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Engine Operating Instructions

VM32

A0

Engine Operating Instructions Type VM32
Engine No.: 34 184 34 185 34 186 34 187 34 188 34 189 Record No.: 262134

en / 24.04.2008

AA000439

1/2

Engine Operating Instructions
VM32

A0

Please note the copyright notice pursuant to ISO 16016
"All documents such as drawings, data and programmes, etc. and models, templates etc. shall remain our exclusive property. They are only handed over to the agreed purpose and must not be used for any other purpose. Copies or other reproductions including storage, processing or distribution by using electronic systems may only be made to the agreed purpose. Neither originals nor copies may be handed over to third parties or be made available in any other form. All rights (in case of registration of patent, utility patent, design patent) reserved. Offenders will be liable for damages." Caterpillar Motoren GmbH & Co. KG

en / 24.04.2008

AA000439

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Total Index
Book A, B and C
-

A0.01

Engine Operating Instructions
Total Index Book A, B and C Introduction Safety instructions Emergency Stop Safety System Specification Engine Design

A0
A0.01 A0.02 A0.03 A0.04 A0.05

Technical Engine Data
Governor Data Working pressures of auxiliary equipment Temperatures of operating media Temperatures of operating media Torsional Vibration Calculation Acceptance Test Records

A1
A1.04 A1.05 A1.06 A1.06 A1.09 A1.10

Operating Instructions
Table of Contents Introduction Safety Instructions Instructions for Heavy Fuel Operation Initial Operation Engine Operational Supervision Engine Removal from operation Engine Danger of Frost Engine Running-in Engine Fault Tracing Engine Emergency Operation Engine

A3
A3.01 A3.02 A3.03 A3.04 A3.05 A3.06 A3.07 A3.08 A3.10 A3.11 A3.12

Operating Media
Table of Contents Introduction Safety instructions Regulations and Recommendations Engine

A4
A4.01 A4.02 A4.03 A4.05

Maintenance
Table of Contents Introduction Safety instructions

A5
A5.01 A5.02 A5.03

en / 24.04.2008

AA020014

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Total Index
Book A, B and C
-

A0.01

Tools
Table of contents

A6
A6.01

Spare Parts Catalogue
Total Index Book A, B and C Introduction

B0
B0.01 B0.02

Spare Parts
Table of contents Safety instructions

B1
B1.01 B1.03

Stand-by parts External Documentation
Total Index Book A, B and C Introduction Electrical Equipment Table of contents

B2 C0
C0.01 C0.02 C5.01

en / 24.04.2008

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Introduction
M20-M601C

A0.02

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 / MaK after-sales service has to be consulted when it is required to change from destillate fuel operation to heavy fuel oil operation, in order to ensure an expert retrofit of the engine plant and to exchange the necessary documentation. When changing over from heavy fuel oil operation to destillate operation, the Caterpillar / MaK after-sales service should also be consulted for a longer period of time so that a documentation with extended maintenance 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:

A1 A3 A4 A5 A6

Technical engine data Operating instructions Fuels Maintenance Tools

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 optimum operating results can be achieved. If you need further information or if you have any other questions, we kindly ask you to contact our responsible 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 / MaK is not responsible for damage caused by improper operation and maintenance.

These operating instructions are only intended for our customers. All rights reserved for this document. All technical data contained in these operating instructions must neither be reproduced, distributed nor utilized for competitive purposes or disclosed to third parties without our express approval.

Postal address: Telephone: Telefax:

Caterpillar Motoren GmbH & Co. KG, P.O. Box 9009, D-24157 Kiel +49(0)431- 3995-01 +49(0)431-3995-2010 (chief operator) (after-sales service only)

http://www.mak-global.com

en / 18.09.2007

AA000024

1/1

Safety instructions
M20-M601C

A0.03

Personnel entrusted with work on the engine/plant must have read the operating instructions and in particular the pages on safety instructions which precede the chapters before beginning work. In order to eliminate danger which may constitute a risk of life and limb of the user or of third parties, all safety regulations which are marked with the to be observed in all cases.

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symbol have

Technical instructions and/or operations to be strictly observed are marked in the documents with attention. They warn of possible damage to the machinery or to other material property.

Note refers to special information on appropriate use and work to be carried ou

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 / 15.12.2005

AA000370

1/2

Safety instructions
M20-M601C

A0.03

Our engine is equipped with a monitoring system and an emergency stop system to prevent damage caused to the operators' health as well as damages to the engine. Within the scope of commissioning all mechanical, electric and pneumatic equipment and systems allowing the engine to be stopped for safety reasons will be demonstrated and explained by our commissioning personnel. Participants in this acceptance procedure are the authorized personnel of CATERPILLAR Motoren Kiel, 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.

en / 15.12.2005

AA000370

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Emergency Stop
Safety System
M20/M25/M32/M43

A0.04

Attention:
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.

*Note:
With some engine assemblies, in particular in marine applications, an alarm or a power reduction may be triggered before a safety/emergency stop is performed. If there are no safety concerns, the engine must also be shut down, if an alarm occurs or engine power is reduced and the causes have to be eliminated.

Actions that must be performed after a safety/emergency stop* occurred:
- Identify the reason for emergency stop based on the points listed below. - Work through list of corresponding sub-points. - Contact your Caterpillar/ MaK Service.

Type of emergency stop:
1. 2. 3. 4. 5. 6. 7. Overspeed condition Lubrication oil (pressure and temperature) Engine room monitoring Cooling water - fresh water - HT (pressure and temperature) Exhaust gas Check pneumatic emergency stop system on engine after every emergency stop Fault messages and measuring points

Note:
The following checks may be of assistance during troubleshooting and permit identification of root causes of an emergency stop. However, they cannot cover the entire spectrum of possible causes.

en / 20.02.2008

AA033984

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2008 AA033984 2/5 .1 Lube oil (lube oil pressure.Emergency Stop Safety System M20/M25/M32/M43 A0. 2. Check free operation of adjustment shaft and joint Check every single regulator rack of fuel pumps in both directions for proper operation by pulling and pressing.04 1. Checking governor drive. 1. lube oil temperature) Emergency stop due to lack of lube oil Checks: • • • • • Visual inspection of engine. Check oil sump and piping for leaks and cracks. Contact your Caterpillar/ MaK Service. Lube oil pump drive: . Overspeed condition Emergency stop due to excessive rpm.2 Contact the Caterpillar/ MaK-Service.02.3 Check if emergency stop safety device is operational.1 1.2 How high was the maximum rpm before emergency stop was triggered? Why did engine go into an overspeed condition? Check: • • • • • 1. Verification of possible out of calibration of actuator (if fitted). 2. 2. Check lube oil pressure switch. Check lube oil filter for metal chips.Check gears for damage or loss. en / 20.

02.3 Emergency stop due to high lube oil temperature Checks: • • • • Check temperature sensor.HT. Pressurize each cylinder through opened indexing valves with shop air. Engine room monitoring Emergency Stop due to excessive oil mist concentration (refer to A3. Check cooling water circuit.11.04 2.nn).18.2008 AA033984 3/5 .02. of cam shaft trough.Emergency Stop Safety System M20/M25/M32/M43 A0. 3. Check oil cooler.1 Contact your Caterpillar/ MaK Service. Visual inspection of engine and gear train. 3.4 Contact the Caterpillar/ MaK Service. nn. of combustion chamber. of turbo charger. Checks: • • • • • Check engine room monitoring device (operational test).01. pressure and temperature) Emergency stop due to excessively high cooling water temperature Checks: • • Visual inspection of engine Check temperature sensors en / 20. 4.11. Cooling water (fresh water . 2.03.05. refer to C5. If there is a rapid pressure drop or if no pressure builds up the cause must be investigated.

Aftercooler (differential pressure) (refer to A5. Checks: • • Check emergency stop pneumatic system on the engine for leaks. Exhaust gas Emergency stop due to excessively high exhaust temperature Checks: • • • • • Check exhaust gas temperature sensors.nn).1 Check fresh water cooler Operational test of LT . Check pneumatic emergency stop system on engine after every emergency stop Attention: In order for emergency stop safety device to operate properly.05.02.11.5 bar pneumatic supply has to be available continuously.nn).07.nn). Injection valves (refer to A5.01. en / 20.08.05. Stop valve to main start line upstream from start valve must constantly be open during operation.(Refer to A3. Turbocharger 5.04. 7. 5.06. Contact your Caterpillar/ MaK Service.2008 AA033984 4/5 .04 • • 4. Fuel pumps and fill level scale on each fuel pump. 6.05.Emergency Stop Safety System M20/M25/M32/M43 A0.02.1 Contact your Caterpillar/ MaK Service.Cooling water circuit with cooling water pump.

Safety system failure .3 Please contact the Caterpillar/ MaK Customer Service.nn. the cause of the fault message must be remedied immediately. Fault messages and measuring points Attention: The fault messages listed below do not directly lead to an emergency stop.05. At any rate.Emergency Stop Safety System M20/M25/M32/M43 A0.nn. the engine plant may only be operated for a short time and under permanent observation.04 7.RPM switch unit failure (overspeed) 7. If such a fault message appears on the monitoring display of the alarm system. en / 20. 7.1 General fault messages: Fault message: (Measuring point number) 6105 * 9631 * 9601 * 9717 * Description: Low shutdown air pressure Oil mist detector failure Terminal set X1 voltage failure Terminal set X3 voltage failure * see also List of Measuring Points C5.01. but they considerably affect reliable engine operation.02. 7.02.2008 AA033984 5/5 .2 Plant-specific fault messages: .

i.Specification Engine Design VM32 A0. In CM and MaK Product Literature by Caterpillar Motoren. the sides of the engine are referred to as Bank A or Bank B sides.10 Engine Valve Clearance (Lash) Inspection: The valve clearance is to be checked every 1.1 mm –0.01. Bank A side and Bank B side of the engine are determined from the flywheel end.e. Bank B is on the right.05. Cylinder number A1 is the flywheel end cylinder on Bank A (on the left as viewing the flywheel from the flywheel end). 15 minutes after shutting down the engine. Bank A is on the left.0 mm 1.1 mm + 0.4 mm + 0. the crankshaft rotates in the following direction: Counter-Clock Wise or Anti-Clock Wise or Left-Hand Rotation Firing Order (Injection Sequence) see A1.1 mm –0. Engine valve clearance Inlet Engine valve clearance Outlet or Exhaust 0. Viewing from the flywheel end at the flywheel.01.0 mm A readjustment of the valve bridge position to the valve spindles must be carried out before every valve clearance adjustment during scheduled inspections or due to service work being carried out on the valve drive components.01. if required. not as “left” or “right” sides to insure clarity in identification during communication. Note: The damper end of the engine is opposite the flywheel end of the engine.nn The engine valve clearance should only be measured with warm engine. Cylinder Number B1 is the flywheel end cylinder on Bank B (on the right as viewing the flywheel from the flywheel end).500 hours and adjusted.2003 AA025775 1/2 . en / 11.05 Engine Design – M 32 VEE When the crankshaft is viewed from the flywheel end at the flywheel.02. Note: See also A5.

Numbers A1 Camshaft Bank A A2 A3 A4 A5 A6 A7 A8 Turbo Bank A VIEW Camshaft Bank B B1 B2 B3 B4 B5 B6 B7 B8 Turbo Bank B Cyl.05 Cyl.Specification Engine Design VM32 A0. Numbers Flyweel Damper 1 2 3 4 5 6 7 8 9 Main Bearing Numbers Flywheel Rotation Inlet Channel Exhaust Channel (Left Hand) ACW CCW (Right Hand) CW View from Propeller/Gen-Shaft to the Flywheel Exhaust Valve ACW = CCW = Anti-Clock Wise = Counter-Clock Wise CW = Clock Wise en / 11.02.2003 AA025775 Inlet Valve 2/2 .

Technical Engine Data M20-M601C A1 Technical Engine Data en / 24.2008 AA000103 1/1 .04.

2008 AA000097 1/1 .Governor Data - A1.02.04 Governor Data en / 20.

Governor-data VM32 A1.2008 AA041603 1/1 .66 en / 21.04.04.26 .

: Engine No. g.: Motor-Nr. z.m Motor-Type: Engine type: Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Kostenträger-Nr. 1 Hebel am Regler Lever on governor Serien-Nr. B.48 UG 40 2.3 Stellgerätdrehzahl: Actuator speed: 3. 1 (corresponds to a governor stroke utilization of: 75 (%) 3.2008 6200 750 kW Regelbereich: Control range: 450-750 1/min 1/min Gesamt-Massenträgheitsmoment: Total moment of inertia: 5533 kg m² 2..1) ist in diesem Fall zu vermerken. von Eismeerfahrt in Tropenfahrt.: 3.1) or adjustment (3. After oil change or repair of the governor the adjustment data must set again.. auftretenden Reglerschwierigkeiten wegen eines Wechsels der Ölsorte bei der Caterpillar Motoren GmbH & Co.02. Every change of the governor equipment (2. der Reglereinstellung (3. If the climatic conditions are considerably changed in the main district of operation (e.326 x Motordrehzahl x engine speed Digitaler Drehzahlregler / Digital Speed Governor Reglertype: Governor type: 723+ Reglerdesignation: Governor designation: 9906-619 Abb.1) bzw. Motordaten / Engine Data Leistung: Power: Vollastdrehzahl: Full load speed: CA31 Name: Steiner Datum: 27.: Serial No. so ist bei evtl.: 16 CM32 Aussteller: Abteilung: 262134-1 34184 * Ortsleistung / Site output 1.1 Bau-Beschreibung / Specification Ausgangswelle: Terminal shaft: Antriebswelle: Drive shaft: Basis: Base: 3/4" .48 1 1/8" . Hebel an der Regulierwelle Lever on injection pump control shaft Anlenkung zwischen Reglerausgangswelle und Regulierwelle siehe Abb.: Record No. Jede Änderung der Reglerausrüstung (2. / Fig.1 Reglereinstellung / Adjustment of governor siehe Programmierliste: see program list: .: Serial No. Caterpillar Motoren GmbH & Co. 1 (entspricht einer Stellgeräthubausnutzung von: Link between governor terminal shaft and injection pump control shaft see Fig.2 Ölfüllung des Stellgerätes: Oil filling of the actuator: Siehe Abschnitt "Betriebsstoffe" See section "Operating Media" Ändert sich das Klimaniveau des Hauptfahrgebietes wesentlich. KG Auskunft einzuholen. 1. KG should be asked with respect to change of the grade of oil 2.: 14959735 2.1) must be recorded on this sheet. change from polar sea navigation to tropical regions) eventually causing failures. und nicht nur vorübergehend.2 Hinweise / Notes Nach Ölwechsel oder Reparatur des Reglers müssen diese Einstelldaten wieder angestrebt werden. Caterpillar: Confidential Green . Stellgerät / Actuator Type: Type: UG40-ACT Designation: Designation: A 8251-772 beidseitig-kerbverzahnt serrated both sides kerbverzahnt serrated Serien-Nr.

48 1 1/8" .2 Hinweise / Notes Nach Ölwechsel oder Reparatur des Reglers müssen diese Einstelldaten wieder angestrebt werden.326 x Motordrehzahl x engine speed Digitaler Drehzahlregler / Digital Speed Governor Reglertype: Governor type: 723+ Reglerdesignation: Governor designation: 9906-619 Abb.1) or adjustment (3. Caterpillar: Confidential Green .: Motor-Nr. After oil change or repair of the governor the adjustment data must set again.m Motor-Type: Engine type: Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Kostenträger-Nr.2008 6200 750 kW Regelbereich: Control range: 450-750 1/min 1/min Gesamt-Massenträgheitsmoment: Total moment of inertia: 5533 kg m² 2.2 Ölfüllung des Stellgerätes: Oil filling of the actuator: Siehe Abschnitt "Betriebsstoffe" See section "Operating Media" Ändert sich das Klimaniveau des Hauptfahrgebietes wesentlich. 1 Hebel am Regler Lever on governor Serien-Nr. Caterpillar Motoren GmbH & Co. und nicht nur vorübergehend.1) ist in diesem Fall zu vermerken. B.48 UG 40 2. auftretenden Reglerschwierigkeiten wegen eines Wechsels der Ölsorte bei der Caterpillar Motoren GmbH & Co. If the climatic conditions are considerably changed in the main district of operation (e. Jede Änderung der Reglerausrüstung (2.1) must be recorded on this sheet. / Fig. Every change of the governor equipment (2.02.. Hebel an der Regulierwelle Lever on injection pump control shaft Anlenkung zwischen Reglerausgangswelle und Regulierwelle siehe Abb.: Engine No. von Eismeerfahrt in Tropenfahrt. 1.: Serial No.. so ist bei evtl.1 Bau-Beschreibung / Specification Ausgangswelle: Terminal shaft: Antriebswelle: Drive shaft: Basis: Base: 3/4" .: Record No. KG should be asked with respect to change of the grade of oil 2. KG Auskunft einzuholen.: Serial No. z.1) bzw. 1 (entspricht einer Stellgeräthubausnutzung von: Link between governor terminal shaft and injection pump control shaft see Fig.1 Reglereinstellung / Adjustment of governor siehe Programmierliste: see program list: . g.: 14891626 2. change from polar sea navigation to tropical regions) eventually causing failures. 1 (corresponds to a governor stroke utilization of: 75 (%) 3.: 16 CM32 Aussteller: Abteilung: 262134-2 34185 * Ortsleistung / Site output 1.: 3.3 Stellgerätdrehzahl: Actuator speed: 3. Motordaten / Engine Data Leistung: Power: Vollastdrehzahl: Full load speed: CA31 Name: Steiner Datum: 27. Stellgerät / Actuator Type: Type: UG40-ACT Designation: Designation: A 8251-772 beidseitig-kerbverzahnt serrated both sides kerbverzahnt serrated Serien-Nr. der Reglereinstellung (3.

und nicht nur vorübergehend. so ist bei evtl.: Serial No.. B. KG should be asked with respect to change of the grade of oil 2.03. KG Auskunft einzuholen. auftretenden Reglerschwierigkeiten wegen eines Wechsels der Ölsorte bei der Caterpillar Motoren GmbH & Co.: 3. Hebel an der Regulierwelle Lever on injection pump control shaft Anlenkung zwischen Reglerausgangswelle und Regulierwelle siehe Abb. Stellgerät / Actuator Type: Type: UG40-ACT Designation: Designation: A 8251-772 beidseitig-kerbverzahnt serrated both sides kerbverzahnt serrated Serien-Nr. / Fig.: Serial No.1) bzw. Caterpillar: Confidential Green . Caterpillar Motoren GmbH & Co.: Motor-Nr. 1 (corresponds to a governor stroke utilization of: 75 (%) 3.48 1 1/8" .2 Ölfüllung des Stellgerätes: Oil filling of the actuator: Siehe Abschnitt "Betriebsstoffe" See section "Operating Media" Ändert sich das Klimaniveau des Hauptfahrgebietes wesentlich.1 Reglereinstellung / Adjustment of governor siehe Programmierliste: see program list: .: 15092904 2.: Record No. von Eismeerfahrt in Tropenfahrt. 1.2 Hinweise / Notes Nach Ölwechsel oder Reparatur des Reglers müssen diese Einstelldaten wieder angestrebt werden.1 Bau-Beschreibung / Specification Ausgangswelle: Terminal shaft: Antriebswelle: Drive shaft: Basis: Base: 3/4" . der Reglereinstellung (3. Every change of the governor equipment (2. g.3 Stellgerätdrehzahl: Actuator speed: 3..2008 6200 750 kW Regelbereich: Control range: 450-750 1/min 1/min Gesamt-Massenträgheitsmoment: Total moment of inertia: 5533 kg m² 2. If the climatic conditions are considerably changed in the main district of operation (e. z. 1 Hebel am Regler Lever on governor Serien-Nr.1) ist in diesem Fall zu vermerken. Motordaten / Engine Data Leistung: Power: Vollastdrehzahl: Full load speed: CA31 Name: Steiner Datum: 05.48 UG 40 2. 1 (entspricht einer Stellgeräthubausnutzung von: Link between governor terminal shaft and injection pump control shaft see Fig.1) must be recorded on this sheet.: 16 CM32 Aussteller: Abteilung: 262134-3 34186 * Ortsleistung / Site output 1. After oil change or repair of the governor the adjustment data must set again. change from polar sea navigation to tropical regions) eventually causing failures. Jede Änderung der Reglerausrüstung (2.m Motor-Type: Engine type: Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Kostenträger-Nr.1) or adjustment (3.326 x Motordrehzahl x engine speed Digitaler Drehzahlregler / Digital Speed Governor Reglertype: Governor type: 723+ Reglerdesignation: Governor designation: 9906-619 Abb.: Engine No.

