and renew bushes on attaining the limitclearance.

New clearance Limit clearance

0,015 - 0.14 0,2

5. Replace bearing bushes.

5.1 Knock bush (Fig. 2/13) out from valve rocker with suitable brass drift.

5.2 Slightly oil the new bush and press in valve rocker.

DANGER

Observe safety regulations when handling fluid nitrogen.

CAUTION

Observe the position of the oil holes (14) and parting joint (15) as well as the dimen-

sion s = 0.2 mm (Fig. 2/Z) (projection of the valve lever to the bush) when pressing inthe new bushes. Do not damage plastic-laminated surface.


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016. Reassembly

6.1 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 movethe valve rocker onto the axle. Do not tiltvalve rocker.

6.2 Fix the valve rocker with supporting disc(2) and circlip (1) axially.

6.3 Mount the valve rocker bracket on the cy-linder head (01.02.01.nn) and carry outlube oil flow control.

NOTEValve rocker axle mustbe un-damaged and free of burrs.


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Valve RotatorInspection / Evaluate

A5.05. 01.03.01.00

150M20

en / 24.09.2010 IB000333 1/1

01See also: 01.07.01.nn, 01.10.00.nn




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Inspection:

of the valve rotator every 150 h


1. Check valve rotation.

2. The valve rotator works properly if a uniform and engine speed dependent rotation can be detec-ted.

3. Lubricate the valve rotator with some drops of lubricating oil/gas oil mixture (mixture ratio 1:1) if aconsiderable deceleration of rotation, is detected in comparison to the new condition.

3.1 If, at nominal engine speed, the rotational speed goes down to approx 1 rpm, the valve rotatorhas to be changed.

CAUTION

Heavy fuel operation:=4 valve rotatorsinlet and exhaust valvesDistillate fuel operation:=2 valve rotatorsinlet valves only

NOTE

Check the rotational speed of the valves versus engine speed immediately after star-ting a new engine or when a plant has been overhauled. Use this rotational speed forreference later.

NOTE

Deceleration of the valve rotation can also be caused by hard motion of the valve stemin the valve guide. Remedy: Inject the gas oil/lubricating oil mixture drop by drop ontothe valve stem.

CAUTION

Do not apply too much lubricating oil/gas oil mixture. There is danger of lubricating oildilution!


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Valve Guide / Oil Scraper RingInspection / Replacement

A5.05. 01.05.01.01

15000M20

en / 31.05.2010 IB021186 1/2

01See also: 01.01.01.nn, 01.02.01.nn, 01.06.01.nn, 01.07.01.nn




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Operating medium: Heavy fuel

Inspection:

of valve guide clearance of inlet and exhaust valves after 15,000 h

Auxiliary material:

Molykote paste G-Rapid Plus **

** or a product of equal standard


1. Replacement of the oil scraper rings(O-rings)

1.1 Dismount valve face, thoroughly cleanstem.

1.2 Remove the O-ring (Fig. 1/1) from thegroove of the guide bush by means of asharp angle-shaped wire.

1.3 Clean the groove.

1.4 Slightly oil the new O-ringand carefullyinsert the O-ring in the groove. The ringmust not be twisted in mounting position.

CAUTION

The O-ring is used to adjust thelubricant quantity and must onlybe replaced by a new originalMaK spare part.


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01

2. Measurement of the valve guide clearance.

2.1 Measure the outside diameter of the valve stem in the zone of the guide bush.

2.2 Measure the inside diameter of the guide bush in traverse direction of the engine.

2.3

Normal clearance (mm) Limit clearance (mm)

ExhaustInlet 0.10 - 0.17 0.4

3. 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 whenthe old valve guide is knocked out.


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Media lineMaintenance / Disassembly and reassembly

A5.05. 01.05.50.00

M20

en / 31.05.2010 IB003153 1/3

01See also:




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


Auxiliary material:soft green soap*

* or product of equal standard


1. Disassembly

1.1 Disassemble lubricating oil line for the injection pump (fig. 1/1) at the flange (3b) of the media li-ne.

1.2 Remove cheese head screws (2).

CAUTION

Depressurize system before commencing work.

A

2

B

A

B

2 4

Z

1

6

7

3b15

3a


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011.3 Remove flange (3a and 3b) together with sleeves (4).

1.4 Remove sleeves (4) from flanges (3a and 3b).

1.5 Check O-rings (fig. 2/12) and, if necessary, insert new O-rings untwisted in the grooves usingsoft soap.

1.6 Remove seals (11) and clean sealing surfaces.

2. Assembly

2.1 Mount sleeves (fig. 2/4) with flanges (3a and 3b).

2.2 Replace seals (fig. 3/11) (centering by dowel pins 21).

2.3 Mount flanges, seals and sleeves with cheese head screws.

4

11

12

3b

11

3a

A-A

2

21X

11

X

B-B

3

11


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013. Cleaning of fuel leakage monitor