: Serial No. z. von Eismeerfahrt in Tropenfahrt..: Serial No.1 Bau-Beschreibung / Specification Ausgangswelle: Terminal shaft: Antriebswelle: Drive shaft: Basis: Base: 3/4" . B. Caterpillar Motoren GmbH & Co. If the climatic conditions are considerably changed in the main district of operation (e. KG should be asked with respect to change of the grade of oil 2. 1. After oil change or repair of the governor the adjustment data must set again. so ist bei evtl.3 Stellgerätdrehzahl: Actuator speed: 3. Caterpillar: Confidential Green .326 x Motordrehzahl x engine speed Digitaler Drehzahlregler / Digital Speed Governor Reglertype: Governor type: 723+ Reglerdesignation: Governor designation: 9906-619 Abb.1) must be recorded on this sheet. change from polar sea navigation to tropical regions) eventually causing failures. 1 (corresponds to a governor stroke utilization of: 75 (%) 3.: Motor-Nr. g. / Fig. auftretenden Reglerschwierigkeiten wegen eines Wechsels der Ölsorte bei der Caterpillar Motoren GmbH & Co. 1 (entspricht einer Stellgeräthubausnutzung von: Link between governor terminal shaft and injection pump control shaft see Fig.: Engine No. Motordaten / Engine Data Leistung: Power: Vollastdrehzahl: Full load speed: CA31 Name: Steiner Datum: 05. KG Auskunft einzuholen. Jede Änderung der Reglerausrüstung (2.2 Hinweise / Notes Nach Ölwechsel oder Reparatur des Reglers müssen diese Einstelldaten wieder angestrebt werden.: 14487726 2.1) ist in diesem Fall zu vermerken.2 Ölfüllung des Stellgerätes: Oil filling of the actuator: Siehe Abschnitt "Betriebsstoffe" See section "Operating Media" Ändert sich das Klimaniveau des Hauptfahrgebietes wesentlich.1) or adjustment (3. Every change of the governor equipment (2..1 Reglereinstellung / Adjustment of governor siehe Programmierliste: see program list: . 1 Hebel am Regler Lever on governor Serien-Nr.03.m Motor-Type: Engine type: Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Kostenträger-Nr.2008 6200 750 kW Regelbereich: Control range: 450-750 1/min 1/min Gesamt-Massenträgheitsmoment: Total moment of inertia: 5533 kg m² 2.1) bzw. Hebel an der Regulierwelle Lever on injection pump control shaft Anlenkung zwischen Reglerausgangswelle und Regulierwelle siehe Abb. Stellgerät / Actuator Type: Type: UG40-ACT Designation: Designation: A 8251-772 beidseitig-kerbverzahnt serrated both sides kerbverzahnt serrated Serien-Nr. der Reglereinstellung (3.48 1 1/8" . und nicht nur vorübergehend.: 3.48 UG 40 2.: 16 CM32 Aussteller: Abteilung: 262134-4 34187 * Ortsleistung / Site output 1.: Record No.

After oil change or repair of the governor the adjustment data must set again. KG Auskunft einzuholen.: Serial No.326 x Motordrehzahl x engine speed Digitaler Drehzahlregler / Digital Speed Governor Reglertype: Governor type: 723+ Reglerdesignation: Governor designation: 9906-619 Abb.1 Bau-Beschreibung / Specification Ausgangswelle: Terminal shaft: Antriebswelle: Drive shaft: Basis: Base: 3/4" .2 Ölfüllung des Stellgerätes: Oil filling of the actuator: Siehe Abschnitt "Betriebsstoffe" See section "Operating Media" Ändert sich das Klimaniveau des Hauptfahrgebietes wesentlich.ã Motor-Type: Engine type: Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Kostenträger-Nr. so ist bei evtl. Hebel an der Regulierwelle Lever on injection pump control shaft Anlenkung zwischen Reglerausgangswelle und Regulierwelle siehe Abb. 1 Hebel am Regler Lever on governor Serien-Nr. change from polar sea navigation to tropical regions) eventually causing failures.3 Stellgerätdrehzahl: Actuator speed: 3. 1 (corresponds to a governor stroke utilization of: 75 (%) 3.04.2 Hinweise / Notes Nach Ölwechsel oder Reparatur des Reglers müssen diese Einstelldaten wieder angestrebt werden. If the climatic conditions are considerably changed in the main district of operation (e.1 Reglereinstellung / Adjustment of governor siehe Programmierliste: see program list: .2008 6200 750 kW Regelbereich: Control range: 450-750 1/min 1/min Gesamt-Massenträgheitsmoment: Total moment of inertia: 5533 kg m² 2. Motordaten / Engine Data Leistung: Power: Vollastdrehzahl: Full load speed: CA31 Name: Steiner Datum: 24. Caterpillar Motoren GmbH & Co.: 16 CM32 Aussteller: Abteilung: 262134-5 34188 * Ortsleistung / Site output 1.48 1 1/8" .: 14487727 2.1) bzw.: Serial No. Caterpillar: Confidential Green . KG should be asked with respect to change of the grade of oil 2. 1 (entspricht einer Stellgeräthubausnutzung von: Link between governor terminal shaft and injection pump control shaft see Fig. Stellgerät / Actuator Type: Type: UG40-ACT Designation: Designation: A 8251-772 beidseitig-kerbverzahnt serrated both sides kerbverzahnt serrated Serien-Nr. und nicht nur vorübergehend.48 UG 40 2. Jede Änderung der Reglerausrüstung (2.: 3.: Motor-Nr.: Engine No. B.1) or adjustment (3. von Eismeerfahrt in Tropenfahrt. 1. g. Every change of the governor equipment (2. / Fig.1) must be recorded on this sheet. z. der Reglereinstellung (3...: Record No. auftretenden Reglerschwierigkeiten wegen eines Wechsels der Ölsorte bei der Caterpillar Motoren GmbH & Co.1) ist in diesem Fall zu vermerken.

Caterpillar: Confidential Green . Caterpillar Motoren GmbH & Co.1) bzw. KG Auskunft einzuholen.3 Stellgerätdrehzahl: Actuator speed: 3. z.: Motor-Nr. 1 (corresponds to a governor stroke utilization of: 75 (%) 3.2008 6200 750 kW Regelbereich: Control range: 450-750 1/min 1/min Gesamt-Massenträgheitsmoment: Total moment of inertia: 5533 kg m² 2. und nicht nur vorübergehend. Stellgerät / Actuator Type: Type: UG40-ACT Designation: Designation: A 8251-772 beidseitig-kerbverzahnt serrated both sides kerbverzahnt serrated Serien-Nr.m Motor-Type: Engine type: Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Kostenträger-Nr.: Record No. After oil change or repair of the governor the adjustment data must set again.1) or adjustment (3.48 1 1/8" .1) ist in diesem Fall zu vermerken. 1 Hebel am Regler Lever on governor Serien-Nr.: Serial No.04.1 Reglereinstellung / Adjustment of governor siehe Programmierliste: see program list: .2 Ölfüllung des Stellgerätes: Oil filling of the actuator: Siehe Abschnitt "Betriebsstoffe" See section "Operating Media" Ändert sich das Klimaniveau des Hauptfahrgebietes wesentlich.: 14487725 2.: Serial No.48 UG 40 2. 1 (entspricht einer Stellgeräthubausnutzung von: Link between governor terminal shaft and injection pump control shaft see Fig. Motordaten / Engine Data Leistung: Power: Vollastdrehzahl: Full load speed: CA31 Name: Steiner Datum: 24.2 Hinweise / Notes Nach Ölwechsel oder Reparatur des Reglers müssen diese Einstelldaten wieder angestrebt werden. B.: 3. If the climatic conditions are considerably changed in the main district of operation (e. der Reglereinstellung (3..: Engine No. Hebel an der Regulierwelle Lever on injection pump control shaft Anlenkung zwischen Reglerausgangswelle und Regulierwelle siehe Abb. von Eismeerfahrt in Tropenfahrt. Every change of the governor equipment (2. g. KG should be asked with respect to change of the grade of oil 2..: 16 CM32 Aussteller: Abteilung: 262134-6 34189 * Ortsleistung / Site output 1. auftretenden Reglerschwierigkeiten wegen eines Wechsels der Ölsorte bei der Caterpillar Motoren GmbH & Co. so ist bei evtl. / Fig. Jede Änderung der Reglerausrüstung (2.326 x Motordrehzahl x engine speed Digitaler Drehzahlregler / Digital Speed Governor Reglertype: Governor type: 723+ Reglerdesignation: Governor designation: 9906-619 Abb.1) must be recorded on this sheet. change from polar sea navigation to tropical regions) eventually causing failures. 1.1 Bau-Beschreibung / Specification Ausgangswelle: Terminal shaft: Antriebswelle: Drive shaft: Basis: Base: 3/4" .

Working pressures of auxiliary equipment
M32

A1.05

Lubricating oil
at the last Camshaft bearing at rated engine speed 4,0 - 5,0 bar

Cooling water
min. feed head at pump inlet 4 m. water gauge 2,5 - 5,0 bar

Fuel at injection pump inlet
Distillate fuel Heavy fuel 3,0 - 5,0 bar 4,0 - 5,0 bar

Injection nozzle opening pressure
take the applicable figures from the acceptance test records(A1.10)

Control air

7,5 bar

Starting air

12* - 30 bar

*

minimum pressure for starting

en / 28.03.2000

TD000065

1/1

Temperatures of operating media
VM32

A1.06

Lubricating oil
engine inlet temperature rise at rated output 60 - 65 °C 10 - 14 °C

Cooling water
engine outlet temperature rise at rated output 80 - 90 °C 7 - 10 °C

Charge air
engine inlet

see also A3.06.05.nn 45 - 60 °C 40 - 50 °C *1 *2

Distillate fuel Fuel before injection pumps
(see diagram)

*2

*1 Lowest avaiable charge air temperature should be chosen. If water condenses in the charge air manifold, raise the temperature until this is avoided. The exhaust gas temperature after turbine must not exceed 420 °C with gas oil and 400 °C with heavy fuel. *2 Permissible injection viscosity must be set on the viscothermic device to enable a kinematic viscosity of 10 - 12 mm2/s (cSt) to be reached before the injection pumps, corresponding to a dynamic viscosity of 9 11 mPas (distillate fuel below 10 mm2/s or 9 m Pas). The heavy fuel specifications defined by MaK (e.g. RHM 35 (~ IF 380) give the heavy fuel temperature before engine starting. However, the maximum temperature at injection pumps must not exceed 155 °C!

en / 15.11.1996

TD000088

1/1

Temperatures of operating media
M32

A1.06

Lubricating oil
engine inlet temperature rise at rated output 60 - 65 °C 10 - 14 °C

Cooling water
engine outlet temperature rise at rated output 80 - 85о С 5 - 10 °C

Charge air
engine inlet

see also A3.06.05.nn 45 - 60 °C 40 - 50 °C *1 *2

Distillate fuel Fuel before injection pumps
(see diagram)

*2

*1 Lowest avaiable charge air temperature should be chosen. If water condenses in the charge air manifold, raise the temperature until this is avoided. The exhaust gas temperature after turbine must not exceed 420 °C with gas oil and 400 °C with heavy fuel. *2 Permissible injection viscosity must be set on the viscothermic device to enable a kinematic viscosity of 10 - 12 mm2/s (cSt) to be reached before the injection pumps, corresponding to a dynamic viscosity of 9 11 mPas (distillate fuel below 10 mm2/s or 9 m Pas). The heavy fuel specifications defined by MaK (e.g. RHM 35 (~ IF 380) give the heavy fuel temperature before engine starting. However, the maximum temperature at injection pumps must not exceed 155 °C!

en / 19.12.2005

TD000100

1/1

Torsional Vibration Calculation
-

A1.09

Torsional Vibration Calculation

en / 20.02.2008

AA020354

1/1

Torsional vibration calculation
VM32

A1.09.11. 07

en / 21.04.2008

AA041607

1/10

c
Motor Nr. / Engine No. 34184, 34185, 34186, 34187, 34188, 34189 34190, 34191, 34192, 34193, 34194, 34195 34196, 34197, 34198, 34199, 34200, 34201

Drehschwingungsberechnung Torsional Vibration Calculation

Bericht-Nr./ Report No.

08032019

Kostenträger Nr. / Record No. 262134 262135 262136

Motortyp / Engine type 16CM32C

Installation Art der Anlage / Type of In stallation Stationäre Landanlage / Stationary Set

Kunde / Customer Black & Veatch

Werft / Yard

Abnahme / Tested by

Station name Kabul Power Block 1, 2, 3

Dieser Bericht wurde erstellt von: This report was made by: Prüfung durch / checked by:

Th.Dombrowsky H.C.Peters
Blatt/Sheet

Inhaltsverzeichnis / Table of Contents

Ergebnis der Berechnung / Result of Calculation .....................................................................................................2 Berechnungsdaten / Calculation Data......................................................................................................................3 Elastisches System / Mass Elastic System ...............................................................................................................4 Drehzahldiagramme / Speed Diagrams ....................................................................................................................5 Eigenfrequenzen / Natural Frequencies ...................................................................................................................7 Erläuterungen / Explanations....................................................................................................................................9

Raum für Genehmigungsvermerke / Space for remarks of approval:

3 2 1
Rev. Date Description Name

de/eng/20.02.2008

Blatt/Sheet: 1 von/of: 9

c
1. 1.1

Ergebnis der Berechnung Result of Calculation

Bericht-Nr./ Report No.

08032019

Betriebseinschränkungen: Normalbetrieb: Nach Herstellerangaben soll grundsätzlich für diese Kupplung eine dynamische Steifigkeit von 135% des nominalen Katalogwertes gewählt werden. Für die Synthese- und Eigenfrequenzberechnung wurde dementsprechend die oben genannte Steifigkeit eingesetzt. Damit errechneten wir in den einzelnen Anlagenteilen keine unzulässigen Beanspruchungen. (siehe beiliegende Drehzahldiagramme) Drehzahlsperrbereich: Motordrehzahl 0 - 450 1/min aus Drehzahlregulierungsgründen

1. 1.1

Operational restrictions: Normal running: According to the data of the manufacturer for this coupling a dynamic stiffness of 135% of the nominal catalogue value is to be chosen. For the synthesis and natural frequency calculation the above-mentioned stiffness value was used. With this we did not calculate any inadmissible stresses in the individual plant components (see attached speed diagrams). Barred speed range: Engine speed 0 - 450 rpm due to speed governing reasons

1.2

Aussetzerbetrieb Hierunter wird allgemein der Betrieb mit ungleichmäßigen Zylinderbelastungen verstanden. Praktisch gibt es zwei Extreme:

1.2

Irregular running This generally means the operation with unbalanced cylinder loads. There are two extreme cases:

1.2.1 Zündaussetzer Keine Einspritzung, aber Kompression voll vorhanden bei einem beliebigen Zylinder. Allgemeine Hinweise: Siehe Betriebsanleitung Notbetrieb (Blatt A3.12.02.01) Spezielle Hinweise: In diesem Betriebszustand wird die Kupplung durch Wechseldrehmomente und durch grössere Wärmeentwicklung höher beansprucht. Gegeben durch die Charakteristik des Gummielementes reduziert sich somit die Steifigkeit in der elastischen Kupplung. Für die Syntheseberechnung wurde 70% des nominalen Katalogwertes eingesetzt. Mit dem oben genannten Steifigkeitswert errechneten wir für die einzelnen Anlagenteilen keine unzulässigen Beanspruchungen. (siehe beiliegende Drehzahldiagramme) Keine Betriebseinschränkungen aus drehschwingungstechnischen Gründen. Es muß allerdings sichergestellt werden, daß die max. Pumpenfüllung den 100% Prüfstandsprotokollwert nicht übersteigt. 1.2.2 Vollaussetzer Keine Kompression, ausgebautes Triebwerk. Allgemeine Hinweise: Siehe Betriebsanleitung Notbetrieb (Blatt A3.12.02.01) Betrieb bei Generatoranlagen weder üblich noch erforderlich. de/eng/20.02.2008

1.2.1 Misfiring No injection, but compression fully available in one of the cylinders. General notes: See Operating Instructions, Emergency Operation (sheet A3.12.02.01) Special notes: At this operating condition the coupling is subjected to higher stress due to alternating torques and a higher heat development. Owing to the characteristic of the rubber element the stiffness in the flexible coupling respectively is reduced. For the synthesis calculation 70 % of the nominal catalogue value was used. With the above-mentioned stiffness value we did not calculate any inadmissible stresses in the individual plant components. (see attached speed diagrams) No operational restrictions for reasons of torsional vibrations. However, it must be ensured that the max. fuel rack position does not exceed 100% of the test bed record value.

1.2.2 Full failure No compression, running gear dismantled General notes: See Operating Instructions, Emergency Operation (sheet A3.12.02.01) Operation in case of generator sets neither usual nor necessary. Blatt/Sheet: 2 von/of: 9

c
Motor / engine: MaK 16CM32C

Berechnungsdaten Calculation Data

Bericht-Nr./ Report No.

08032019

Viertakt, 16 Zyl. V-Motor / four stroke, 16 cyl. Vee engine V-Winkel: 50 Grad / Vee angle: 50 deg Dauerleistung / continous rating: 7680 kW bei / at 720 1/min / rpm Bohrung / bore: 320 mm Pleuelst.-verh. / con.rod ratio: 0.217 Hub / stroke: 420 mm Osz. Gewicht / recipr. weight: 217.9 kg Zündfolge / firing order: A1-B3-A3-B5-A5-B7-A7-B8-A8-B6-A6-B4-A4-B2-A2-B1 Blattfederdämpfer / leaf spring damper nach MaK-Zeichnung / acc. to MaK drawing: 0.00.6-63.13.00-39 Außenteil / outer part Red. Länge / equ. length Innenteil / inner part 30.30 625.00 2.53

Kurbelwelle / crankshaft nach MaK-Zeichnung / acc. to MaK drawing: 1.98.7-25.10.01-03 Abschnitt Dämpfer-letztes Triebwerk / section damper-last running gear MT-Moment eines Triebwerks / moment of inertia of a running gear Abschnitt zwischen zwei Triebwerken / section between two running gears Abschnitt Zylinder B1-Schwungrad / section cylinder B1-flywheel 16 Gegengewichte / 16 counter weights Je 2 Stück an den Triebwerken / 2 pcs each on running gears 1 to 8 Schwungrad / flywheel: MaK-Zeichnung / MaK drawing 1.90.7-73.10.02-06 Schwungradnabe / flywheel hub: MaK-Zeichnung / MaK drawing 1.90.7-73.10.01-03 Elastische Kupplung / flexible coupling: Vulkan Rato-R G381NR , series 2200, Zeichnung Nr. / drawing no.: 1G3810R007 Primärteil / primary part Elastizität / flexibility 135% / 70% Sekundärteil / secondary part Drehstromgenerator / alternator: LeroySomer, Type: LSA58-XL11/8p - HV, Zeichnung Nr. / drawing no.: P1 059 0060, Rev.A Wellenabschnitt bis Lüfter / shaft section up to fan Lüfter / fan Abschnitt Lüfter - Polrad / section fan - rotor Polrad + Welle / rotor + shaft Abschnitt Polrad - Erreger / section rotor - exciter Erreger + Gleichrichterbrücke / exciter + rectifier bridge

11.50 44.10/46.10 11.50 12.00 38.80

439.40

21.50

36.00 673.40/1299.00 69.40

22.79 113.30 6.51 1738.00 7.89 21.10

de/eng/20.02.2008

Blatt/Sheet: 3 von/of: 9

00 0.53 11.4 12 113.00015 11.5 κ/ω= . A1/B1 running gears Cyl.50 28.0000 06 Triebwerke Zyl. A2/B2 121.0000 de/eng/20.00 1.10 0.51 36.70 11.c 30. A6/B6 121.30 625.00 1.70 11. A4/B4 121.00 1.3 1 2.00015 11.00 28.0000 07 Triebwerke Zyl.00 1.7 3 121.5 κ/ω= .5 κ/ω= .0000 03 Triebwerke Zyl.50 28.00015 12 673.7 5 121.50 28.0000 08 Triebwerke Zyl. Kupplung flywheel + pp coupling 496. A1/B1 123. A8/B8 121.00 1.0000 12 ST elastische Kupplung sp flexible coupling 69. A2/B2 running gears Cyl. 08032019 121.0000 13 Lüfter fan 113.3 13 1738 14 21.7 8 121.70 11.70 11.89 30.70 11.2008 Blatt/Sheet: 4 von/of: 9 .5 κ/ω= . A4/B4 running gears Cyl.7 9 123.70 11.00 1.00 1.9 10 11 69.00 7.50 1.00 1.0000 11 Schwungrad + PT.50 28.79 22.0000 04 Triebwerke Zyl.0000 14 Generatorpolrad generator rotor 1738. A7/B7 121.0000 09 Triebwerke Zyl.00015 11.51 7.7 496.50 28.0000 15 Erregermaschine exicter 21.63 Nr. A7/B7 running gears Cyl.00 1. A5/B5 running gears Cyl.1 15 625 κ/ω= .5 κ/ω= .00 1. A3/B3 121.9 / .02./ Report No.7 4 121. A5/B5 121.89 ψ= .00 1.79 6.0000 10 Triebwerke Zyl.7 7 Elastisches System Mass Elastic System Bericht-Nr.00 1.00 1.5 κ/ω= . A6/B6 running gears Cyl.5 11.50 28.53 2 121. A3/B3 running gears Cyl.5 κ/ω= .4/1299 0.90 673.00156 11.30 6.70 12.70 11. A8/B8 running gears Cyl.50 28.0000 02 IT-Schwingungsdämpfer ip-vibration damper 2.50 28.00015 11.00 0.4 / 1299 22.0000 05 Triebwerke Zyl.00015 11.00 1.40 22.00015 11.7 6 121. Bezeichnungen Designations I[kgm2] L[rad/GNm] D[cm] i[-] --------------------------------------------------------------------------------------------01 AT-Schwingungsdämpfer op-vibration damper 30.

8 . 08032019 Generatorcharakteristik (P=const) / Alternator Characteristic Wechselspannung Systemstelle 2..0) Ordnungen: 4.5 .14 Spannung/Stress [N/mm2] Total 640 660 680 700 720 740 760 780 800 820 840 640 660 680 700 720 740 760 780 800 820 840 Motordrehzahl/engine speed [1/min] (i=1.7.3.12 Moment/Torque [kNm] 1 .8 ...0 .5 .5 _____ 1.0) Ordnungen: 1.6 . 10 9 8 7 6 5 4 3 2 1 0 Wechselspannung Systemstelle 12.5 1 . de/eng/20.5 _____ 9.1 0 Elast.3 Total ..0 _____ 2..5 Total 3 2.12 Verlustleistung/Power loss [kW] zulässig/admissible zulässig/admissible Total 640 660 680 700 720 740 760 780 800 820 840 640 660 680 700 720 740 760 780 800 820 840 Motordrehzahl/engine speed [1/min] (i=1. 11...14 Alternating Stress Location 13.5 .0) Ordnungen: 0.0 .5 _____ 9... Motordrehzahl/engine speed [1/min] (i=1.4 1.0 _____ 0...7 ...2 0 Drehzahldiagramme Speed Diagrams Bericht-Nr..8. Motordrehzahl/engine speed [1/min] (i=1.5 .0) Ordnungen: 0.3 Alternating Stress Location 2.0) Ordnungen: 0..5 Alternating Stress Location 4.4.13 Alternating Stress Location 12.13 Spannung/Stress [N/mm2] 5 4..4 .4... 11......5 4 3. Coupling Location.5 0 Wechselspannung Systemstelle 13.5 2 1..8...2008 Blatt/Sheet: 5 von/of: 9 .6 1. Coupling Location...12 Flex.5 ..3 Spannung/Stress [N/mm2] Wechselspannung Systemstelle 4.0 .8 1...2 .5 ....5 Spannung/Stress zulässig/admissible [N/mm2] 50 45 40 35 30 25 Total 20 15 10 5 0 Total 640 660 680 700 720 740 760 780 800 820 840 640 660 680 700 720 740 760 780 800 820 840 Motordrehzahl/engine speed [1/min] (i=1.c 2 1...0 . Motordrehzahl/engine speed [1/min] (i=1./ Report No.02.4 ..2 1 ..5 _____ 1.. Kupplung Systemstelle 11..12 Flex...9 ..0) Ordnungen: 0. 50 45 40 35 30 25 20 15 10 5 0 Elast..0 .. Kupplung Systemstelle 11.5 ..5 ..6 ..

02..5 .0) Ordnungen: 0. A 8) Alternating Stress Location 13.3 .0 . 08032019 Generatorcharakteristik (P=const) / Alternator Characteristic Wechselsp.8 1. A 8) Flex..12 (Misfiring Cyl. Systemstelle 8.. A 8) Flex. A 8) Spannung/Stress [N/mm2] 2 1. Coupling Location. 50 45 40 35 30 25 20 15 10 5 0 Elast..13 (Aussetzer Zyl.4.0) Ordnungen: 0.5 _____ 9.. Systemstelle 13.5 _____ 9.2. A 8) Alternating Stress Location 12.0 . 11.14 (Misfiring Cyl.0 ..6 Wechselsp.5 ...0) Ordnungen: 1. A 8) Alternating Stress Location 2...5 2 1.. A 8) Moment/Torque [kNm] 1 .0 .12 (Aussetzer Zyl...9 . Systemstelle 2. Motordrehzahl/engine speed [1/min] (i=1.0) Ordnungen: 0..9 (Aussetzer Zyl.. 10 9 8 7 6 5 4 3 2 1 0 Wechselsp...3 (Aussetzer Zyl..8 .0 .0 _____ 0.....13 (Misfiring Cyl..0 .1 0 Elast.5 4 3. A 8) Spannung/Stress [N/mm2] Total Total .5 .5 0 Drehzahldiagramme Speed Diagrams Bericht-Nr.2 1 .8 . de/eng/20...4 ..3 (Misfiring Cyl..5 _____ 1..5 ...8. Motordrehzahl/engine speed [1/min] (i=1. Coupling Location.5 .2 0 640 660 680 700 720 740 760 780 800 820 840 640 660 680 700 720 740 760 780 800 820 840 Motordrehzahl/engine speed [1/min] (i=1.2 . A 8) Alternating Stress Location 8.5 1 .14 (Aussetzer Zyl. Systemstelle 12./ Report No. A 8) Spannung/Stress zulässig/admissible [N/mm2] 50 45 40 35 30 25 20 Total 15 10 5 0 Total 640 660 680 700 720 740 760 780 800 820 840 640 660 680 700 720 740 760 780 800 820 840 Motordrehzahl/engine speed [1/min] (i=1..4 .. Kupplung Systemstelle 11...6 1..0) Ordnungen: 3..7 ..5 ...4 1.0) Ordnungen: 0. A 8) Verlustleistung/Power loss [kW] zulässig/admissible zulässig/admissible Total 640 660 680 700 720 740 760 780 800 820 840 Total 640 660 680 700 720 740 760 780 800 820 840 Motordrehzahl/engine speed [1/min] (i=1..0 _____ 2.2008 Blatt/Sheet: 6 von/of: 9 ....2.5 _____ 1.6 . Motordrehzahl/engine speed [1/min] (i=1. A 8) Spannung/Stress [N/mm2] Wechselsp.1. Kupplung Systemstelle 11.9 (Misfiring Cyl.. 11...2.12 (Misfiring Cyl.c 5 4.5 3 2..12 (Aussetzer Zyl..5 .

Grad / Node 0.6238 de/eng/20.0 8.5 11.0566 7.0 14.0961 0.5 8.0147 0.c 1. 08032019 8 9 10 11 12 13 14 15 2.2451 0.3255 0.8109 4.0 5.0 8.0 7.5 0.0214 0.0515 0.6415 8.0570 0.2463 1.2858 3.6166 2.5 7.5 0.5 0.0963 6.0125 0.0035 11.5 6.0 4.0 5.7901 0.8894 0.0 0.5515 6.0 0.0 0.0 0.2443 1.1096 1.5 9.0 2.2049 0.0 7.0 9.0115 0.0 2.5 4.0 3.5 5.0155 6.5 0.0715 0.5 11.0984 0.5 3.1388 0.2688 0.5 2.5 1.5 2.0 5.9063 1.0 10.7753 0.0 2.3367 5.2180 0.1427 0.1897 0.0 0.5 1.3445 0.5 9.2117 9.0326 0.5 6.0 5.5 10.0331 1.5 0.4667 1.3217 0.4262 0.2766 0.0199 0.0 1.4161 0.5 4.Grad / Node 1989 1/min 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 3.2530 5.0 9./ Report No.0110 2.3787 6.0380 0.5 2.5 7.5 3.0 7.0050 11.0337 0.Grad / Node 2455 1/min 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Vektorsummen bezogen auf Masse 3 / Phase Vector Sums referred to Mass 3 1.5 10.0 1.2259 0.0 0.3462 0.02.5 5.2344 0.2489 8.1193 0.0 3.2585 2.5 4.5 5.Grad / Node 2.7225 0.0 3.6836 3.1202 0.0755 12.Grad / Node 387 1/min 1 2 3 4 5 6 7 Eigenfrequenzen Natural Frequencies Bericht-Nr.0 1.5 8.0 6.3043 6.5 1.0 11.0 11.7055 0.0 4.0 4.2015 0.0 0.1904 0.5 12.2008 Blatt/Sheet: 7 von/of: 9 .5 12.0061 10.1399 0.0145 10.3472 0.0 10.0258 7.5 0.7214 0.0402 9.Grad / Node 3.5 6.5 3.

1239 0.2397 0.Grad / Node 6716 1/min 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 6.0767 1.5 5.0 3.0 4.5 9.0 7.0 5.5 10.2423 0.0 1.6403 0.5448 0.1962 2.0 8.5 12.5 3.0 11.5 8.9895 4.Grad / Node 0.0825 3.9799 7.9050 0.3869 0.0 9.1904 de/eng/20.0 3.Grad / Node 4804 1/min 1 2 3 4 5 6 7 Eigenfrequenzen Natural Frequencies Bericht-Nr.5853 0.5 2.5 8.9270 1.6316 6.0 4.1990 0.8992 1.5 4.4936 0.5 12.6599 3.0 2.5 4.5 8.0 1.6650 6.9739 0.5 5.5 6.0 2.5 11.3632 1.7039 2.5 11.3409 0.0 2.4173 1.5 1.Grad / Node 7382 1/min 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Vektorsummen bezogen auf Masse 3 / Phase Vector Sums referred to Mass 3 4.0 3.7714 6.0 2.7745 6.6812 4.2677 0.1240 0.4134 1.0 10.5668 1.7649 1.c 4.5 2.5 4.4539 8.Grad / Node 6.2559 0.0875 4.5 9.3108 1.5 9.0 1.3968 5.5885 2.0 11.2008 Blatt/Sheet: 8 von/of: 9 .0 5.1603 0.1849 5.5 1.9020 0.2519 0.6596 0.8191 0.0 7.0777 0.6945 0.5 12.5 7.0 4. 08032019 8 9 10 11 12 13 14 15 5.0 1.2094 0.0 11.1632 0.8175 2.7380 7.02.9991 1.1000 1.5 11.2148 3.2494 0.4820 6.5014 6.0 8.5 6.5 2.1742 3.2374 2.5 10.0 3.0 10.0 10.5 7.3477 2.0 8.5 3.5 10.0 1.7594 0.0 7.0 5.5353 0.5 3.0 1.3204 2.0 9.8447 1.5 6.7472 0.6827 1.5 1.2627 0.0 9.5 7./ Report No.4688 0.5 5.1707 4.7253 0.8545 1.Grad / Node 5.0 5.

which.ausgeschlossen. Es wird empfohlen. Die Ergebnisse und Schlussfolgerungen sind nur gültig.gleich aus welchem Rechtsgrund . Drehschwingungsersatzsystem: Die Antriebsanlage ist auf ein berechnungsfähiges Ersatzsystem. Weitergehende Ansprüche sind . Sämtliche Massenträgheitsmomente sind in der Einheit 2 [kgm ] angegeben. G = 10 . sind auf die Motordrehzahl reduziert. can only be influenced by us within our scope of supply. die schneller drehen als der Motor haben ein Übersetzungsverhältnis größer als eins. die nicht mit Motordrehzahl umlaufen. Important note: This torsional vibration calculation has been carried out according to the rules of vibration engineering to the best of our knowledge and with the assistance of the most modern calculation aids. 08032019 Verwendete Maßeinheiten: Alle in diesem Bericht genannten Zahlenwerte entsprechen dem internationalen Maßsystem (SI-System). Alle Anlagenteile. Unsere Gewährleistung wird neben der Beseitigung eines evtl. Berechnungsfehlers auf Nachbesserung oder Ersatz des schadhaften Teiles an unserem Liefergegenstands beschränkt./ Report No. um diesen eine Nachprüfung auf Richtigkeit der Daten und Zulässigkeit der auftretenden Beanspruchungen zu ermöglichen. Any other claims are excluded irrespective of their basis in law. We recommend our customer to make the torsional vibration calculation available to each component supplier for checking the correctness of the data and the admissibility of the stresses to be expected. All components not running at engine speed are referred to engine speed.2008 Blatt/Sheet: 9 von/of: 9 . Instead of the usual torsional rigidity c [kNm/rad] we indicate the reciprocal value L [rad/GNm]. zurückgeführt. 9 Our guaranty is limited to the correction of any computational error and the repair or replacement of the defective part of the equipment supplied by us. G = 10 . Anlagenteile. Anstelle der üblichen Drehsteifigkeit c [kNm/rad] wird der Reziprokwert L [rad/GNm] angegeben. The results and conclusions are only valid as far as the data given are correct. Wichtige Anmerkung: Vorliegende Drehschwingungsberechnung wurde . 2 The unit of all moments of inertia is [kgm ]. Components running faster than the engine have a gear ratio greater than unity. Equivalent torsional system: The propulsion plant is substituted by a computable equivalent system. dass der Auftraggeber allen Bauteillieferanten die Drehschwingungsberechnung zur Verfügung stellt.c Erläuterungen Explanations Bericht-Nr. das abwechselnd aus Massen und Federn besteht.entsprechend den Regeln der Schwingungstechnik nach bestem Wissen und unter Zuhilfenahme modernster Rechenhilfsmittel durchgeführt. soweit die Eingabedaten korrekt sind. de/eng/20.02. however. which alternately consists of moments of inertia and springs. 9 Units of measurement used: All figures mentioned in this report correspond with the International System of Units (SI Units). worauf wir jedoch nur bezüglich unseres eigenen Lieferanteils Einfluß haben.

2008 AA000095 1/1 .02.10 Acceptance Test Records en / 20.Acceptance Test Records - A1.

20.Technical Data Acceptance test records VM32 A1.10.04.28.2008 AA041605 1/13 .25 en / 21.

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Operating Instructions M20-M601C A3 Operating Instructions en / 24.04.2008 AA000108 1/1 .

06.04.02 en / 24.05.01 Operating Instructions Table of Contents Introduction Safety Instructions Instructions for Heavy Fuel Operation Instructions for Heavy Fuel Operation Fuel system Instruction for heavy fuel operation Care and supervision / Engine fuel Instructions for heavy fuel operation Lubricating oil system Instructions for heavy fuel operation Care and supervision / Lubricating Oil Initial Operation Engine Initial operation Fuel system Initial operation Lubricating oil system Initial operation Cooling water system Initial operation Starting air system Initial operation Starting air system Initial operation General performance testing Initial operation Putting into service/starting Initial operation Putting into service/loading Operational Supervision Engine Monitoring Intake air temperature Monitoring of operation Exhaust system/Firing pressure Operational supervision Exhaust system/supercharging A3 A3.00 A3.05.05.Table of Contents - A3.08.08.06.00 A3.04 A3.05.05.00 A3.01 A3.01 A3.06.00 A3.01 A3.08.04.05.05.01 A3.04 A3.00 A3.10.06.05.06.18.2008 AA020023 1/3 .03 A3.04.09.05.00 A3.04.00 A3.02 A3.15.18.11.00 A3.04.02 A3.06.00 A3.07.00 A3.07.05.00 A3.07.

18.00 A3.07.2008 AA020023 2/3 .00 A3.01 A3.01 en / 24.10.10.06.07.11.00 A3.11.00 A3.00 A3.06.06.09.06.04.01 A3.01 Operational supervision Fuel system Operational supervision Changing the type of fuel Operational supervision Lubricating oil system Operational supervision Cooling water system Operational supervision Adjustment Instructions Operational supervision Starting system Operational supervision Partial load operation Removal from operation Engine Removal from operation Placing out of service/stopping Danger of Frost Engine Danger of frost Antifreeze protection Preservation Engine Preservation Short term preservation Preservation Long term preservation Preservation Depreservation Running-in Engine Running-in Engine Fault Tracing Engine Fault tracing Introduction Fault tracing Oil mist detector A3.09.01.00 A3.00 A3.00 A3.00 A3.09.06.09.06.11.09.08.07.00 A3.01.00 A3.18.01.01.06.09.00 A3.00 A3.00.08.02.18.00 A3.08.18.10.01 A3.03.00 A3.07.Table of Contents - A3.00 A3.

02.01 en / 24.02.00 A3.12.12.00 A3.18.12.01 Fault tracing Remedial measures Emergency Operation Engine Emergency operation With a defective turbocharger Emergency operation Operational misfire Emergency operation Operational misfire A3.01.2008 AA020023 3/3 .11.02 A3.04.12.Table of Contents - A3.01 A3.

Unless otherwise indicated. the limiting position must also be accordingly lower. As such. our information always refers to the maximum continuous power and if this is unknown to the operator he should make inquiries to the manufacturer. Any other arrangements can be seen from the acceptance test records (A1.Introduction M20-M601C A3. The alteration of the fuel rack position may only be carried out by personnel who have received permission to do this from Caterpillar / MaK ! en / 17. For any working data mentioned in this book. to meet special requirements.10).02 Contained herein are certain points regarding the initial operation. Thereby in compliance with DIN ISO 3046 we differentiate between: • Maximum continuous power this is the maximum permissible output for this type of engine. This is especially the case after a change of fuel from that of an essentially higher density as it is the case when changing from distilled fuel to heavy oil. • Full stop power this is the power output limited by a restrictor on the injection pump racks.2006 AA000295 1/5 .01. • Rated power this is indicated on the acceptance test records for your engine. please bear the following in mind: It is possible for the engine power to be limited before reaching its full performance capacity. Attention: When using heavier fuel grades independent on the density of the fuel. the rated power will be reached at a fuel rack position that is accordingly lower. The power is limited by a restrictor at the fuel injection pump control shaft during the test bed run and normally at rated power and speed. the assurance of a reliable service as well for overcoming the need for long periods of non operation. thus ensuring a rapid return to service.

They are the basis for a long useful life with a constant degree of economy for your engine installation. Attention: After every cleaning of the engine with fat solvent detergents all metallic blank patts must be protected again slightly with an oil film! Special care must be taken to ensure that all bearing points affected by the cleaning are thoroughly lubricated afterwards! en / 17.02 The operators have to work with the necessary care and to keep to the safety notes. Safety devices may only be changed in special cases by personnel who have received permission to do this from MaK. all important data and work should be recorded in either the engine log book or in our ship management system DIMOS. and any damage detected must be immediately reported. The preparations for the first startup are made by the MaK service engineer. The existing protection and safety devices must not be removed nor changed.Introduction M20-M601C A3. who will explain the plant to the engine room staff in detail.01.2006 AA000295 2/5 . After commissioning the engine. Please observe the data and recommendations in your operating instructions together with the maintenance and servicing measures recommended by us. Detail questions are to be settled on site from the operating instructions and explanations should be noted down in the instructions.

In extreme cases this may even result in valve burnout and piston burn. although they do meet the generally applicable requirements (ISO. and liner are the operating conditions of the engine. More and more often different residues from the refinery process and processes of the manufacturing industry and the chemical industry are added to the basic fuel. it is becoming increasingly difficult for operators and manufacturers of heavy-fuel compatible large engines to assess the combustion properties of the fuel. Therefore.Introduction M20-M601C A3. In the following some instructions will be provided for the operator on how to increase the service life of these components and save maintenance and operating costs. en / 17. The analysis should cover the following: • • • Content of aromatic compounds and asphaltenes in the fuel Nitrogen content Vanadium content Upon receipt of the analysis consultation with the field organization responsible for your support should take place. At the moment.01. CIMAC).g. i. Fuels with poor ignition qualities will normally lead to increased piston and valve burn due to the formation of fuel deposits that eventually burn or smolder on these components. In the worst case vanadium may act as a catalyst to the formation of acid.02 Basic notes on engine operation relating to the service life of combustion chamber components Of vital importance to the service life of highly loaded combustion chamber components such as inlet and exhaust valves. This may result in fuels that tend to have poor ignition qualities and a slow rate of combustion and are inclined to form hard. piston. these standards do not provide any information about the combustion properties of fuels. 1. We are. can be influenced to a very large extent by the operator of the plant. Suppliers of fuels are currently working to define properties and limits more accurately. however. abrasive constituents. Maintenance and monitoring of operating media Fuel The quality of heavy fuel has continuously deteriorated during the last years. recommending to the operator to request an extended analysis from the analyzing laboratory at regular intervals or if there is a suspicion of poor fuel quality. therefore. Past experience has shown that this may already be caused by one charge. thus considerably decreasing the expected or scheduled TBO.2006 AA000295 3/5 . These. sulphur) beyond the normal extent.e. strong acids will be formed from constituents of the fuel (e.

the viscosity must range within the specified limits. in bearings). the viscosimeter is continually capturing the current viscosity.Introduction M20-M601C A3. These forming acids must be neutralized in order to protect the engine components against corrosive attack. 2.g. This will be done until there is no more discrepancy between the current and the preset viscosity value. which in turn leads to piston burn. Depending on the measuring method the vanadium content can indicate a rising percentage of heavy fuel in the lubricating oil. Low temperatures of the fuel always lead to higher viscosity and vice versa. Through the combustion air and the fuel acid formers are introduced into the engine. steam bubbles may form under certain pressure and temperature conditions (e. Percentages of individual chemical elements: Especially important is the vanadium content.02 Lubricating oil As regards the lubricating oil treatment it is of particular importance to ensure correct separation and filtration and keep an eye on the operating values of the oil. The connection between the viscosity of the fuel and its temperature is used for controlling the injection viscosity. Monitoring of the operating conditions Injection System We particularly want to emphasize the importance of monitoring the fuel for correct injection viscosity. TBN (Total Base Number): Characterizes the neutralizing capability of the oil. Important characteristics of the lubricating oil are: • • • • Viscosity: For the formation of a corresponding lubricating wedge a correct viscosity is of vital importance.2006 AA000295 4/5 . To this end. In case of discrepancies between the current and the preset value the viscosimeter will transmit a signal to the fuel preheater which in turn regulates the temperature of the fuel. Furthermore. To this end. Water content: A high percentage of water in the oil has a corrosive effect. A high percentage of heavy fuel in the engine lubricating oil may particularly affect piston cooling. Due to this control principle it is very important to avoid long distances between viscosimeter and the injection pump on the engine so as to ensure that the adjusted fuel temperature actually reaches the engines. we recommend to have the lubricating oil analyzed at regular intervals by a laboratory.01. In order to avoid damages to the engine. interrupt the lubricating film and thus cause damages. en / 17.

piston crown. injection pump.Introduction M20-M601C A3. cam follower. Especially during the hot summer months or in warm regions of the world particular attention should be given to this aspect. a positive effect can be achieved by aligning the fins of the louvers so that the air flow reaches the turbocharger in an optimal way. High viscosity: • Poor atomization of the fuel which may lead to severe formation of soot due to poor combustion. Engine room ventilation Prerequisite for a properly working turbocharger and thus for proper air supply to the engine is a good engine room ventilation. en / 17.02 Problems in case of wrongly adjusted injection viscosity: a) Low viscosity: • • b) Seizure of the injection pumps due to decreased lubrication of the pump plunger (especially in case of gas oil operation).2006 AA000295 5/5 . high mechanical load on the entire injection system and combustion chamber components: Roller.01. An indicator of sufficient ventilation by a given engine room ventilation system is a slight overpressure in the engine room. which may significantly reduce service life particularly of the combustion chamber components. Turbocharging The turbocharger is one of the most sensitive components of the engine. Formation of steam bubbles due to excessive temperature and resulting excess consumption. The efficiency of the turbocharger depends on its degree of contamination. fuel injector. Furthermore. which determines whether the individual cylinders are supplied with a sufficient amount of air. It is absolutely required to make sure that all available engine room ventilators are running and all air ducts are fully open. Consequences of a poorly performing turbocharger can be: • • • Drop in power produced by the engine Rising fuel consumption High temperatures of the combustion chamber components.

heat insulation. Before the initial operation of special systems.03 Safety Instructions The Caterpillar / MaK engine has been built in accordance with state-of-the-art standards and the recognized safety regulations. the service personnel must be fully aquainted with the characteristic features therein. For the operators of the system this is a necessary requirement to the order. General safety instructions During all operational and service measures the relevant pointers in the prevention of accident regulations of the particular employee's liability insurance association or equivalent institution. An introduction to the system specifications.2008 AA000338 1/2 . for example: • • Observe all fire-warning and fire-fighting procedures! Operating elements of the emergency-off device are to be free acessible! Further valid is the following: • • • • Unauthorized modifications and changes to the system can impair the safety! Alteration may only be carried out by personnel with received permission to do so from Caterpillar / MaK! Avoid any work procedures which may affect the safety! Only operate the engine if all protection facilities. this must be reported immediately to the competent person! Stop the engine/ plant immediately and secure it if necessary against restart! Damages and faults should be rectified immediately! Stop and secure the engine/plant immediately against restart in the case of functional disorders! Malfunctions should be rectified immediately! • en / 20. linings. The service personnel must possess the corresponding qualification and authorization (qualification certificate) for the engine system in operation. requirements/characteristics can be carried out in the training center of Caterpillar / MaK. in the case of improper operation • • • physical or life-threatening danger to the operator or others damage to the unit and other valuable objects a reduction in the economy of the unit. are to be observed.02. detachable protection facilities. extractors are available and functional! Check the engine/plant at least once per shift for damage and defects which can be recognized from the outside! If any changes occur (including changes of the operational behaviour). Nevertheless.Safety Instructions M20-M601C A3.g. e.