3.1 Secure pipe (Z/5)!

3.2 Disassemble pipe (5) with screwed socket(6) and sealing ring (7).

3.3 Check that bore (Fig. 4/Y) is free andclean if necessary.

3.4 Assemble pipe (Z/5) with screwed socket(6) and new sealing ring (7).

3.5 Check operation of alarm probe (41) forleakage fuel (41).

7

644

Y

41

Z

5

6

7


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Cylinder HeadMaintenance / Disassembly

A5.05. 01.06.01.00

M20

en / 30.09.2010 IB001347 1/4

01See also:

Spare parts list:



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Tools:

Hydr. equipment set consisting ofHigh-pressure pump W1 0.9204-D

High-pressure hose (1 m) W2 0.9205-BHigh-pressure hose W3 0.9205-CHydr. tensioning element W4 0.9213-ADistributor W5 0.9203-8Bearing ring W6 0.9203-108Spacer W7 0.9203-107Pin W8 0.9203-110Cylinder head lifting device W9 * 2.9221-ATurning rod W10 * 2.9100-380Cylinder liner hold-down W11 * 2.9217-A



1. Mount liner holding device (W11) (02.10.01.nn). Turn the piston to firing TDC. Remove cylinderhead cover and pump room lining.

2. Drain cooling water completely into a draining tank (connecting line: distributor line inlet/outletopen).Inspection:

Unscrew plug in pressure line behind cooling water pump after return valve.

NOTE

When lifting the cylinder head or when turning afterwards, the liner is always to besecured with the hold-down in order to prevent the liner from becoming loose.

CAUTION

Do not fall below minimum bending radius r = 120 mm of the high-pressure hoses.Only use hydraulic oil as an operating material (see Section A4.05.08, Operating

materials). Store equipment protected against corrosion.

DANGER

No parts of the body should be over the equipment which is under pressure. Secureengine against unintentional starting.


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013. Disassemble lube oil line for the injection pump at the respective block piece of the medium guideand at the injection pump.

4. Loosen and remove block pieces and/or end flange (Cyl. 1) of the medium guide of the cylinderhead to be disassembled.

5. Loosen pressure screws (Fig. 1/1 and 2) and lever off transverse pressure piece (3) with cover(X) and pull to the left out of the injection pump and the cylinder head.

6. Slide sleeve (Y) to the left in the cylinder head frame.

7. Disassemble covering plate between exhaust pipe and cylinder head,unscrew hexagonal screws on exhaust pipe.

CAUTION

Screw off pressure gage line from end flange (lube oil jet cooling) during disassemblyof the last cylinder head at counter-coupling side.


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018. Loosen the four cylinder head screwstogether with the hydraulic tighteningdevice.

8.1 Screw spacer (Fig. 2/W7) on cylinderhead screw (11).

8.2 Place bearing ring (W6) over round nut

(12), thereby, make surethe slots (13) areeasily accessible.

8.3 Screw hydraulic tensioning element (W4)on spacer (W7) and connect with high-pressure pump (W1) via high-pressurehoses (Fig. 3/W2 and W3) distributor(W5).

CAUTION

Max. lift of 5 mm must not beexceeded.


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018.4 Press hydraulic tensioning element (Fig. 3/W4) with pin (W8), by turningdown against the bearingring (W6) onto block length (Valve [Z] at the high-pressure pump [W1] is open) and establish gapof

2.5 mm

(approx. 1 rotation) (Fig. 2/S).

8.5 Close valve (Fig. 3/Z) at high-pressure pump (W1) and at the same time extend all 4 cylinderhead screws continuously with a hydraulic pressure of

p = 600 bar.

8.6 Disconnect round nuts (Fig. 2/12) with pin (W8).

8.7 Release tensioning elements, romove hydr. equipment and screw off round nuts.

9. Mount the cylinder head lifting gear (W11) on the cylinder head by means of the attachedhexagon nut M12x35.Lift the cylinder head by means of a crane.Thereby, observe push-rod fitting!

10. Place cylinder head down on a wooden support.

NOTE

If the round nuts cannot be loosened, the cylinder head screw can be furtherprestressed with approx.

50 bar.

If the pressure is increased further, there is a risk of the round nut sticking due tostretching of the bolt thread.

CAUTION

Risk of damaging cooling water transition nozzles, cylinder head screws, push rodsand charge air intake nozzles.


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Nozzle SleeveMaintenance / Disassembly and reassembly

A5.05. 01.06.50.00

15000M20

en / 30.09.2010 IB021941 1/2

01See also: 01.06.01.nn, 07.07.01.nn




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Maintenance:

Change the O-rings every 15.000 h

Tools:

Pin spanner W1 2.9122 BRing spanner A/F 27 W2* 1.9456 BTorque wrench W3* 1.9454-6

* no illustration

Auxiliary material

Vaseline**High-temperature thread paste Dag S-5080**

**or product of equal standard


1. Dismount the nozzle sleeve (1).

1.1 Attach the pin spanner (W1) to the nozzlesleeve (1) so that nozzle sleeve and pinspanner are engaged.

1.2 Attach the ring spanner (W2) to the pinspanner and unscrew the nozzle sleeveuntil nozzle sleeve and cylinder head (2)are fully unscrewed and loose.