2008 AA000338 2/2 . and other reproductive harm. en / 20.Safety Instructions M20-M601C A3. potentiometer with locking facility)! • Starting: • • Check the instrument readings! Do not switch off extractors and ventilators while the engine is running! Attention: In no case the starting air shut-off valve must be closed during engine operation. California / USA Proposition 65 Warning • Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer.02. operating controls. ensure that there is no danger to persons by the starting engine/plant! Move operational controls to neutral position and/or minimum position (r. Inland ships must also observe the relevant customary safety recommendations! Safety measures for local control of the engine Before the start: • Check the system for defects. check lamps! • • • • defective instruments.p. control lights Clean up spillages of fuel and oil! Protection guards must be in operation position and operative! Hearing protection must be worn! Before putting the engine into operation.m. birth defects.03 Remote control The engine remote control of seegoing ships and inland ships will be constructed according to the safety regulations of the classification society.

1997 AA000291 1/1 .nn en / 10.nn • Lubricating oil system A3.Instructions for Heavy Fuel Operation M20-M601C A3.07. as the readiness for service and operational reliability of the engine system during high extremes of use. requires perfect fuel and depends upon optimal concentrations and monitoring supervision. • Fuel system A3.12.04 The instructions stated below are to be stringently observed.08.04.04.

07.Instructions for Heavy Fuel Operation Fuel system M20-M601C A3. The remainig contaminating matters influence the operation of the “heavy fuel engine”! Optimum treatment of the fuel and an intensive supervision of the plant are therefore a precondition for economical operation of “heavy fuel engines”.12.04.05.nn. For information about heavy fuel quality and for instructions and maintenace see section A4. sodium and cat fines etc. en / 10. The distinguishing properties of such residual oils are their high viscosity and their density as well as the increased portion of chemical compounds with sulphur. increased.00 Fuel system The evermore intensive utilization of crude oils by modern processing is the reason the portion of the residual oils (heavy fuel) has become smaller and the portion of the in the residual oils remaining contaminating matter has.1997 BA000004 1/1 . vanadium.07. however.

03.1997 BA021421 1/4 .04. Basic schema of the heavy fuel system DT1 HF1 HF2 HF3 HF4 HH1 HH3 HH4 HP1/HP2 HP3/HP4 HP5/HP6 HP7 Diesel oil day tank Fuel fine filter (duplex filter) Fuel primary filter (duplex filter) Fuel coarse filter Self cleaning fuel filter Heavy fuel final preheater Heavy fuel preheater (separator) Heating coil Fuel pressure pump Fuel oil circulating pump Heavy fuel transfer pump Sludge pump HR1 HR2 HS1/HS2 HT1 HT2 HT5/6 KP1 KT2 Fuel pressure regulating valve Viscometer Heavy fuel separator Heavy fuel day tank Mixing tank Settling tank Fuel injection pump Sludge tank en / 10.01 Care and supervision If you are uncertain of the bunker quality. a careful ascertation of the quality must take place.Instruction for heavy fuel operation Care and supervision / Engine fuel M32 A3.07.

07. 1.04.06. en / 10. Before cutting a tank in. thoroughly remove any water and sludge. • • Both separators are always to be operated parallel independently of the manufacturer/system. Separation temperature 98 °C.90 °C 3. Storage tank When fueling with heavy fuel. They lower the content of solids and water of the heavy fuel to the minimum that can technically be reached. the set temperature of the tank should be between 80 .1997 BA021421 2/4 . The operational capacity is designed according to the rules and regulations of the individual manufacturer. • • Connect the two tanks alternaly irrespective of the fuel consumed so as to obtain the best settling effect possible. HS2 The separators have the most important task in the heavy fuel treatment.03. During operation. This is to avoid segregation or the consequences of any incompatibilty that may occur when taking on different types of fuel. The longer the fuel remains in the settling tank.01 Note: The shown fuel circutory diagram is as well valid for operation with destillate fuel after periods of longer operation on low partial load and prior to planned service measures. For permanent operation of the engine with destillate fuel. and a part of the water and heavy contaminations are separated from the heavy fuel as sludge. only empty storage tanks are to be used.07. Separator HS1. HT6 Emulsions are normally broken up under temperature influence in a settling tank. 2.nn.Instruction for heavy fuel operation Care and supervision / Engine fuel M32 A3. Two setting tanks are to be provided for HFO-operation and each one is to be designed for a full load operation of 24 hours. whose authorised department has coordinated the design with MaK-Kiel. Settling tank HT5. the HFO pumpability of the heavy fuel for the required temperature range must be obtained from the supplier or check the setting point by cooling. If a plant has no storage tank heating. please refer to diagram A3. the more contaminants and water will be deposited.

04. Self cleaning fuel filter HF4 For fuel (heavy fuel and destilled fuel).95 °C should be maintained. the operation of the separators must be checked and the filter cleaned (for servicing instructions see the document of the manufacturer.05). open the vent valve several times for a short time by hand. which is activated between the flushing intevals if the differential pressure is accessive. for a minimum of 4 hours of full load operation.Instruction for heavy fuel operation Care and supervision / Engine fuel M32 A3. en / 10. HP2 The fuel pump pressurizes the mixing tank. The pump relief valve has to be closed in operation. A temperature level between 80 . • • Daily de-sludging is important. it will always be filled to the overflow level. In the event of alarm and/or when filling the tank.1997 BA021421 3/4 . Fuel pressure-regulating valve HR1 The valve is installed in the excess return line and must be set so that the pressure at the engine is of that required (see A1. 6. This prevents the formation of water condensation. book C). 5. Mixing tank HT2 This mixing tank is equipped with a level monitor. Fuel pressure pump HP1.07. 8.01 4. filter elements with a mesh size of 10 µm are required. Test procedure: The system pressure must not rise when increasing the valve spring load.03. Day tank HT1 The day tank is designed to collect the treated fuel. 7. In the event of filter alarm. If the treatment plant is in order.

a condensation trap should be installed at the steam outlet to ensure sufficient heating if possible.03.05.04. HP4 This pump is designed like a force pump. 10 . Viscosity measurement and control equipment HR2 (Viscometer) Check whether the indicated viscosity is actually run: whenever taking on fuel.8 . 180 °C • If the preheater is of steam type. It is important to clean the filter when 50% of the red area on the differential pressure gauge is visible or when the filter alarm has been activated.07. • If the preheater is of electrical type. 11. en / 10. check the temperature and viscosity against the viscosity-temperature sheet (see A4. Final preheater HH1 The preheater is to lower the fuel viscosity to a level that is optimal for injection.07.07.01 9.06) and ajust the viscometer if necessary.Instruction for heavy fuel operation Care and supervision / Engine fuel M32 A3. in order to reach a good atomisation and fuel-air mixture.12. see A5.12 mm2/s cSt.01. (1. Attention: Fuel temperature before engine intake ≈ 150 °C. 10. For service measurements. Circulating pump HP3.nn. The pump relief valve has to be closed in operation.1997 BA021421 4/4 . ensure the temperature switch may be set to at max. Fine filter HF1 The fine filter prtects the fuel injection system and removes solids not previously separated.2 °E). 12.

08. valves and cylinder liners.: • • Replace metallic friction with the much lower fluid friction of the oil film.08.00 Lubricating oil system The progressively declining quality of heavy fuel oils and the contamination contained therein can lead to engine troubles with increasing frequency if the lube oil is not cared for in an adequate manner. Note: Sulphurous residues and combustion products of the fuel form sulphuric acid with the water vapor which results from combustion and which afterwards condenses.Instructions for heavy fuel operation Lubricating oil system M20-M601C A3.04. This produces corrosive wear on bearings.1997 BA020008 1/1 . Suspend abraded particles. Lubricating oil The selection of the suitable lube oil and the limit values are observed according to the operating media A4. Protect engine parts from corrosive combustion gases.05. For this reason. pistons.12. Improve the seal between piston. combustion residues and products of deterioration. Act as a coolant (pistons).g. • • • • Dissipate frictional heat.nn. en / 11. the following instructions point out the importance of a careful lube oil treatment and supervision of the lube oil circuit so as to ensure a trouble-free and economical engine operation. to limit gas blow-by. piston rings and cylinder liner. The lube oil has important functions in engine operation as e.

1.Instructions for heavy fuel operation Care and supervision / Lubricating Oil M32 A3.01 Care and supervision In heavy fuel operation. Perform during operation regularily.nn. if 20% of the specified quantum has been consumed. Lubrication oil filtering Oil cleaning in separators is specified for heavy oil operation.nn.08.2005 BA020010 1/4 . • The separation temperature must be between 90 . see A4. The lubricating oil is then pumped via the subsequent oil cooler to the duplex filter (with indicator) and then via the safety strainer to the oil pressure limiting valve. en / 01. After this. There are no other means to eliminate from the oil. Oil level control • • • • Check the oil level daily.02. 2. lube oil purification by separators is indispensible for a proper treatment. (For restrictions of guarantee see A4. Top up with fresh oil.03. This will replace parts of the additives consumed. the products resulting from cleaning and neutralisation (carbon and asphalt compounds) including water.04.08. it is distributed among the engine lubricating points. see A3.08.05. Lubricating oil system The pump fitted on the engine takes the oil from the sump tank via a protective strainer (where fitted) and pumps it to the automatic lube oil filter.95 °C. and after longer periods of shutdown an analysis circulatory lubricating oil.05. 3.

Instructions for heavy fuel operation Care and supervision / Lubricating Oil M32 A3.08.2005 BA020010 2/4 .04.03.01 Basic schema of the lubricating oil system LF1 LF2 LF4 LH1 LH2 LP1 LP2 LP9 Duplex lube oil filter Lube oil automatic filter Suction filter Lube oil cooler Lube oil preheater Lube oil force pump Lube oil auxiliary pump Transfer pump (separator) LR1 LR2 LS1 LT1 Lube oil temperature control valve Lube oil pressure limiting valve Lube oil separator Lube oil sump tank en / 01.

Attention: The functioning of the entire series of filters is indispensible for the proper filtration of the lube oil.3. Lube oil automatic filter LF2 An automatic filter with oil or compressed air flushing or an automatic filter with oil flushing is employed as automatic lube filter.03. It must therefore only be bypassed in extreme emergencies. 3.Instructions for heavy fuel operation Care and supervision / Lubricating Oil M32 A3. 3. Check the operation of the engine-driven force pump LP1 • Check the oil pressure (at rated speed and working temperature).08.04. Prime the circuit until the pump pressure is steady. if the pressure is too low. check • • • • • is the oil pressure limiting valve closed? is the pump relief valve tight? are the suction pump seals tight? is the suction strainer clogged? is the flushing quantity of the automatic filter too large? 3.2.1. the cause of the oil contamination must be detected: check the separator function charge air is too cold (soot formation) en / 01.1. • • Check the pressure build-up at the last main bearing (if there is no automatic engine locking). The automatic filter is the main filter and as such it has the finest filtration. Prelubrication LP2 (standby or prelubrication pump) Only a sufficient prelubrication will produce the necessary oil filn on all bearings for engine starting. Lube oil automatic filter LF2 (flushing with oil or compressed air) The flushing frequency results from the quantity of the dirt particles that remain in the lube oil (which indicate the separator function).3.2005 BA020010 3/4 . • Monitor the flushing intervals of the filter (the flushing cycle counter indicates the contamination level). If there are more than 100 flushing per day.01 3.

the filter cartridges being installed at working temperature. carefully clean the isolated filter chamber. • • 3. Carefully check the filter elements for damage. Lube oil automatic filter (with permanent oil flushing) • Regular checking and cleaning of the gauze inserts (the differential pressure indication shows the contamination level of the elements).Remove the cartridges during every third cleaning.04.nn.07.3. If the back-flushing filter is equipped with flushing oil preparation. If the back-flushing filter flushes with oil. Renew damaged filter cartridges For servicing instructions see A5. Renew damaged cartridges.05.05. See servicing instructions in the documents form the manufacturer. book C. set the flushing flow (valve in the flushing line) so that there will be no drop in the working pressure.2005 BA020010 4/4 .5. standby und separator pump every 7500 operating hours and/or when work has been done on the suction side of the lube oil piping system. book C. If the filter has various cartridges. See servicing instructions in the documents of the manufacturer. Strainer filter LF4 • Clean the strainer filters (made available by the customer) in the suction pipes of the service. Duplex lube oil filter LF1 (with indicator) • Check the filter at regular intervals. If required (differential pressure indicator shows 50% of the red area or filter alarm).Instructions for heavy fuel operation Care and supervision / Lubricating Oil M32 A3.08.12. • • 3.01 • Check and clean the filter elements.2.01. one damaged cartridge means a malfunction of the entire filter. the inserts of this must be cleaned or exchanged in he event of a filter alarm. en / 01.03. see A1. • 3.4.

02.2008 BA000022 1/1 .00 Initial Operation en / 20.05.Initial Operation Engine - A3.

12.Initial operation Fuel system M20-M601C A3. The fuel temperature before the injection pumps is to be checked according to its viscosity (see A1.05.06). Use auxilary fuel pump. • Check for smooth operation of the control rack linkages: Each individual control rack has movement in both directions so as to give perfect operation.01.08.nn.05. Additional preparation work for heavy fuel operation (see A3.nn) • • Switch on all necessary preheaters for the correct time. • • • • Drain the day fuel tank. • • Set all equipment parts of the fuel and nozzle cooling systems into the operating position. The rule is: heavy fuel . it will not be necessary to fit uncooled nozzles.12.07. en / 11.05.07. Check the nozzles and opening pressure according to A5. Switch the fuel circulating pump on and check the vent screws. Ensure that all cocks and valves are in the correct position. remove the sludge and refill. In case the day tank is at a higher level and the pump has a bypass line: open the stop valve at the pump.01.01.cooled nozzles distillate fuel .07.nn. Switch the fuel circulation pump on.uncooled nozzles If an engine equipped for heavy fuel.05. flange connections and threaded pipe unions for leaks. Clean the fuel filter according to A5.07.00 Fuel system After a long break from service and/or before the initial operation with heavy and destillated fuels we recommend: • • Remove the fuel injectors according to A5.nn. Vent the fuel system.04. is to be only temporarily run on distillate fuel.07.07.1997 BA000018 1/1 .

Switch on the standby or pre-lubricating pump and Vent the entire lubricating oil system.05.nn) Dry sump .nn.05. see A4.01.Initial operation Lubricating oil system M20-M601C A3. these both being situated in front of the lube oil force pump and the standby pump (see A5.08.08.04. Check all flanges and threaded connections in the system for tight connection.Check the oil level Wet sump .08. Check the lubrication of the following points: Big end and small end bearings Main bearings Camshaft bearings Valve rockers Oil nozzles for timing gear train Oil nozzles for the pumps actuating gear A slight oil flow must be visible.05. • • • Plants with lubricating oil separator: • Start the separator and preheat the oil in this manner in due time before starting the engine.1997 BA000026 1/1 .00 Lubricating oil system The lubricating oil should be analyzed regularily during operation and after a longer period of engine downtime.01. The working pressure has to be reached with switched-on standy or pre-lubricating pump.05. en / 28.08.Check the oil level in the sump by means of a dip stick. Turbocharger with independent lubricating oil supply: • Check the oil levels at the turbine and compressor ends (sight glass). A5.02.Drain off the water from the oil tank .nn. see A1. • Clean the lubricating oil duplex filter and the suction strainer.02.05. Check lubricating oil pressure.

05. turbocharger etc. a sufficient permanent venting must be ensured. see book C.g.). It is required that the cooling water has a level of corrosion protection (see A4.05 an A1. If an engine is running on heavy fuel from pier to pier. • • • • • en / 16.nn. For pressures and temperatures see A1.05. for draining individual cooling water spaces for repair (e. Preheat the engine in good time before starting: Switch the preheater and circulating pumps on or open the isolating valves if the cooling water circuit is connected with the circuit of the engine running.00 Cooling water system • Fill the cooling water system via the expansion tank.09. The vent pipe from the engine to the header tank generally has a stop valve to throttle the water flow. check whether these cocks or valves are open. If there are cocks or valves in the cooling water piping on the engine.1997 BA000030 1/1 .06. For preheating temperature see A3. The starting performance is better with distillate fuel. so that there will be no heat accumulation in the parts to be cooled.Initial operation Cooling water system M20-M601C A3. Unless connected to a permanent venting arrangement.09. cylinder head. all components and pipes belonging to the system must be consecutively vented. preheating is absolutely necessary. Set the correct position of the isolating and changeover cocks and/or valves on the cooling water system.nn).05. Switch on the fresh water standby pump and check the system for leaks. While the engine is running. Water condensation is avoided and the time needed until the engine has been warmed up to normal working temperature is considerably shorter.12.18.

the engine will have a fuel limiter depending on charge air pressure.nn) If there are special requirements to be met.1997 BA000405 1/1 . Check: A5.05.03. Check emergency stop unit (A5.05.01.10. Open the main valve on the air bottles.07.11.01.05.nn)! en / 01. and this also limits the starting fuel.05. • • • • Drain the starting air equipment.nn.05.05.05.02.05.nn A5. For bottle pressure see A1.00 Compressed air system • Check the following components for ease of movement and leaks: Starting air distributor Master starting and vent valve • A5.Initial operation Starting air system M32 A3.05.nn Check the piston of the starting and maximum fuel limiter for smooth operation: The piston must move freely without binding or catching by air pressure or spring action (A5.02.04.05.nn).01.05.02.01. In no case the starting air shut-off valve must be closed during engine operation (A3.05.10.10.

the air supply of the emergency stop cylinders at the injection pumps and at the crankcase oil mist detector are shut off. to ensure the operational reliability of the engine.07. • When the shut-off valve is closed. in addition to the starting air.1997 BA000719 1/1 .11. the engine air system also supplies the emergency stop devices and the crankcase oil mist detector.Initial operation Starting air system M20/M25/M32/M43/M282/M332C/M452/M453C/M551/M552C/M601/ M601C A3. • • Thus the function of 2 safety systems is prevented! It is absolutely necessary that the starting air supply is always open during engine operation.00 Do not close starting air shut-off valve during operation! • Apart from the starting system.05. • In no case the starting air shut-off valve must be closed during engine operation! en / 01.

engine is ready for commissioning. Close indicator or decompression valves.Initial operation General performance testing M20/M25/M32/M43 A3.00 General performance testing • • • Ensure that the air admission into the engine room is in order. • • Open the indicator or decompression valves. Drain the water from the exhaust piping after the turbocharger and check pipe for free passage. Do not start the engine to avoid the danger of water shocks. When the engine is cold. Turn the engine by baring gear or rod.15. a small amount of water may come out as a result of condensation. Check the permanent water drain at the charge air manifold for free passage. for this If the engine has a clutch: • • Declutch the engine Carry out starting attemps. until no water is blown out.05.2000 BA000034 1/1 . en / 11. Note: If the amount of water is large.05. the cause must be traced.

In no case the starting air shut-off valve must be closed during engine operation (A3. see A1.05. Unless these facilities are included in the contractual supply scope of Caterpillar / MaK. These are not dealt with in this section. then a functional scheme and description of the functional scheme applying especially to this particular system will be prepared and coordinated (see book C).11. apart from the basic equipment for the local control of the engine (emergency control) further special fittings and facilities to operate these are provided. manually checked or executed. In order to ensure the functioning. For operating pressure.nn)! • en / 05.05. safety systems and also revolution counters are switched off normally all functions are automatically monitored. Put emergency operating lever into the operation position at the operating stand or at the control linkage. 5 min. Direct start at the generator engine In the scope of this initial operation we are dealing exclusively with the starting procedure on the generator engine.1996 BA000042 1/1 .08. When alarm. Manually start the engine at the starter solenoid or master starting valve. Engine prelubrication: Switch on the engine prelubrication pump or auxilary pump approx.05.02 According to the application of the engine and the degree of automation. prior to start. it is important to know the automation degree of the system. In the event of a direct engine start with electronic governors the stop must be reset parallel to actuating the starting solenoid valve.Initial operation Putting into service/starting M20/M25/M32 A3. • • • Attention: Manual starting of the engine may only occur when the engine is at a total standstill! • Switch off the prelubrication or auxiliary pump (automatically or by hand). Set revolution speed by means of the revolution speed head on the mechanic-electric governor to nominal setting. Starting (operating panel in the gauge board) • • • Switch position selector in the board on “2 = OFF”. Keep the starting attempt as short as possible.18.

18.: 20 °C 5 °C approx. generating sets. Severe working conditions If for example.04 Caterpillar / MaKLoading Precondition: during the warming up of a generator motor The jacket water has been preheated to the temperature (t) given below when running on: Distillate fuel Heavy oil fuel t = 40 °C t >=10 °C below working temperature at the engine outlet or engine inlet. the engine is equipped with automatic starting/stopping or is used as a standby generating set. When working temperature has been reached. proceed as follows: Prime the engine lube oil circuit (if there is no continual prelubrication) and start operation as described under “Normal working conditions”.06. with heavy oil). For routine testing of. at maximum intervals of 1/2 h. en / 01. Extreme loading should be avoided when simulating an emergency. load may be added as described in operating media increasing the load of a warmed-up engine.g. loading of the engine is possible after a correspondingly shorter period. The engine is started at a nominal speed.06. 20 min approx. the water jacket has to be kept at working temperature and the engine lube oil circuit automatically primed for 2 min. 40 min If the engine has been preheated to a higher temperature (e.05.Initial operation Putting into service/loading M20-M601C A3. as this would not provide any additional findings about engine availability in the case of need. See A1. Normal working conditions After preheating to 40 °C (distillate fuel operation) the warming-up time at low load should depend on the ambient temperature e.g. for instance.93 BA000050 1/3 .

The diagram shows guide values for load stages in % engine rating depending on the mean effective piston pressure of rated output. load stage from max. 4rd load stage Load increase referred to rated output (%) 3rd load stage Limit curve for 3rd load stage 2rd load stage Limit curve for 2rd load stage Limit curve for 1rd load stage 1rd load stage Pme of rated output (bar) 1. 3. load stage from max.93 BA000050 2/3 .Initial operation Putting into service/loading M20-M601C A3. 2.06.05.9 bar.18. 4. load stage from max.04 Increasing the load of a warmed-up engine (generator engine) The load can only be increased depending on the continuous power Pme according to the values recommended by DIN 6280 and ISO 3046. load stage from 0 % to 37 % to 61 % to 37 % Pnom 61 % Pnom 83 % Pnom 83 % to 100 % Pnom en / 01. max. on the example of a 6 M20-engine with a full load pme = 21. The graph below shows the possible load stages at which the frequency settling time stipulated by DIN/ISO is possible.

Initial operation Putting into service/loading M20-M601C A3.09. depends on various factors. running gear and engine housing must be reduced according to the duty required and its frequency. en / 01.06. will produce sulphurous acid which will damage the valves and exhaust ducts in conjunction with other corrosive combustion residues. If higher load increases are required than previously recommended.18. then in every instance these must be discussed with Caterpillar / MaK. thermometers and tachometers must be continually watched. particularly in short test runs. such as pressure gauges.05. If there is a bad speed range owing to torsional vibration. The local control station should only be left when the readings have approximately reached a steady-state condition in the desired power range.04 Accelerated load increase Loading within the shortest period possible. this should be passed as rapidly as possible. Running the engine for a short time only. The time between two load increases must never be shorter than the settling time to rated speed (entry into the steady-state band). See the plate on the engine and/or A1.93 BA000050 3/3 . the indicators. The maintenance intervals for cylinder heads. The engine should always reach working temperature after every start. With local control or manual monitoring of the engine.

Operational Supervision Engine - A3.2008 BA000058 1/1 .00 Operational Supervision en / 20.06.02.

06. en / 28.05.00 Operation in the case of low intake air temperatures The engine is only allowed to be operated at max.05. 90 % power if the air intake temperatures are below +10 °C as otherwise the permissible nominal ignition pressure is exceeded. In the case of compressor inlet temperatures below +10 °C.Monitoring Intake air temperature M20-M601C A3. full power is only permissible if the air charge after the compressor is blown off so that the boost pressure does not exceed the values at +20 °C. It can be run at full power if the intake air is pre-warmed or mixed with machine air so that the temperature at the compressor inlet is higher than +10 °C.1998 BA000595 1/1 .

Owing to this measure. The injection pumps also have very narrow tolerances between the pump foot and the control edge of the pump element so that every pump can be used on every cylinder. An adjustment of the filling would result in the cylinders having different performances and torques. there are very small differences in the delivery take-up of the individual cylinders in the scope of manufacturing tolerances for the angular position of the cams and their accidental summation. cylinder-tied.06. firmly mounted plates. The maximum firing pressure is set at the camshaft drive gear which has a hydraulic detachable shrink brace for this pupose.2000 BA000498 1/1 . en / 11.05.Monitoring of operation Exhaust system/Firing pressure M20/M25/M32/M43 A3. the engine does not have this adjustment possibility. As the camshaft is assembled from individual sections per cylinder.01 The engine is designed so that an adjustment of delivery take-up as well as filling of the individual cylinders is no longer necessary.06. all tolerances are eliminated between the base circle of the cam up to the upper edge of the push rod. The individual erection heights of the injection pumps of the individual cylinders are secured by ground. To prevent the existing firing pressure differences from being balanced by adjusting the filling at the injection pump.

Operational supervision Exhaust system/supercharging M20/M25/M32/M552C/M601C A3. The influence of the prevailing air intake conditions on the engine data must be seen and taken into account.2008 BA000658 1/4 .06. Injection pump or nozzle wear. Check the temperature after the cylinders regularly.nn. should not deviate more then ± 30 K from the respective cylinder value given in the acceptance test certificate A1. refer to A3.04. The temperatures after the cylinder.11. the fuel injection of the injection pumps alone is decisive for balancing the cylinder power values.10. Attention: It is not permissible under any circumstances to alter the fuel injection or feed data on the injection pumps to obtain identical temperature readings! This would unbalance the power of the cylinders! Provided the fuel cam setting is correct.g. injection. Any deviations among the cylinders within the scope of the values given in the acceptance test certificate are perfectly normal despite balanced individual cylinder power. combustion). Such as measurement therefore only has a limited informative value which could be misleading. en / 04. injection pump.18. The exhaust temperatures after the cylinders cannot be used for an exact performance assessment of the individual cylinders as the exhaust temperatures measured in the cylinders are influenced to a varying degree by turbulence influences in the exhaust manifold. for instance.02 Exhaust temperatures A comparison of the exhaust temperatures with the values in the acceptance test certificate or the records during testing/sea trials is best suited to assess the thermodynamic performance of the engine and to analyse any deviations from the new condition of the engine (supercharging. exhaust valve). nozzle. will have a direct effect on the thermal engine performance.06. The cause must be determined if there are any deviations (e. however.

10 by more than 30 K.18. Assessment of the exhaust colour: refer to A3. after turb.02. max. If combustion is good. The temperatures after the turbocharger should not exceed the full load value in the acceptance test certificate A1. Total misfiring can cause damage to the flexible coupling! It should be noted that partial misfiring already subjects the flexible coupling to impermissible loads. Note for exhaust temperature monitors: Contrary to the monitor for the average exhaust temperature. after turb. fouled charger etc.2008 BA000658 2/4 . 400 °C ttexh.06. an alarm is only activated when limit values are reached when monitoring the exhaust temperatures of each cylinder (thermal overload of a cylinder or misfiring). Refer to A3.12. then determine the cause of the temperature rise (different ambient conditions. If ∆ t > 30 K.11.04.).Operational supervision Exhaust system/supercharging M20/M25/M32/M552C/M601C A3.10. Reduce the engine power if the maximum permissible temperature after the turbine is exceeded during operation with Heavy fuel Distillate fuel ttexh. en / 04. ∆ttexh. Also refer to A3.06. type of fuel. the exhaust will be invisible or a light grey.nn. 420 °C • Make an additional check of the combustion by assessing the exhaust opacity.nn. max.11. after turb.18. ≈ 30 K • Compare the exhaust temperature after the turbocharger during full load operation with the specification in the acceptance test certificate A1.nn.02 The exhaust temperatures before and after the turbocharger are used to assess the thermodynamic load condition of the engine as they cover the overall thermodynamics of the engine. exhaust turbine and intake condition.

Indication is always necessary if the assessment of the exhaust temperatures shows that there are changes in individual cylinders. Even if irregularities cannot be discerned during the monitoring of the exhaust temperatures. Blow out the indicator valves so that no carbon deposits can get into the indicator.2008 BA000658 3/4 . exhaust temperature after the cylinder.02 Indication of the firing pressure Use the following electronic indicator for gauging the pressure: • Lemag PREMET LS This method is useful to determine changes in the firing pressure of individual cylinders.06.Operational supervision Exhaust system/supercharging M20/M25/M32/M552C/M601C A3. engine number.04. • Indicating Attention: Completely close the indicator valve after the indication process. • • • Operating instructions for the indicator: refer to manual C. fuel injection. This will reduce the cylinder power! en / 04. • Note the following on the diagram: date. cylinder number.06. engine speed. stored with care and the manufacturer's instructions observed. Draw indicator diagrams at full load if possible. charging air pressure. Attention: The screwed connection between the indicator and indicator valve must be gas-tight during assembly! A finger-tight. The measuring device must be. form and force-locking connection must be attained. it is advisable to check the engine at regular intervals by means of indication. Attention: The firing pressure is not allowed to be corrected by changing a correctly adjusted feed start. Loosen the connection when there is no pressure at the indicator. Only perfect measuring instruments will make exact measurement results possible.

04.05.nn.00.Operational supervision Exhaust system/supercharging M20/M25/M32/M552C/M601C A3. refer to the operating instructions for the turbocharger in manual C.06.06.02 Turbocharger: Compressor During operation fine adhesive dust is deposited on the inner air carrying parts of the turbocharger which can significantly reduce the performance of the compressor. check the air charge cooler for leakage. raise the air charge temperature until condensation stops. Refer to Exhaust temperatures after the turbine. • • Daily cleaning of the compressor Periodic washing of the turbocharger during heavy fuel operation: refer to A5. • • Electronic thermostat: Raise the temperature by adjusting the thermostat.05. If the volume of discharged water is not reduced despite the temperature increase.06. Attention: This increases thermal engine stress. en / 04.2008 BA000658 4/4 . Air charge cooler • Check the permanent drain/separators of the air charge manifold Note: Manual correction of the air charge temperature control is only necessary in special cases! If there is water in the air charge manifold. For cleaning the compressor. Thermostat with diaphragm valve: Raise the temperature of the water or reduce the flow in the low temperature cooling circuit by opening an external bypass. • • Observe the maximum permissible exhaust temperatures after the turbine.

nn. en / 12. If the engine is running on heavy fuel.06.06. For operating with heavy oil see diagram in A3. see changing the type of fuel A3.00 Fuel system • • • Drain the water from the day fuel tank and check it at regular intervals. change over to distillate fuel in time. Changing over to distillate fuel may be necessary: after lengthy service at partial load operation.06.18.Operational supervision Fuel system M25/M32 A3. or before scheduled maintenance work on the fuel system.07. (See A3.07.nn. Inspect the fuel treatment plant.1997 BA021416 1/4 .nn). Note: The following fuel diagram is only valid for a permanent operation of the engine with distillate fuel.04.03.07.

Operational supervision Fuel system M25/M32 A3. only empty storage tanks are to be used. 2. 3.1997 .03. It shall lower the content of solids and water to the minimum that can technically be reached.00 Principal diagramatic view of the distillate fuel circulatory system DF1 DF2 DF3 DH1 DH2 DP1 DP2 DP3 DP5 Fuel fine filter (duplex filter) Fuel primary filter (duplex filter) Fuel coarse filter Diesel oil preheater Electrical preheater for diesel oil (separator) Diesel oil feed pump Diesel oil standby feed pump Diesel oil transfer pump (to day tank) Diesel oil transfer pump (separator) DR2 DS1 DT1 DT2 DT4 KP 1 KT1 Fuel pressure regulating valve Diesel oil separator Diesel oil day tank Diesel oil intermediate tank Diesel oil storage tank Fuel injection pump Drip fuel tank 1. Separator DS1 The separator is only switched on. if distillate or mixed fuel is used instead of distillate fuel with 7 cSt/ 40 °C. Day tank DT1 BA021416 2/4 en / 12. This is to avoid segregation or the consequences of any incompatibility that may occur when taking on different types of fuel. Storage tank DT4 When fueling.06.07.

6.Operational supervision Fuel system M25/M32 A3. This avoids the formation of water compensation. 7.07. 4. Fuel fine filter DF1(duplex filter) en / 12.06. • If the preheater is of electrical type. If the treatment plant is in order. Diesel oil feed pump DP1. a condensation trap should be installed at the steam outlet to ensure sufficient heating as possible. it will always be filled to the overflow level. The intermediate tank is equipped with a level monitoring device. Intermediate tank DT2 Note: The intermediate tank DT2 does not apply upon employment of: . that the relief valves of the pumps are closed during operation.00 The day tank is designed to collect the treated fuel for a minimum of 4 h load operation. Diesel oil preheater DH1 Note: The diesel oil preheater DH1 does not apply upon employment of: .distillate fuel with 7 cSt/40 °C o .heated day tank DT1.distillate fuel with 7 cSt/40 °C o . It has to be ensured. 8.1997 BA021416 3/4 . Upon alarm and/or when filling the tank. open the vent valve several times for a short time by hand. Fuel preliminary filter DF2 (duplex filter) The fuel preliminary filter DF2 is very coarse and needs only to be checked or cleaned in cases of work on the fuel system. of 50 °C • If the preheater is of steam type. diesel oil standby feed pump DP2 These pumps are designed as force pumps. The preheater is to lower the fuel viscosity to a level that is optimal for injection. 5. in order to reach a good atomization and fuel-air mixture. ensure that the temperature switch is set to a min.03.heated day tank DT1.

9. For service and maintenance instructions see A5.Operational supervision Fuel system M25/M32 A3.05. en / 12.00 The fine filter protects the fuel injection system and removes solids not previously separated.03.07. Note: When operating on distillate fuel (mixed fuel) and repeated filter alarms occur the separating temperature should be increased. Fuel pressure regulating valve DR2 The valve is to be set so that the pressure at the engine is of that required (see A1. It is important to clean the filter when 50 % of the red area on the differential pressure gauge is visible or when the filter alarm has been activated.01.12.nn.1997 BA021416 4/4 .07.06.05).

The change-over has to be exclusively made by the three-way selector cock for heavy fuel/distillate fuel.07. the circulating pump/final preheater should be switched off 1 h after change-over.05. before the mixing tank. to empty heavy fuel filled system more rapidly. is only permitted when the engine has been shut down! Fuel pressure system (only within heavy oil circle): The fuel pressure may only be set at the pressure regulating valve. If the engine is to continue with distillate fuel operation.06.07. At the earliest. 2.06.07. Changing over from distillate fuel to heavy fuel Prepare the system according to A3. Changing over from heavy fuel to distillate fuel while the engine is running see diagram in A3.Operational supervision Changing the type of fuel M20-M601C A3. en / 27.01 Changing the type of fuel 1. Note: A change-over of the flow towards the heavy fuel day tank (emergency) and flushing with distillate fuel.04. The three-way cock in the return line (from the engine to the heavy fuel day tank and/or to the mixing tank) has to remain in its position so that the excess fuel will be returned.nn. A differe nt procedure may lead to sticking (scuffing) of the injection pump plungers.nn. the system must be changed over in time because the change-over to distillate fuel will only be completed after 1/2 to 1 h.1996 BA000074 1/1 .

05 and A1. Temperature indications see A1. en / 16.00 Lubricating oil system • Check daily the levels in the: • Lube oil sump tank Base frame Oil sump Monitor the lubricating oil pressure.06.10.12.temperature For Pressure-.06 and also Acceptance Test Records page A1.08.Operational supervision Lubricating oil system M20-M601C A3.1997 BA000078 1/1 . .

If for any reason whatsoever temperatures are too high. temperatures and temperature rise.05.10.09. For pressure-temperature indications. Attention: If the cooling is too rapid. it will create thermal stresses and possible damage. For specifications and care of the engine cooling water see Operating Media A4. lower them gradually to the normal values.05 of the operation media.nn en / 17.06 as well as Acceptance Test Records A1.Operational supervision Cooling water system M20-M601C A3.10. Check the water pressure.06. for Temperatures of the Operating Media A1.2007 BA000082 1/1 . see A1.00 Cooling water system • • Check the level in the fresh-water expansion tank.09.

06.2 bar below the minimum cooling water pressure.01 Adjustment Instructions for Cooling Water Pressure (Start of Standby Pump. The alarm chain is as follows: Minimum operating pressure * Start of standby HT freshwater pump Low HT freshwater pressure at engine inlet – Alarm 2102 Low HT freshwater pressure at engine inlet – Emergency stop 2103 2.2 bar.09. outlet temperature of 90 °C.2008 BA021432 1/4 .5 bar 2. The following values are to be adjusted and checked: en / 10. 1. an alarm will be triggered. In the following examples static pressure is also considered. If the cooling water pressure drops by another 0. Example . This static pressure is to be added to the operating pressure.Operational supervision Adjustment Instructions M20/M25/M32/M43 A3. The pressure indicator for HT freshwater on the engine control stand displays the static pressure for HT freshwater.9 bar If the cooling water pressure in the cooling water system is 0.5 bar. the flow rate in the cooling water system is to be adjusted by means of orifice plates. Terminal temperature difference Under full load operation the cooling water will be heated up by 7 to 10 K to a max. If the pressure in the cooling water system continues to drop down to 1. If these temperature values are not reached.04. and Emergency Stop) There must be a minimum cooling water pressure of 2. Alarm.5 bar at the engine in order to safely dissipate from the engine the amount of heat generated under full load operation. The engine should be run at full load for at least half an hour so that the temperature in the entire cooling system can reach a steady state.Controllable pitch propeller plant with two electrical standby pumps The HT freshwater pressure tank is full of cooling water and both electric standby pumps are switched off.9 bar.3 bar 2. an emergency stop will be triggered. Example: Static pressure at engine control stand is (both electric pumps switched off) 1 bar This results in a minimum operating pressure of 3.1 bar 1. a standby pump will be started. *These values do not take into account the static pressure of the gravity tank.

the electric standby pump and the engine are switched off. Example: Static pressure at engine control stand is (electric standby pump switched off) 2 bar This results in an operating pressure of 4.5 bar 3.9 bar Adjustment at nominal speed: The engine is running at nominal speed and the electric standby pump is switched off.3 bar 3. outlet temperature of 90 °C. The pressure indicator for HT freshwater on the engine control stand displays an operating pressure of min. The pressure indicator for HT freshwater on the engine control stand displays the static pressure.09.5 bar.Controllable pitch propeller plant and generator plants with attached and electric cooling water pump The HT freshwater pressure tank is full of cooling water.Operational supervision Adjustment Instructions M20/M25/M32/M43 A3. 2.01 Minimum operating pressure (add static pressure) Start of standby HT freshwater pump Low HT freshwater pressure at engine inlet – Alarm 2102 Low HT freshwater pressure at engine inlet – Emergency stop 2103 3.04. Example .06.9 bar For sensor equipment adjustment and test instructions please refer to the manual.3 bar 3.1 bar 2.1 bar 2.5 bar at nominal speed. The following values are to be adjusted and checked: Minimum operating pressure at 70% (including static pressure) Start of standby HT freshwater pump Low HT freshwater pressure at engine inlet – Alarm 2102 Low HT freshwater pressure at engine inlet – Emergency stop 2103 3.5 bar 3. Under full load operation the cooling water will be heated up by 7 to 10 K to a max. en / 10.2008 BA021432 2/4 . This static pressure is to be added to the operating pressure.5 bar . 4. At nominal speed the attached cooling water pump must generate an operating differential pressure of 2.

3.01 Adjustment at 70 % nominal speed The engine is running at 70 % nominal speed and the electric standby pump is switched off.8 bar en / 10. For sensor equipment adjustment and test instructions please refer to the manual. Example .Operational supervision Adjustment Instructions M20/M25/M32/M43 A3.06.6 bar 1.Fixed pitch propeller plant with attached and electric standby pump The HT freshwater pressure tank is full of cooling water. the electric standby pump and the engine are switched off.0 bar 1. The following values are to be adjusted and checked: Minimimum operating pressure at 70 % (including static pressure) Start of standby HT freshwater pump – Alarm 2101 Low HT freshwater pressure at engine inlet – Alarm 2102 Low HT freshwater pressure at engine inlet – Emergency stop 2103 Low HT freshwater pressure at engine inlet.4 bar 0. speed below 70 % . At 70 % nominal speed the attached cooling water pump must generate an operating differential pressure of 1. Under full load operation the cooling water will be heated up by 7 to 10 K to a max.5 bar. Below 70 % nominal speed the complete cooling water pressure monitoring system is to be switched off.5 bar This results in an operating pressure of 3 bar at nominal speed. This static pressure is to be added to the operating pressure.2008 BA021432 3/4 . The pressure indicator for HT freshwater on the engine control stand displays the static pressure.04.09. 3. Cooling water temperature monitoring must not be disabled.8 bar 1. outlet temperature of 90 °C.5 bar.Alarm 2106 2. The pressure indicator for HT freshwater on the engine control stand displays an operating pressure of min. Example: Static pressure at engine control stand is (electric standby pump switched off) 0. (Note: The electric standby pump shall only intervene in the event of a failure of the attached pump) The cooling water circuit is monitored for cooling water temperature throughout the entire speed range.