1.3 Use a brass mandrel and gently drive outthe nozzle sleeve.

CAUTION

Nozzle sleeve and cylinderhead must be fully unscrewedand loose.

3

4

1

2

W1


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Nozzle SleeveMaintenance / Disassembly and reassembly

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011.4 Remove the O-rings (3 and 4).

2. Mount the nozzle sleeve

2.1 Apply a film of green soft soap to the new black O-ringand insert it in the groove (4). Make surethe O-ring is not twisted.

2.2 Apply a film of green soft soap to the newgreen O-ringand insert it in thegroove (3).Make surethe O-ring is not twisted.

2.3 Grease the threads of the nozzle sleeve with high-temperature thread paste.

2.4 Insert the nozzle sleeve and tighten the sleeve with the pin spanner (hand-tight).

2.5 Tighten the nozzle sleeve at a torque of

M =100 Nm.

CAUTION

Do not change the position of the O-rings. Observe the mounting instructions.


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Inlet and Exhaust Valve ConesInspection / Disassembly and reassembly

A5.05. 01.07.01.01

15000, 7500M20

en / 31.05.2010 IB021215 1/2

01See also: 01.02.01.nn, 01.05.01.nn, 01.06.01.nn, 01.08.01.nn




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Operating medium: Heavy fuel

Inspection:

of inlet and exhaust valves of one cylinder after 7,500 hCheck contact reflections of the valves and coating.

Maintenance:

of all inlet and exhaust valves after 15,000 h

Tools:

Valve spring compressor W1 2.9222-A

Sequence of operations: (Fig. 1)

1. Disassembly

1.1 Remove cylinder head (01.06.01.nn).

1.2 Remove the valve rocker (01.02.01.nn)and lift off valve bridge.

1.3 Place the valve spring compressor (W1)onto the spring plate (2).

1.4 Compress the valve springs (3) andremove the clamping cone halves (4).Expand valve springs (3) carefully.

NOTE

The overhaul intervals of the valves depend on the fuel grade used, the operating

conditions of the plant and the quality of the reconditioned valves and seats. Theyare therefore different for each plant.

For this reason, the operator must fix the maintenance intervals according to the con-dition of valves inspected. With any removal of valves, check seat geometry and re-cut if necessary (01.08.01.nn, 01.08.02.nn.).

WARNING

Spring tension


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Inlet and Exhaust Valve ConesInspection / Disassembly and reassembly

A5.05. 01.07.01.01

15000, 7500M20

en / 31.05.2010 IB021215 2/2

011.5 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.

1.6 Extract valves from the cylinder head

2. Reassembly

2.1 Check valve guide clearance, renewthe O-ring (01.05.01.nn).

2.2 Lubricate the valve stem well before fitting and fit the valve cone by screwingit in.

2.3 Assembly is carried out in reverse order to removal.

2.4 After inserting the clamping cone halves, slowly expand the valve springs and make sure that theclamping cone halves are in the correct position.

NOTE

Renew any valves which are heavily worn in the clamping area and any clampingcone halves which have large burrs. Remove projecting burrs before disassemblingsuch valves. Maintenance of valve cone/valve seat (01.08.01.nn/01.08.02.nn).


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Valve ConesRepair / Checking

A5.05. 01.08.01.00

M20

en / 31.05.2010 IB001351 1/5

01See also: 01.07.01.nn, 01.08.02.nn



Personnel qualification: Chief engineer / skilled engine hand

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


Tools:

Valve refacer W1 2.9224-A

Auxiliary material:

Diamond paste Dp 30/10 - 15 m *Thinner F25 *

* or a product of equal standard


1. Check of valve condition

1.1 Valves may be reused without refinishingwhen

the circumference of the valve cone face is metallic bright

the valve cone face does not indicate carbon pockets with blowholes,

by inspecting cracks, using magnifying glass with light (8 fold magnification) or powder sprayingprocedure (Met L'Check) and/or in the flux procedure, no crack formation is discovered at thevalve cone face.

NOTE

Grind new or refinished and/or used undamaged inlet and exhaust valve cones befo-

re the installation in accordance with sequence of operations 4.

Refinishing of the valve cones (in accordance with sequence of operations 3) may benecessary in the following cases:

after extended operating periods,

in the case of negative result, e.g. damaged sealing faces, deep scars, unevencontact reflections of the valve cone/seat


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01 when the deviation from the straightness is not greaterthan 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:

1.2 Valves cannot be reused when

the valve cone face is damaged(cracks,blowholes)

the wear caused by corrosive material is> 2 %

of the valve head diameter (comparisonwith new valve)

concave burns s caused by high-temperature corrosion at the lower side

of the valve head> 1.5 mm (Fig. 2)

the lower part of the valve headindicates severe pitting (formation of so-called paving stones)

corrosion pits and mechanical damagein the area of the valve stem, stemtransition and valve head

refinishing limit dimension is exceeded.


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01

2. Cleaning

Clean the valve cone, e.g. blasting withglass beads. Cleaning with sharp-edgedtools as well as pickling with inorganicacids (hydrochloric acid, sulphuric acid,hyd

M20+ M20 C MAINTENANCE

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