Operational supervision
Adjustment Instructions
M20/M25/M32/M43

A3.06.09.01

Adjustment at nominal speed: The engine is running at nominal speed and the electric standby pump is switched off. The pressure indicator for HT freshwater on the engine control stand displays an operating pressure of min. 3.0 bar. At nominal speed the attached cooling water pump must generate an operating differential pressure of 2.5 bar .

Adjustment at 70 % nominal speed The engine is running at 70 % nominal speed and the electric standby pump is switched off. The pressure indicator for HT freshwater on the engine control stand displays an operating pressure of min. 2.0 bar. At 70 % nominal speed the attached cooling water pump must generate an operating differential pressure of 1.5 bar. Below 70 % nominal speed the cooling water pressure monitoring system is to be switched off except for alarm point 2106. (Note: The electric standby pump shall only intervene in the event of a failure of the attached pump). If the engine is operated at speeds below 70 % only alarm point 2106 is active. The cooling water circuit is monitored for cooling water temperature throughout the entire speed range. Cooling water temperature monitoring must not be disabled. For sensor equipment adjustment and test instructions please refer to the manual. Under full load operation the cooling water will be heated up by 7 to 10 K to a max. outlet temperature of 90 °C.

en / 10.04.2008

BA021432

4/4

Operational supervision
Starting system
M25-M601C

A3.06.10.00

Air starting system

• • •

Check the pressure in the air bottles. Drain the water daily from the air bottles, compressed air filter, water traps and fittings. Secure the compressed air supply for the emergency stop facility! In no case the starting air shut-off valve must be closed during engine operation (A3.05.11.nn)!

en / 16.12.1997

BA000086

1/1

Operational supervision
Partial load operation
M20-M601C

A3.06.18.00

Partial load operation with heavy fuel
In order to prevent increased wear and tear, pollution of air and exhaust systems and an increased contamination of the lube oil, the partial load operation has to be carried out with distillate fuel only. The distillate fuel provides for an unlimited partial load operation. The heavy fuel operation is not useful and economic below a rated output of 25 %. If a heavy fuel engine is working in the lower partial load range in pier to pier operation, the combustion can be incomplete. After a lengthy operation at very low load, carbon deposits might be found in the combustion chamber and exhaust gas ducts. If operation is then to be continued in the upper load range, the load must only be increased gradually for a period of up to 15 min., for reasons of safety. If the laod is raised too rapidly, deposits may impair the oil film, damaging the piston and cylinder liner. Restrictions for partial load operation on heavy fuel cannot be avoided for some special ships, such as supply vessels, diver base vessels etc. and for generators, if the low load is run for a lengthy period, because deposits from combustion residues will then greatly increase. The graph below represents the restrictions for such cases. Continuous heavy fuel operation is permitted above 25 % Pe. Below this range, the heavy fuel operating time must be limited according to the load stage, unless the operating conditions permit a continuation at a high load stage.

Cleaning run of engine

Cleaning run after partial load operation

Example:
Load increase period

The engine runs on heavy fuel at Pe = 15 %. After 4 h, changing-over to destillate fuel is required or the engine will continue at a Pe > 70 % if this is possible. The deposits will burn away in approx. 40 min. and it will be possible to run with heavy fuel at low load again.

approx. 15 min.

HFO-operation

Restricted HFO-operation

Pe, versus h graph, for engines with two-stage charge air cooler and HFO-operation. Charge air heated to 60 - 70 °C at partial load. Centrifugal lube oil purifying for 24 hours/day.

en / 11.12.1997

BA000090

1/2

Operational supervision
Partial load operation
M20-M601C

A3.06.18.00

Note: If neither a changing-over to destillate fuel nor to high-load operation is possible, an increased contamination of the lubricating oil is to be expected!

Notes: • The permissible exhaust gas temperature after the turbine (see A3.06.06.nn) must not be exceeded over the entire operating range, including partial load. Differing rules may be applicable at partial load, to protect the entire engine, during for instance, turbocharger failures. See A3.12.00. If a new engine is first operated only occasionally for several hours in a load range < 50 %, as is some times the case when a power station is being erected, operation with destilled fuel is strongly recommended. If an engine with automatic charge air control is changed over from heavy fuel to distillate fuel operation, the setting of the charge air temperature control must not be changed.

en / 11.12.1997

BA000090

2/2

Removal from operation
Engine
-

A3.07.00

Removal from Operation

en / 21.02.2008

BA000094

1/1

Removal from operation
Placing out of service/stopping
M20/M25/M32

A3.07.18.01

The scope of this placement from service deals exlusively with the engine stop procedure on the generator engine.The function of the remote control within the Caterpillar / MaK scope of supply, is described by a functional diagram in the documentation (see book C).

Attention:
Avoid sudden stops under load! Before stopping the engine, run it under low load or let it idle for about 5 minutes! If the engine has to be stopped under load, always cool the engine, see “Cooling”!

Operation directly at the generator engine Engine stop
• • • • Switch position selector in the board to “2 = OFF”. Set revolution speed by means of speed revolution head at the mechanic-electric governor to nmin. Stop the engine by manual operation of the starter magnetic valve. Close the isolating valves on the starting air bottles and fuel day tank.

Engine emergency stop
• • • Place the emergency cut out lever on the console into the stop position or Activate external emergency stop device. Close the isolating valves on the starting air bottles and fuel day tank.

Note:
After actuation of the external emergency stop device, the button “Reset” at the safety system is to be actuated!

Cooling
If the engine has be stopped under load, ensure that it is being cooled for approx. 5 min. to avoid the formation of steam bubbles. • • • If the coolant water pump is independent: If the pumps are engine-driven: Various engines with mutual preheating: electrical pumps should be left in operation. start the standby or preheating pump. operate the valves according to the piping diagram.

If the engine is to be started again after a short interval

en / 25.03.1997

BA000102

1/2

Removal from operation
Placing out of service/stopping
M20/M25/M32

A3.07.18.01

To avoid the accumulation of heat immediately before or after shutting down, start all system circuits and keep the engine at working or preheating temperature according to the duration of the stop and the type of fuel used (see A3.05.18.nn). When the engine is running on heavy fuel, a changeover to destillate fuel (see A3.06.07.nn ) is only required if servicing the fuel injection system is intended or if, as is possible in some cases, the engine will be operated at low load for a lengthy period of time (see A3.06.18.nn). • • • • Cut the preheating equipment in. Start the coolant water circulating pump. If the engine is preheated by other engines in operation, open the isolating valves. In heavy fuel/distillate fuel operation, running of the fuel system must continue, as when operating the engine, to keep it warm: circulating pump, fuel preheating via viscosimeter, back-flushing filter (if provided) are in operation. The fuel separator before the day tank will also continue to operate. Keep the lubricating oil system warm and thus free from condensate and sludge deposits by continuous separator operation. Ventilate the machinery spaces only as required to avoid excessive cooling of the engines.

• •

Before a lengthy period of standstill (e.g. up to 4 weeks), heavy fuel engines are to be changed over to distillate fuel operation (see A3.06.07.nn ). Engine preservation is required if the non-operational period exceeds 4 weeks. Climatic conditions and duration of storage, determine the nature of the measures to be taken (see A3.09.01.nn and/or A3.09.02.nn).

en / 25.03.1997

BA000102

2/2

Danger of Frost
Engine
-

A3.08.00

Danger of Frost

en / 20.02.2008

BA000106

1/1

09.1996 BA000110 1/1 . For a lengthy down-time period with a danger of frost the engine is to be preserved.05. can generally be mixed with commercial antifreeze.00 Antifreeze protection If the engine is repeatetely taken out of service for only short periods (without a device in the system to keep it warm). during times when the temperature can fall under freezing point.01.06. it will be necessary to protect the system by the use of an antifreeze solution with protection against corrosion (see A4.09. must be enquired from the manufacturer of the anti-corrosive agent.09. Attention: The concentration level of the antifreeze solution is to be choosen in such a way that a sufficient degree of protection is ensured! Contrary to anti-corrosion emulsions.08.nn).nn.nn and/ or A3.02. see A3. Exact instructions for the use.01. the chemical corrosion inhibitors used in the coolant water. en / 24.Danger of frost Antifreeze protection M20-M601C A3.

nn) is to be carried out for a shut down of the engine with following storage of up to 2 months in national or Central European areas.00.12. The various climates of the relevant storage locations and/or destinations as well as the intended peroid of storage determines the kind and scope of the measures for a short term preservation or long term preservation.09. Attention: Some components are to be disassembled and consequently reassembled for a preservation! The disassemble and reassemble work is always to be carried out or monitored by by skilled mashine personnel! Short term preservation: A short tern preservation (A3. It is also suitable for a possibly necessary road transport within Central Europe. A long term preservation (A3.09.nn) is to be carried out.09.1997 BA000114 1/2 .00 The durability and effectivity of a preservation is determined by the following components: • • • implemented preservation measures implemented package maximum period of storage Only the careful implementation and tuning of these measures ensures a sufficient protection of the engine and the fittings. but not longer than 1 year and stored within national or Central European areas.02.01. These measures apply as well for a possibly necessary transport on board (under deck) of seagoing ships into similar international areas! Long term preservation: Attention: The measures for preservation for subtropical or tropical areas are to be coordinated with Caterpillar / MaK according to the destination and storage location and the intended period of storage! en / 16.Preservation Engine M20-M601C A3. if the engine is shut down for longer than 2 months.

00.09.09.09.Preservation Engine M20-M601C A3. In Central Europe.nn and/or A3.nn.05.03. Found damages are to be immediately corrected. check tarpaulin and preservation regulary every 4 weeks.nn) are to be carried out according to the implemented measures for a short term preservation or long term preservation prior to commisioning of the engine! en / 16.1997 BA000114 2/2 .12.nn) are to be carried out and the engine and the fittings/tools are to be checked below the tarpaulin every 2 weeks. In case of bad climate conditions. Secure tarpaulin/foil against mechanical damages. If there is a danger of frost. Ensure sufficient ventilation below the covering.02.09. Depreservation: The measures for depreservation (A3.nn and A4. In case of storage in the open the engine is to be carefully protected against atmospheric influences with a water restistent tarpaulin or a plastic foil. sufficient protection must be provided.02.01. the measures of a long term preservation (A3.09.00 Package/Storage: The measures for storage and package depend on period of storage and storage location. see A3. The short term preservation provides sufficient protection when stored and placed in well ventilated machine rooms/halls and when transported on road under European climate conditions. Remove already existing corrosion and renew preservation.08.

g. Monitor the level in the day tank and stop the engine.07. Rust Ban 310) ethylene glycol inhibitor (e. brush preserving oil that can be sprayed and does not dry (e.4 1.1996 BA000118 1/3 .nn.2 1.nn. preservation.01.05.g. Clean fuel duplex filter. Preservation measures engine The preservation measures for the individual engine components are to be carried out according to the following sequence of operations.20 min. The required quantity of fuel “B” (liters) for 15 .g. Operate warmed up with the fuel/corrosion inhibiting oil at 75 % of the nominal revolution speed at a low load. Valvoline Tectyl 506) corrosion-inhibiting oil (e. injection pipe. Required tools.07. Glysantin) slovent-free cleaning and/or washing agent Attention: The engine finish may not be etched by cleaning and/or washing agent! Use only suitable washing agents! Keep to the operation.12.5 1.6 spray gun. sticking and drying preservative (e. see A5. run the engine until the fuel system is empty. Aral Konit SAE 30) a viscous.01. 2. Then firmly seal the connection points with plastic plugs! en / 24.1 Fuel system • • • In case of heavy fuel driven engine.00 Light preservation (short term preservation) 1.06. safety and sanitation instructions of the manufacturer! 2.4.06.1 1. ensuring that the fuel system (piping and equipment) remain full. cleaning and auxiliary means 1.g. see A3.3 1. Note: If the engine is seperated from the plant. switch over to destilled fuel. Mix destilled fuel and corrosion inhibiting oil in a ratio of 1 : 1.Preservation Short term preservation M20-M601C A3. running time depends on the engine type and may be calculated by the following formula: B (liters) = 7 x • • • kW rating 1000 Empty the destilled fuel day tank and fill it with with the mixture of fuel/corrosion inhibiting oil.09. see 1.

roller tappets for valves. see A4.01. Fit and tighten the rocker gear cover. running gear. • Engines with caged exhaust valves: fill the water spaces of the cages with glycol if there is a danger of frost.09.05.2) and reclose. The lubricating oil remains in the circuit if the values required for engine operation are in order (see A4.00 2. charge air manifold • • Spray the parts with preserving oil (see 1.5. Note: The cooling water tracts are protected by the corrosion inhibiter in the cooling water.5 Upper valve rockers • • • • Slacken and remove rocker gear cover.02.08.4 Crancase.1996 BA000118 2/3 . remove lubricating oil. Clean the seating of the rocker gear cover.nn. Then firmly seal each connection with blind flange or stop plug. Open the charge air manifold and spray the interior with preservation oil (see 1.06. cam shaft.04.05.2 Lubricating oil system • Cleaning the lubricating oil duplex filters. Note: If the engine is separated from the plant. until clean oil drips out of the last small end bearing. connecting rods and gears are coated.2).nn).05. see 1. Recommendation: • Pump fresh lubricating oil through the engine circuit. cam shaft. en / 24. 2. see A5. injection pumps.3 Cooling water system • Cool the engine down to 30 °C and drain the cooling water.08. Spray the parts fitted in the cylinder heads with preservation oil (see 1.2) and make sure that all areas of the crankshaft.01. 2.09. 2.Preservation Short term preservation M20-M601C A3.

1996 BA000118 3/3 .01. en / 24.Preservation Short term preservation M20-M601C A3.3).6 External preservation • Clean or wash all unpainted bright parts of the engine.00 2.09. Preservation measures fittings and tools Preservation measures for 6 and 12 months see heavy preservation. Attention: The engine finish may not be etched by cleaning and/or washing agent! Use only suitable washing agents! Keep to the operation. 3. safety and sanitation instructions of the manufacturer! • Dry the cleaned parts and coat them with a drying preservative (see 1.06.

rotate to the engine in nominal direction of rotation to TDC and spray the inlet valves as well with preservation oil (see 1. Close the indicator valves.g.01.5 1. cloth preserving oil that can be sprayed and does not dry (e.g.nn. injection pipe.00 Heavy preservation (long term preservation) 1. Turn the piston of one cylinder in the normal direction of rotation to BDC with opened exhaust valve. Then. Shell ALVANIA 3) governor oil (e. Aral Konit SAE 30) a viscous.10. sticking and drying preservative (e. en / 30. brush.1 1.8 spray gun.g.08.7 1.09. Valvoline Tectyl 506) non-drying corrosion-inhibiting grease (e.2000 BA000122 1/3 .nn) slovent-free cleaning and/or washing agent plastic plugs (e.05.g. Preservation measures engine In case shut down of the engine for longer than 2 months. safety and sanitation instructions of the manufacturer! 2.4 1. Repeat this operation for the other cylinders.2). following work is to be carried out beside the measures stated under A3. 2. cleaning and auxiliary means 1.Preservation Long term preservation M20-M601C A3.g. preservation. Kapsto unisersal protective plugs GPN) Attention: The engine finish may not be etched by cleaning and/or washing agent! Use only suitable washing agents! Keep to the operation.2) through the indicator passage into the combustion chamber by means of spray gun and injection pipe.2 1.3 1.02. Hydrol DO 46) clean turbine or hydraulic oil (A4. Spray preserving oil (see 1.6 1. Required tools.09.1 Combustion chambers and cylinder liners • • • • • • Open indicator valves.

carry out further preservation measures according to instructions of manufacturer.4 Turbocharger • Change oil and fill turbocharger up to max. en / 30.5). Spray in preservation oil (see 1.10.2000 BA000122 2/3 . Slacken the drain plug at the staring valve as well as the banjo plugs of the air feed lines at the starting valves of all cylinders. While spraying. see book C.02. if necessary. 2. Fill governor according to manufacturer document (book C) up to the rim with governor oil (see 1. Note: • Keep to the instructions of the manufacturer. . In case the engine is taken out of the plant: .3 Mechanic-hydraulic governor • • • Change the oil in case of due interval. Refit the banjo plugs. Slacken and take out banjo plug of the starting air distributor. 2. drain plug and flange.2) through the distributor lines. level with clean turbine or hydraulic oil (see 1.4) to the gear wheel behind the governor dial. open the starting valves several times by means of a drift inserted through the air control bores.wrap air filter with PET-foil and lute air-tight. with a batten wall). . Apply non-drying preservating grease (see 1.6).protect foil against shocks (if necessary.Preservation Long term preservation M20-M601C A3.00 2. Preservation oil must emerge at the control apertures. Spray preservation oil (see 1.09.2 Starting system and starting air distributor • • • • • • • Remove the sealing flange from the starting air distributor.seal exhaust flange with cover and seal.2) and refit banjo plug.

8).Preservation Long term preservation M20-M601C A3. all not immersed fittings are to be welded.10. Then seal small parts immersed with thermoplastic.5 External preservation • • Close the crancase ventilation with protective plug so that it is air tight (see 1. Preservation measures fittings and tools • • • Thoroughly clean the small parts. Bigger and complex components may not be immersed! They are to be coated with drying corrosion inhibiting paste (see 1. Seal opening of the box with plastic foil prior to putting on the cover. If necessary. en / 30.2000 BA000122 3/3 . Make sure. grooves and similar parts with self-adhesive aluminium foil. • • Note: The above mentioned package is sufficient for a transport on sea (below deck) and a storage period of up to 6 months! In case of longer storage (up to 1 year).3) at the bright parts and packed in oil paper! Store fittings and tools in wooden box lined with bituminous felt. all part are secured within the box. Attention: The engine finish may not be etched by cleaning and/or washing agent! Use only suitable washing agents! Keep to the operation. safety and sanitation instructions of the manufacturer! • • Dry the cleaned parts and coat them with a drying preservative (see 1.3).02. cover threads. bores. 3.09. When this has dried.00 2. Clean or wash all unpainted bright parts of the engine. apply a second coat of drying preservative for securing a sufficient thickness.

Depreservation measures The following measures are to be implemented after a light or heavy preservation.4 Cooling water system • • Check the condition of the cooling water system and flush with fresh water if necessary.02.00 Depreservation 1. If chemical corrosion inhibitors are to be used and corrosion inhibiting oil has been previously used.08.2 Clean turbine or hydraulic oil (A4. Restart the engine with this possibly in the system remaining mixture.08. • 2.nn) Solvent-free washing and/or cleaning agent Attention: The engine finish may not be etched by the cleaning and/or washing agent! Use only correspondingly suitable washing agents! Keep to operation. safety and sanitation instructions of the manufacturer! 2.3 Lubricating oil system • • No depreservation measures are required. If the lubricating oil was drained.1 General work • Establish the condition the engine was in before the preservation and disassembly measures were taken: remove the protective plugs.Preservation Depreservation M20-M601C A3. 2. covers.05.1997 BA000416 1/2 . the entire system must be flushed with an alkaline solution.03.1 1. refill with the specified grade. blanking flanges or other sealant parts and any locking devices.05. 2. see A4. Required cleaning and auxiliary means 1.09.nn.09.2 Fuel system • • Depreservation is not required.05. Reconnect the engine to the plant if it has been necessary to seperate it. en / 15. even if the piping is still filled with the mixture used for the preservation run. see A4. 2.12.

5 Governor (mechanical-hydraulic regulator) • • Re-establish the correct oil level in the governor. Drain protective oil. 2.6 Turbocharger (with independent lubrication) • • • If necessary. 2. Assemble new bearings and fill up oil.1997 BA000416 2/2 . safety and sanitation instructions of the manufacturer! en / 15. if necessary.03. clean the preserved parts according to instructions of the manufacturer. wash.12.Preservation Depreservation M20-M601C A3.09. Dial governors: remove any excess preserving grease from the gear wheels behind the governor dial. Attention: The engine finish may not be etched by the cleaning and/or washing agent! Use only correspondingly suitable washing agents! Keep to operation.7 External depreservation • Remove corrosion inhibiting coating completely from all coated. bright engine parts.00 2.

10.Running-in Engine - A3.00 Running-in en / 16.02.2001 BA000242 1/1 .

10. piston rings (A5. thus no further running in instructions are required.01.01.03. such as reconditioning work on pistons (A5. the fuel should be of the distillate variety because of the higher production of combustion residues at part load (A3.02. M 601. as is pointed out on the job card in question. en / 26.01. In the case of certain repairs however.00 Running-in All engines leaving our works have been fully run in.04.03.nn).2001 BA000126 1/1 . M 601 C M 43 6h 8h 8 . the following instructions must be observed: • When the engine has been preheated.10 to assess the engine working conditions.10.18.nn).06.nn). M 332 C M 25.nn) and cylinder liners (A5. start at 20 % rated power and then go to full power within the time provided for each type of engine: M 20.Running-in Engine M20-M601C A3. M 32.02.02.07.05. compare the pressures and temperatures with the figures on the exceptance test records A1. M 282.05.10 h 10 h If a heavy fuel engine is to be run in again and is operating between 20 % and 50 % of the rated power. No running-in instructions need to be followed when repairs have been carried out on the main and big end bearings. While increasing the power.05. M 453 C M 552 C.

00 Fault Tracing en / 20.2008 BA000130 1/1 .02.11.Fault Tracing Engine - A3.

Attention: In case of discernible faults stop the motor timely to avoid the risk of greater damages. If there is a failure in the measuring instruments or monitors.nn. If a defective engine cannot be quickly repaired.02.1996 BA000134 1/1 .06.nn and/or A3.01.00 Fault tracing In the event of any irregularity in the machinery the characteristic of the trouble should be ascertained.09.18. Any essential fault deviations will be signalled by the alarm and safety system. en / 24. In the event of trouble in the remote control or certain components such as governor. They have to be repaired as soon as possible. This is especially so if an alarm or safety device is concerned. that cannot be repaired immediately. if such a degree of automation has been provided. see the respective sections in book C. it has to be preserved as in section A3.. depending on the foreseeable date of reconditioning. Minor troubles. whose cause is not obvious or whose influence on operation seems to be less important for the present. run the engine with particular care. will be the determining factor as to whether the power or speed have to be reduced for the duration it lasts. the fault traced and the cause found.11. The nature of the trouble.Fault tracing Introduction M20-M601C A3. Remedial actions must be initiated immediately. turbocharger etc.09. must never be ignored.

an automatic engine stop will be triggered! An increased oil mist concentration in the crankcase may be indicative of operational disturbances. This may lead to severe personal injuries and engine damages.03.2006 BA021345 1/3 . timing gear train damages. fixed value first an alarm and then. If. contact the Caterpillar/ MaK-Customer Service! Checks after an engine stop due to oil mist alarm: 1. the cause of it must be identified as quickly as possible. in case of a further increase in concentration.01 Introduction: The crankcase monitoring device (oil mist detector) monitors the oil mist concentration in the crankcase.01. wait 10 to 15 minutes before opening the crankcase doors in order to prevent a possible explosion by air supply from outside.05.11.Fault tracing Oil mist detector M25-M601C A3. If there should be any traces of water. the actual oil mist concentration exceeds a preset. Water vapour may trigger a false alarm.18. with bearing damages. nn).02. Note: Besides carrying out a normal functional check of the oil mist detector the measuring chamber should be examined for traces of water.11. Check of the oil mist detector: Check the oil mist detector for correct function according to the documentation of the manufacturer (siehe C5. When an alarm is triggered.02. In case of doubt stop the engine immediately by hand. Attention: Do not restart an engine that has run hot without first eliminating the cause of the alarm! After standstill of an engine that has run hot. however. Attention: With increased oil mist concentration there is a risk of crankcase explosion. If necessary. en / 21. During engine operation there is always a slight oil mist concentration. piston seizure or blowby from the combustion chamber being the most frequent causes. the measuring chamber and the sensors must be cleaned.

2006 BA021345 2/3 .01. 5.11. piston skirts. Measure all bearing temperatures. etc.) for discoloration and traces of seizing. Inspection of the combustion chamber: • Admit compressed air to each cylinder via opened indicator valves. Check the oil pan for chips. Inspection of the camshaft casing: • • • Remove all camshaft casing covers. the cause of this must be identified.02. cam followers and rollers of all valve and injection pump drives for discoloration. pay particular attention to major differences. and chips. Measure the temperatures of all camshaft bearings. Check of the main running gear: • • • • • • Remove all crankcase doors.18. wear (seizing).01 Extended checks: 2. en / 21. Visually inspect the timing gear train for discoloration. If the pressure drops very quickly or no pressure builds up. Visually inspect camshaft. Visually inspect the main running gear (bearings. Check the main running gear for ease of movement by turning the crankshaft. liners. traces of seizing. Check of the timing gear train: • • • Remove all inspection doors from both sides. Visually inspect the drives of all attached pumps. and chips. 4.Fault tracing Oil mist detector M25-M601C A3. Check the lubrication oil filters for metallic material. 3.

en / 21.01 6. However. Check the operating parameters. check the indicator valves for emerging oil. Prior to starting the engine is to be turned and blown through with open indicator valves for a sufficient period of time by means of starting air! While doing so. Contact the Caterpillar / MaK Customer Service! Note: The indicated checks are intended to assist in troubleshooting and will allow to identify the main causes of an oil mist alarm. The engine may then only be started with fully functional oil mist detector.2006 BA021345 3/3 .18.02. • • • Remove intake air filter.11.Fault tracing Oil mist detector M25-M601C A3. Check of the turbocharger: Note: An incipient turbine bearing damage will also be indicated via the oil mist detector. they cannot cover the full range of all possible causes. Attention: Only after having completed all the above checks and if no failure causes have been identified the engine may be restarted. the root cause must absolutely be found out. Check the turbine shaft for ease of movement.01. If an emergency stop should occur again after a short time. fuel or water. The engine must not be restarted until the disturbance or damage has been eliminated.

07. see A5.2007 BA000727 1/4 .01.05. fuel feed pressure is set too high Lack of fuel • Day tank is empty • Inadequate venting of the fuel system • Isolating valves are not in operating position • Fuel filters are clogged • Fuel feed pump is defective Vent the system.18.11.nn ____________________________________________________________________________________ en / 10.05.nn Repair or replace pump.01. see A3.07.07.13.05 for required bottle pressure • • • Air pressure in the starting air bottle is too low Solenoid valve to the air starter is defective Air starter is defective ____________________________________________________________________________________ Engine reaches ignition speed but does not fire Possible cause: Governor does not admit fuel • Stop cylinders are jammed and do not admit fuel • Governor oil pressure is too low Remedy: see manufacturer’s instructions in book C: siehe Governor failures Linkage between governor and injection pump control shaft is defective see manufacturer’s instructions in book C: Governor failures • • • Faulty connection between governor terminal shaft and injection pump control shaft Elastic element in the linkage of the injection pump control shaft Injection pump control shaft cannot move freely Control shaft is jamming.nn Lube oil pressure switch is defective or misadjusted so that the solenoid valve switches off after the starting attempt • Engine is too cold Warm up engine.05.02 Engine starts poorly or does not start at all Possible cause: Remedy: See A1. see A5.12.05.18.nn • Clean filters.12.Fault tracing Remedial measures M20-M601C A3. see A3.

01.05.01.02.13. see A5.11.12. A5.02 Filter differential pressure is too high during starting/pre-lubrication Possible cause: Remedy: Fuel filter is dirty Clean filter.18.03.05. see A5.07.05.06. see A5.07.nn • TTurbocharger is damaged For repair see manufacturer’s instructions in book C • Turbocharger is fouled For cleaning the compressor end see manufacturer’s instructions in book C ____________________________________________________________________________________ en / 10. see A5.nn.nn For servicing the injection pump.05.04.nn Quantity of combustion air is insufficient • • • Air intake filter is clogged Air intake ducting is obstructed Charge air cooler is fouled see manufacturer’s instructions in book C: Cleaning For cleaning the charge air cooler see A5.05.01.nn Differential pressure gauge is defective Oil is too cold Water in the oil causes greasy emulsion and oil thickening • Oil cooler is leaky ____________________________________________________________________________________ • • • • Engine does not reach full speed and/or full power Possible cause: Governor failure Remedy: see manufacturer’s instructions in book C: Governor failures Filter of fuel limiter (depending on charge air pressure) is clogged Fuel system is defective • • • • • • • Air in the fuel system Water in the fuel Fuel feed pump is defective Fuel filter is clogged Pressure valve of injection pump is defective Pump plunger is seized Nozzle is clogged.01.01.nn Clean filter.12.2007 BA000727 2/4 .Fault tracing Remedial measures M20-M601C A3.07.05.08.12.07.07. nozzle needle is seized Repair or replace pump.

01. is leaky or the spring is broken Vibration damper is defective Rough drive owing to wear and tear or damaged teeth Governor failure Check the vibration damper Opaque exhaust gas .07. da freier Exhaust gas back pressure is too high because the exhaust ducting is clogged • Valves are leaky Remedy: • • • • • • Reduce fuel filling For servicing the valves see.01.05.08.2007 BA000727 3/4 . especially at heavy fuel operation ____________________________________________________________________________________ en / 10.engine is emitting soot Possible cause: Pressure of injection valve is too low Nozzles are fouled by carbon deposits Nozzle needle is jammed or nozzle is defective Combustion air supply is insufficient Air intake filter is clogged Charge air cooler is fouled Turbocharger is damaged Turbocharger is fouled Engine is retarded too far Abgasgegendruck zu hoch.11.nn For increasing the load or change over to gas oil operation see A3.Fault tracing Remedial measures M20-M601C A3.18.12.nn • Poor combustion due to very low load. Governor failures ____________________________________________________________________________________ Too much clearance in the linkage between governor and injection pump Fuel line is sluggish Friction in the injection pumps caused by excessive fuel feed pressure Injection pump plunger is temporarily caught. A5.02 Engine speed is not steady Possible cause: Remedy: • • • • • • • see manufacturer’s instructions in book C.06.

03.01.nn • Cylinder head is cracked ____________________________________________________________________________________ en / 10.11.05.02 Exhaust gases are blue Possible cause: Oil in the combustion chamber Remedy: • • Piston rings are sticking For servicing the pistons and rings see.03.06.nn see A3.nn „Charge air cooler“ For replacement of cooled valve seat inserts see A5.Fault tracing Remedial measures M20-M601C A3.01.18.03.01.05.07.18.01.nn ____________________________________________________________________________________ Valve guide and/or seal are worn Exhaust gases are white Possible cause: Remedy: • • • • • Exhaust gas condensation due to low ambient temperatures Part of the fuel is unburnt because the engine is too cold Water in the fuel Water in the charge air manifold Leakages in the cylinder head For engine warm-up see A3. A5. ovality • For checking the valve guide clearance see A5.02.nn Severe wear and tear of cylinder liner: scoring.06.05.08.05.nn For checking the cylinder liners see A5.05.05.12.2007 BA000727 4/4 .01.

12.00 Emergency Operation en / 20.Emergency Operation Engine - A3.2008 BA000142 1/1 .02.

5 bar at nominal power • • • Stop the engine Remove the air filter silencer Shut down the turbocharger (block the rotor. disconnect all consumption as far as is possible.01 Emergency operation of the generator engine Plant service permitting.unscrew the connection of the pipe at the engine and close the connector with a plug an union nut. en / 26.obturate the exhaust gas side against bearing housing and air side by means of a blind flange. Finishing with emergency operation After an emergency operation with heavy fuel. If an engine shut-down is not possible. = abt. If the installation is for heavy fuel. ^ Note: If blocking is not possible: . especially if exhaustgas alarms have been cut out.Close the air outlet casing of the turbocharger taken out of service with a blanking cover. 500 °C Carefully monitor the exhaust gas temperatures during emergency operation. Note: The cooling water supply is to be interrupted only in case there is a considerable leakage at the turbine housing on gas side.11. • Interrupt the oil supply to the turbocharger.01. we recommend the change to distillate fuel in emergency operation.disassemble the rotor. . Special tools are not included in the scope of supply). Note: • Start the engine and reduce the output. at least one cylinder head must be removed for reasons of safety and to ascertain whether a general overhaul of the valves is necessary. the set with a defective turbocharger should be shut down and separated from the mains. which would endanger the engine. see manufacturer´s instructions book C. If there are two turbochargers feeding into one charge air manifold: .12.Plug and fasten the free end of the pipe. . Monitoring the engine while the turbocharger is defective Change the fuel rack position gradually until the exhaust gas temperature after the turbine is a max.1997 BA000737 1/1 .Emergency operation With a defective turbocharger M25/M32 A3. so that the motor can operate with a Pme ≤ 4. 25 %. for this: .

09. For this reason. en / 24. Stop the engine not later than 30 min.protection of the flexible coupling The following instructions and restrictions refer only to engines with flexible couplings. this will always increase the stresses in the flexible coupling.1996 BA000154 1/2 . If misfiring operation cannot be avoided. Attention: If one cylinder fails partially or completely. and touch the coupling with your hand to check it for heating. A cylinder head.02. contact the manufacturer or make the following provisional arrangement: Single-engine installations with fixed or CP propeller • • • First run the engine at only 50 % of the rated output by reducing the propeller pitch or speed.06. No changes reducing the output to any one cylinder on the engine should therefore be made.Emergency operation Operational misfire M20-M601C A3. If the gear becomes noisy and/or the speed hunts. the smaller that the output of a defective cylinder is. valve or piston and connecting rod should only be removed if unavoidable. vary the speed until the operation is acceptable.00 Operational misfire . it may be necessary to limit the power output of the whole plant in conformity with its type. compression should remain. Notes will be given to this effect on the engine control console or in the torsional vibration calculation. For results of this calculation. see A1. if one cylinder completely misfires. If you have any doubt.12. The additional loads will be the heavier.

80 % of the rated power. occasionally check the flexible coupling visually and its temperature.12. en / 24.00 The permissible surface temperature in misfiring operation is approx.06. Twin engine installations: Shut the defective engine down and run the plant with the other engine alone.Emergency operation Operational misfire M20-M601C A3.02. If this is impossible. If heating is only moderate. The defect should be repaired immediately. 60 °C. the emergency operating mode can be started analoguously with single-engine installations with fixed CP propeller. • • At this speed stage.1996 BA000154 2/2 . Before returning to normal operation again. the power output can be increased in steps up to max. which should not be exceeded for thermal reasons. the flexible coupling should be checked for damage by a specialist of the maker. Defective engines of generating sets should also be shut down.

i.12. • • • • Required output and speed restrictions are indicated in the torsional vibration calculation (A1. it is recommended to check a flexible coupling for excessive heating. Attention: Therefore we strongly recommend not to carry out any adjustments at the engine which might result in an output reduction of individual cylinders! In any case. This will cause additional loads which are the higher the more the march of the gas pressure of a defective cylinder deviates from the remaining cylinders. Connect the drain pipe to the indicator valve with the means available on board so that there is no risk of accident. The compression pressure of the troubled cylinder. cannot be repaired by means of onboard tools.02. „operational misfire“ means that the engine is operated with non-uniformly loaded cylinders. This will prevent the oil taken in during longer emergency operation through piston clearance / ring package from lifting the cylinder head.2006 BA000753 1/2 .10.09). is applied. Even if there are not restrictions regarding the position of the torsional vibration. troubles detected at individual cylinders should be remedied immediately! In case the operational misfire cannot be avoided.01 Operational misfire In general. At engine operation the following has to be observed: Attention: Operation with closed valves is only permissible if the indicator valve is opened every hour for one minute at lowest engine speed and output. en / 26. It has to be avoided that with permanently existing engine load variations a „surging“ of the turbocharger occurs in any operating point. Misfire Misfire means engine operation with interrupted injection at any cylinder. In case of an excessive vibration of the control rack you should relocate the operating point in order to reduce the vibrations.Emergency operation Operational misfire M20/M25/M32/M43 A3. depending on the severity of the troubles: 1. we differentiate between the following extreme conditions.e. however.

the engine has to be fixed in accordance with the instructions A5.02.2006 BA000753 2/2 .10. 35 % of the rated output.12. The engine output possible under these conditions is approx.12.00. 2. Output and/or speed have to be changed in case transmission noises and/or high speed variations occur The temperature at the surface of the coupling must not exceed 60 °C.05. en / 26. The exhaust gas temperatures upstream turbocharger must not exceed the temperatures indicated in A1. In case of doubt please contact Caterpillar / MaK . This limit value applies to engines arranged rigidly as well as flexible. Total misfire In case the engine is supported by flexible bearings and a running gear has to be dismounted completely. The possible outputs and speeds at which a damaged engine can be operated.nn. and the actual values must not fall below the limit values: • • • • • • The engine speed must not exceed 80% of the rated speed (A1.Emergency operation Operational misfire M20/M25/M32/M43 A3.02. During emergency operation. The following limit values have to be strictly observed.1 Twin engine systems / generator systems The damaged engine should not be restarted. the anchor bolts of the fixing device of a flexible bearing support are to be checked permanently for tight fit. depend on the system in question and have to be made out by touching while speed and output are slowly increased.10).01 2.10. „Surging“ of the turbocharger has to be avoided.

Operating Media - A4 Operating Media en / 24.2008 AA020105 1/1 .04.

05.01 Operating Media Table of Contents Introduction Safety instructions Regulations and Recommendations Engine Regulations and care Engine fuel Regulations and care Heavy fuels Regulations and care CCAI-limit curves Regulations and care Limit specification Regulations and care Heavy fuel specification Regulations and care Viscosity temperature sheet Regulations and care Lubricating Oil Regulations and care Cooling Water Regulations and care Treatment of cooling water Regulations and care Changing the cooling water Regulations and careÿ Diagram I Regulations and care Diagram II + III A4 A4.01 A4.Table of Contents - A4.05.05.00 A4.04.04 A4.00 A4.08.05.02 A4.00 A4.05.07.09.09.05.05.09.2008 AA020032 1/1 .05 A4.02 A4.05.07.04 en / 24.01 A4.03.03 A4.07.02 A4.05.05.07.07.07.09.00 A4.03 A4.06 A4.05.05.05.01 A4.09.

Introduction M20-M601C A4.02. For that. • Scope These operating media instructions are valid for Caterpillar-engines according to the delivery program. the following notes and instructions must be observed. • Product Selection For not listed products exist not experience at Caterpillar. en / 12. • Warranty When unsuitable operating media are used or are maintained insufficiently. no warranty for trouble free operation can be guaranteed.2008 AA000056 1/1 .02 The use of suitable and unobjectionable operating media is an assumption for working readiness and reliability of surface of the engine system.

antifreeze • d et erg ent/solven t • coo lan t ( CO 2 .1996 AA000347 1/1 . N 2 ) the safety instructions/safety specification sheets of the product manufacturer are to be observed! California / USA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer.Safety instructions M20-M601C A4.02. birth defects. en / 13. g rease • fu el (d istillate.03 Safety instructions • • • • No open fire during work at the fuel system! No smoking! Lube oil and fuel vapours may ignite on contact with ignition sources! Caution! Burning and scalding hazard when handling hot process materials! During all work or contact with: • lub e oil. hyd rau lic flu id . and other reproductive harm. h eavy oil) • wat er with ant icorro sive.

Regulations and Recommendations Engine - A4.02.2008 BA000158 1/1 .05.00 Regulations and Recommendations en / 20.

05. these are: • Destillate fuel • Heavy oil en / 28.00 For the Caterpillar / MaK-engines used in shore-based and ship-based operation according to their equipment condition two product groups of fuels are allowed.06.07.1996 BA000162 1/1 .Regulations and care Engine fuel M20-M601C A4.

2008 BA000170 1/5 .05). the following designations are still used a lot at the present: Bunker Fuel Oil Marine Fuel Oil Bunker C Fuel Intermediate Fuel Light Fuel Oil Thin Fuel Oil Various organizations. such as: BSI CIMAC ISO – – – British Standards Institution Conseil International des Machines à Combustion International Organisation for Standardisation (BFO) (MFO) (IF) (LFO) (TFO) are busy to find internationally applicable limit value specifications for marine fuels. en / 18. alcali) if not explicitely noted in the specification.Regulations and care Heavy fuels M20-M601C A4. viscosity at 50 °C (mm2/s) (see A4.05. ISO-Specification (ISO 8217) The ISO-Specification for Marine Fuels was issued in April 1987. The fuel must not contain other substances (e. IF 30 with satisfactory data) (before. at 50 °C for ISO) All fuels are called heavy fuels that consits in the main of residual oils from oil refining.05. e. The classes difer from ISO-F-RM1) A2) 303) up to ISO-F-RM K 700 1) 2) 3) (before.07. g. and because of their activities new designations will be introduced to describe fuel properties. e. especially for heavy fuel oils. A classification according to quality characteristics and viscosities was introduced. Minor quantities of additives to improve special fuel properties are permitted. g IF 700 with in case using the maximum limit values) RM = Residual Marine Quality classification Max. Depending on whether it is the highest available viscosity or a mixture with distillates to obtain the required viscosity.07.01. g.02 Heavy fuels (Viscosity in mm2/s (cSt) at 100 °C for CIMAC. mineral acids. General Requirements: The fuel must represent a homogenous mixture of hydro-carbon coming from the mineral oil processing. A revised edition was published in 2005.

In accordance with ISO. BSI-Specification The BS MA 100 which came into force in 1982 was with drawn in September 1989. The CIMAC-specification is the basis for the Caterpillar / MaK heavy fuel specification (A4.D15 classes.07. Introduction of minimum viscosity with CIMAC.05. Since then the contents of BS MA 100 conforms with ISO 8217. which are decisive for a reliable engine operation.01.02 CIMAC-Specifications On the basis of the ISO-Specification. The Caterpillar / MaK Heavy Fuel Specification indicates the equivalents of the CIMA-Specification and the ISOSpecifications.2008 BA000170 2/5 . The most important differences are as follows: – – CIMAC provides fewer density limits for the A10 . e. g. the CIMAC Working Group “Future Fuels” has divided the fuels according to their physical and chemical data. The most important change is the limitation of: Density Carbon residue Vanadium Aluminium + Silicium Pour Point Sediments (separability) (Conradson)(combustibility) (hot corrosion) (scuffing by catfines) (pumpability) (stability) A classification limit about the ignition quality could not be specified up to now in default of suitable test methods. ISO refers Viscosity to 50 °C.05). CIMAC-A10 corresponds to ISO-F-RMA 30.07. CIMAC to 100 °C The CIMAC-Specification does not fully agree with the ISO-Specifications.Regulations and care Heavy fuels M20-M601C A4.05. identical character/figure combinations are used for the identification of quality. en / 18.

03.07. the type of engine and the condition of the fittings and included in A4.05 shows the conversion to 50 °C.07. Ignition characteristics are predominantly acceptable. the following applies: When taking a specific CCAI value as a basis.2008 BA000170 3/5 . there is more risk of a poorer ignition behaviour if the viscosity is low. not be excluded.05. according to the valid CCAI limit curves (A4. (CCI = calculated Carbon aromaticity index). The Caterpillar / MaK assessments make allowances for these factors: A lower as well as an upper CCAI limit curve is defined depending on the viscosity.07.Regulations and care Heavy fuels M20-M601C A4.03. 80 °C and Redw. The three sub-ranges which develop in this manner mean the following: Unrestricted permissible range. Problematic fuels can. depending on its viscosity.07. The CCAI is determined from density D (kg/m3 t 15 degrees C) and viscosity V (mm2/s or cSt at 50 degrees C) according to the following equation: CCAI = D – 141 log log (V + 0.05. Impairments by insufficient ignition characteristics are not expected. en / 18. absolute limit values cannot be specified. Furthermore.05. Range which should be avoided.03. In so doing. Impairments and even damage to the engine can be expected.07. Since the CCAI is no measurement for the ignition behaviour. you should ensure that restrictions with regard to the permissible densities are possible.01). A4.85) – 81 In principle.02 The so-called CCAI is a useful indicator when assessing the ignition behaviour. the poorer the expected ignition behaviour.05.07. however. the following applies: the higher the CCI. The diagrams permit the determination of the permissible and/or maximum acceptable density of a fuel in a simple manner. The heavy fuel grades permitted for Caterpillar / MaK engines can be found in the table “Permissible limits for heavy fuels to be burnt in Caterpillar / MaK engines” (A4.03.00 an A4. I sec. 100 °C is to be the reference temperature for indicating the viscosity of a heavy fuel.01. but rather an assessment aid.00 or A4.05.07.05.05.04).01.

we recommend to contact Caterpillar / MaK first.05. Note In the residues from catalyst cracking there can be catfines which lead to extensive engine wear if they are not separated out very carefully. for instance.08. It is therefore preferable to bunker ready mixed fuels.07.Regulations and care Heavy fuels M20-M601C A4. It will frequently happen in the near future that the limits of the Caterpillar / MaK heavy fuel specification are reached owing to a general change on the fuel market. So preference should be given to heavy fuel with a low ash content.A weight ratio of 1:3 to 1:4 Sodium to Vanadium must be avoided. The technical development in handling of crudes has led to a noticeable increase in the proportion of fuels from new refining processes (catalyst cracking.2008 BA000170 4/5 . the exhaust valve seat rings have no cooling or the pistons are of the monobloc aluminium type.2 % weight). If there are mixing facilities on board ship the compatibility of the components must be assured by the supplier.00). There may be restrictions.01. visbreaking) with which mixing presents more of a problem than with the established heavy fuels. A separate filling of the two components into the ship bunker as well as the use of mixed components that are incompatible can cause a great deal of trouble. Mixing of fuel components to obtain the desired viscosity should be done in suitable mixing appliances before bunkering. The flash point of the heavy fuel must be above 60 °C in accordance with the requirements of the classification societies.05. Fuels to CIMAC-A10 are to be used in such cases.02 Notes to the specification of the permissible limits: The equipment of the engine and the fuel treatment system are decisive for the determination of the permissible heavy fuel grade. If it is intended to take such fuels for a lengthy period of time and the owners have no experience with this. The ash content determines the mechanical wear. specially at high content of Vanadium to stop excessive high temperature corrosion. Heavy fuel operation makes necessary the use of a medium alkaline lubricating oil in accordance with our recommendation of lubricating oil brands (A4. en / 18. and this must be taken into account when fuelling in the Caribbean area. Analyses can be carried out by Caterpillar / MaK against payment of costs incurred or by the fuel supplier. The sodium and water content should be kept as low as possible after the separator (water less than 0. Caterpillar / MaK should be contacted if necessary. if the engine has no cylinder lubrication. A high vanadium content accelerates corrosion on the exhaust valves and turbines. In any case a sample of the heavy fuel should be taken while bunkering.

2008 BA000170 5/5 . Caterpillar / MaK does not require additives against high-temperature corrosion. it must at least be ensured that they are not sensitive to water.07.Regulations and care Heavy fuels M20-M601C A4. en / 18. Should they be used. for instance. classified here according to their main effects.01.02 Fuel additives Two types of fuel additives. compatible with the fuel in any case and no cause of troubles. b) Additives against high-termperature corrosion High-temperature corrosion can occur on exhaust valves and turbine blades when burning heavy fuel containing vanadium and sodium. however. in the fuel filters. can prevent sludge-like agglomerations and break up stable water-heavy fuel emulsions in heated settling tanks which could not be separated in a simple separating process (mixing proportions 1 : 3000 to 1 : 6000). are used in various cases as required: a) Demulsifying additives (emulsion breakers) These additives. put in during bunkering. Proven additives can be obtained from most oil or additive suppliers.05.

05.03.Regulations and care CCAI-limit curves M20-M601C A4.1998 BA000178 1/1 .01 CCAI-limit curves Density (kg/l 15 °C) to be avoided * limited approved * permissible Viscosity (cSt 50 °C) en / 28.05.07.

Regulations and care Limit specification M20/M25/M32/M43 A4.07.nn)! en / 27.07.1999 BA000424 1/1 .05.07.03.04 Admissible limit specification for the operation with heavy fuel in Caterpillar/MaK engines Engine series Limit specification CIMAC A10 CIMAC B10 CIMAC C10 CIMAC D15 CIMAC E25 CIMAC F25 CIMAC G35 CIMAC H35 CIMAC K35 CIMAC H45 CIMAC K45 CIMAC H55 CIMAC K55 X admissible M 20 M25 M32 M43 X X X X X X X X (X) X (X) X (X) X X X X X X X X (X) X (X) X (X) X X X X X X X X (X) X (X) X (X) (X) X X X X X X X X (X) X (X) X (X) admissible in connection with? suitable treatment system only (increased density limit) Caution: Observe CCAI limit curves (A4.05.

after ageing Totaler Sedimentanfall nach Alterung % (m/m) max Water Wasser % (V/V) max Sulphur Schwefel % (m/m) max Vanadium mg/kg max Aluminium + Silicon mg/kg max Zink Phosphor Calcium mg/kg mg/kg mg/kg max.10 0.5 4.10 0.5 0.5 150 80 15 15 30 15 15 30 80 80 15 15 30 300 350 200 500 4. I sec.15 7) 0.5 300 80 15 15 30 0. Visk. 100 °F is given below: Kinematic viscosity at Kinematic viscosity at Kinematic viscosity at 100 °C 50 °C 100 °F mm2/s (cSt) mm2/s (cSt) Redw.05.10 0. max.15 0.10 0.10 0.10 0.5 4.20 Related to ISO8217 (05):F– Characteristic Dim.5 4.2006 950 2) 6 5) 10 15 5) 15 25 35 45 975 3) 980 4) 991 991 1010 991 1010 991 55 1010 60 0 6 24 30 30 30 30 30 60 60 60 60 60 12 6) 0. I sec. Viskositäten bei 50 °C sowie in Redw.5 600 80 15 15 30 der Kraftstoff soll frei von gebrauchtem Schmieröl sein (ulo) Eine ungefähre Zuordnung der kin.CIMAC – REQUIREMENTS for RESIDUAL FUELS for diesel engines (as delivered) – ANFORDERUNGEN an RÜCKSTANDS-KRAFTSTOFF für Dieselmotoren (wie geliefert) M20-M601C Designation: Bezeichnung: RMA30 RMB30 RMC30 RMD80 RME180 RMF180 RMG380 RMH380 RMK380 RMH 500 RMK500 RMH700 RMK700 CIMAC A 10 CIMAC B 10 CIMAC C 10 CIMAC D 15 CIMAC E 25 CIMAC F 25 CIMAC G 35 CIMAC H 35 CIMAC K 35 CIMAC H 45 CIMAC K 45 CIMAC H 55 CIMAC K 55 en / 27. bei 100 °F enthält die nachstehende Tabelle: 7 30 200 10 40 300 15 80 600 25 180 1500 35 380 3000 45 55 500 700 5000 7000 2) 3) 4) 5) 6 7) ISO : 975 ISO : 981 ISO : 985 ISO : not limited nicht begrenzt ISO : Carbon Residue Koksrückstand 10 ISO : 0.10 0. Limit Density at 15 °C Dichte kg/m3 max Kin. I sec. Fuel shall be free of used lubricating oil (ulo) 1) An indication of the approximate equivalents in kinematic viscosity at 50 °C and Redw. A4.15 7) 22 0. bei 100 °C cSt 1) max min Flash point Flammpunkt °C min Pour point (winter) (summer) Stockpunkt °C max Carbon Residue (Conradson) Koksrückstand % (m/m) max Ash Asche % (m/m) max Regulations and care Heavy fuel specification BA000186 Total sedim.07.5 600 80 15 15 30 0.5 3.15 7) 14 14 15 20 18 22 22 0.11.10 0.15 0. viscosity at 100 °C Kin. max.5 0.5 600 0.10 0.05 1/1 .0 4.

07.Regulations and care Viscosity temperature sheet M20-M601C A4.05.06 en / 28.1996 BA000190 1/1 .06.

For Caterpillar/MaK engines operating on heavy fuel this value should be between 30 and 40 mg KOH/g for fresh oils.2 Additives The additives in the oil must remain effective and uniformly distributed at all temperatures occurring in normal operation between pour point and 220 °C as well as in storage and also fulfil the following requirements in Caterpillar/MaK engines: 1. 1. a special oiltype should be used after consultation with MaK.08.1 Base Oil The base oil should be a high-quality solvent refined product from a source suitable for engine lubricating oil and have a good oxidation stability as well as a good load carrying capacity and thermo-stability.Regulations and care Lubricating Oil M20-M601C A4.2. Have an adequate alkalinity in order to be able to neutralize the sulfur acid compositions which occur during the combustion process.05. High demands must therefore be placed on the lubricants to be used in respect of suitability.00 1.1 Good detergent and dispersant properties (which for heavy fuel operation equals at least the APICF level) to prevent the depositing of combustion products (coke and asphalt-like compositions) or dissolves these deposits and keeps them in suspension. The oil to be used should be selected according to the specifications of the fuel which is used to run the engine. On engines which are equipped with special cylinder lubrication the same oil should be used in the circulation system and for the cylinder lubrication.2.2008 BA020067 1/8 . Regenerated oils are not permitted. This is usually given as the Base Number (BN).02. or as Alkalinity Value (AV) and recorded in mgKOH/g. must be rendered harmless and for this reason only lubricating oils which have been developed for medium-speed trunk piston Diesel engines are approved. When using heavy fuel the effect of the increased amounts of coke-type and acid deposits which form during combustion as a result of the high ash and sulfur content.2 en / 29. If there is a high luboil consumption also indicated. 1. Engine Lubricating Oil The quality of the engine oil has a large influence on the service life and engine efficiency and thus the economical operation. When using fuel with a very low sulphur content liner lacquering may appear. 1.

Mechanical filters suitable for filtering blended oils may be used only.08. Exception: automatic filters 1. 1. a double filter with manual change-over is sufficient. Caterpillar/MaK has no experience with oils not mentioned here.05.1 Lubricating oil filtering (By-pass) By-pass oil cleaning in separators is specified for heavy-fuel operation because the finely distributed combustion deposits cannot be removed effectively from the oil in any other way. Furthermore no guarantee can be given for poor quality engine and lubricating oil care nor for the use of non-approved fuels.4.Regulations and care Lubricating Oil M20-M601C A4.04. the installation of an “Automatic back-flush filter” in conjunction with a following indicator filter as double filter is necessary. when ordering. en / 29.3. oil centrifuges and by-pass filters.3.2 Lubricating oil filtering (full flow) In order to combat the higher amount of contamination in the lubricating oil when operating on heavy fuel. Proof that a defect has not been brought about by the lubricating oil must be provided by the user. be placed in front of the designation to avoid confusion. the firm’s name is part of the brand designation of the lubricating oil and should.02.1 List of brands of lubricating oil for Operation with distillate fuel The viscosity class SAE 40 is specified for all Caterpillar/MaK engines. (See the details in the Instructions for Heavy-Fuel Operation A3.2008 BA020067 2/8 .3 Care of lubricating oil The time between oil changes can be lengthened by the use of separators.00 1. 1. Chemically active filters are not permitted.nn One stipulation for good separation of the lubricating oil is a low viscosity which requires a correspondingly high temperature. When separating the temperature should be between 90 and 95 °C. The intended use of any of these oils must therefore be discussed with the engine manufacturer beforehand as otherwise the warranty is no longer valid. Caterpillar/MaK cannot give any guarantee for the oil used because. The separator capacity should be designed in accordance with the Instructions for Heavy-Fuel Operation in A3.08.nn) For gas oil or MDO operation. Caterpillar/MaK has insufficient experience with brands of lubricating oil listed in column II. 1.4 Lubricating oil brand recommendations – Limitation of warranty In most cases. For gas oil or MDO operating by-pass filters can be used instead of separators.04. for example. the composition and manufacture cannot be influenced by Caterpillar/MaK.08.

en / 29. Otherwise the warranty cover is invalid.2008 BA020067 3/8 .02.08. Caterpillar/MaK must be informed because at the moment there is insufficient experience available in Caterpillar/MaK engines. 1) See also brand list for lubricating oils for heavy fuel operation.10 °C.Regulations and care Lubricating Oil M20-M601C A4.05.00 Lubricating oil firm AGIP BP Lubricating oil brand DIESEL SIGMA S CLADIUM 120 ENERGOL HPDX 40 ENERGOL DS 3-154 ENERGOL IC-HFX 204 VANELLUS C3 DELO 1000 MARINE DELO 2000 MARINE MARINE MLC MHP 154 TLX PLUS 204 KORAL 1540 DELO 1000 MARINE OIL DELO 2000 MARINE OIL EXXMAR 12 TP EXXMAR CM+ ESSOLUBE X 301 MOBILGARD 412 MOBILGARD ADL MOBILGARD M430 MOBILGARD 1-SHC GADINIA GADINIA AL SIRIUS FB ARGINA S ARGINA T TARO 12 XD TARO 16 XD TARO 20 DP RUBIA FP DISOLA M 4015 AURELIA XL 4030 I II X X X X X X X X X X X CALTEX CASTROL CEPSA CHEVRON ESSO X X X X X X MOBIL 1) 2) X X X X X X X X X X X X X X SHELL 1) TEXACO TOTAL LUBMARINE X 1) I Proven in use I I Permitted for controlled use.For engines under SAE 40-regulation only allowed if the oil inlet temperature can be decreased by 5 .When these lubricating oils are used. 2) Synthetic oil with a high viscosity index (SAE 15 W/40).

4. Otherwise the warranty cover is invalid. en / 29. Caterpillar/MaK must be informed because at the moment there is insufficient experience available in Caterpillar/MaK engines.00 1.2008 BA020067 4/8 .08.2 List of brands of lubricating oil for heavy oil operation Only the viscosity class SAE 40 is permitted.When these lubricating oils are used.Regulations and care Lubricating Oil M20-M601C A4. Lubricating oil firm AGIP BP CALTEX CASTROL CHEVRON ESSO Lubricating oil brand CLADIUM 300 S CLADIUM 400 S ENERGOL IC-HFX 304 ENERGOL IC-HFX 404 DELO 3000 MARINE DELO 3400 MARINE TLX PLUS 304 TLX PLUS 404 DELO 3000 MARINE OIL DELO 3400 MARINE OIL EXXMAR 30 TP EXXMAR 40 TP EXXMAR 30 TP PLUS EXXMAR 40 TP PLUS MOBILGARD M430 MOBILGARD M440 MOBILGARD M50 ARGINA T ARGINA X TARO 30 DP TARO 40 XL AURELIA XL 4030 AURELIA XL 4040 I X X X X X X X X X X X X X X X X X X X X X X II X MOBIL SHELL TEXACO TOTAL LUBMARINE I Proven in use I I Permitted for controlled use.05.02.

500 h en / 29. Under such conditions and due to the low refilling requirement the usability limit can already be reached after shorter times depending on the oil grade used (BN) and the influence of the other operating parameters.3 l/kW cannot be avoided. The oil level must be checked daily (the level must not drop below the minimum mark). Due to the above-mentioned factors the indicated oil change intervals are guide values only.Regulations and care Lubricating Oil M20-M601C A4.6. We therefore recommended checking of the lubricating oil by means of regular oil analyses. The essential criterion for determining the time for an oil change is compliance with the limt values specified under item 1. These analyses will be carried out by the lubricating oil service of the oil supplier or by Caterpillar/Kiel at cost price.500 h – every 7. the operating conditions. the engine oil consumption.5 Lubricating oil changing The oil change interval is dependent to a large extent on the quality of the oil used and is influenced also by the fuel used. Independent of the kind of treatment it is necessary to replenish by adding new oil when the BN limit (item 1.2) is reached. An oil change must be made every 6 months at the latest. shorter oil change intervals are necessary. which in individual cases may even be significantly below this value. The oil for the analysis must be taken from the oil circuit before engine during operation.500 h – every 3.0 l. the lubricating oil care and engine maintenance. The amount required is approx.36 l/kW.2008 BA020067 5/8 .and main filter Additional by-passfilter or oil centrifuge Separator – every 1.36 l/kW when fitted with: Pre.00 1. the amount circulating in the engine lubricating system.08.02. Oil change after operating hours (h) based on 1.05. If in special exceptions circulation amounts of at least 0. In such cases the oil change times given below must be multiplied by the quotient of the actual quantity to the normally required quantity. The optimal oil circulation quantity should 1. 0. Note: Modern MaK engines are characterized by low lubricating oil consumption rates of < 1 g/kWh.5 to 1.6. It must be topped up at the latest when 20 % of the amount in circulation has been used.

02. the total base number of the circulation oil must not fall below 18 mg KOH/g. The limit is 2 % by weight. 1.6. Reaching the limits at least 25 % of the oil should be changed. 1.2 Alkalinity (TBN) For heavy fuel operation.1 Lubricating oil dilution by fuel Flash point decrease not below 180 °C (measured according to Penski-Martens DIN 51758) or viscosity decrease for SAE 40 (40 °C) not below 120 mm2/s (cSt). Vanadium content not higher than 150 ppm. If the content increases beyond 1 % weight.6. separators are specified to keep the oil clean.3 Water content If the water content rises above 0.Regulations and care Lubricating Oil M20-M601C A4. If the engine is running on gas oil or MDO.6.2 % the cause of the increase should be identified and eliminated immediately.08. the oil must be separated more intensively. the alkalinity should be increased by the addition of new oil. the limit value is 15 mg KOH/g. For gas oil operation as well the pentane or heptane insolubles must not exceed 2 % by weight.4 Contamination When Caterpillar/MaK engines are running on heavy fuel.00 1. viscosity increase at 40 °C not above 200 mm2/s (cSt). en / 29.6 Limits: 1. 1.05. In this way the content of insolubles can usually be kept well below 1 % by weight. the total base number must not fall below 50 % of the value of the new oil. The oil must be separated or it must be changed. If only the base number has reached the lower limit and the other analysis values show a satisfactory oil condition.2008 BA020067 6/8 . For engine with cylinder lubrication.6.

en / 29.T.Regulations and care Lubricating Oil M20-M601C A4.00 1. RE-Governor should be fitted with a normal 15W40-multipurpose oil. Lubricating oil firm AGIP Lubricating oil brand OSO 68 OTE 68 DICREA SX 68 ENERGOL SHF-HV 68 ENERGOL THB 68 ENERSYN TC-S 68 RANDO HD 68 REGAL R & O 68 CETUS PAO 68 PERFECTO T 68 HYSPIN AWH-M 68 AIRCOL SR 68 HD TURBINAS 68 EP HYDRAULIK OIL 68 OC TURBINE OIL 68 TERESSO 68 TROMAR T COMPRESSOR OIL 68 D.E OIL HEAVY RARUS SHC 1026 TELLUS OIL T 68 TURBO OIL T 68 CORENA OIL AS 68 RANDO HD 68 REGAL R & O 68 CETUS PAO 68 PRESLIA 68 AZOLLA ZS 68 TURBINE T 68 BARELF SM 68 DACNIS SH 68 1) BP 1) CALTEX 1) CASTROL 1) CEPSA CHEVRON ESSO 1) MOBIL 1) SHELL 1) TEXACO 1) TOTAL LUBMARINE 1) 1) Fully synthetic special oil for extended oil change intervals in highly loaded ABBturbochargers with independent lubrication. For highly loaded ABB-turbochargers fully synthetic special oils (see footnote) are recommended. Woodward etc.08.7 Lubricating oil for exhaust turbocharger.02. should therefore be noted.2008 BA020067 7/8 . hydraulic governor and reversing controls A turbine or hydraulic oil with very good anti-oxidation properties and a viscosity between 68 and 90 mm2/s (cSt) at 40 °C should be selected.05. When selecting the lubricating oil the regulations of the maker such as ABB.

2008 BA020067 8/8 .Regulations and care Lubricating Oil M20-M601C A4.08.02.05.00 1.8 Multi-purpose grease – lithium saponified – consistency number 2 (also suitable for pneumatic control instruments) Lubricating oil firm AGIP BP CALTEX CASTROL CHEVRON ELF LUBMARINE ESSO MOBIL SHELL TEXACO TOTAL LUBMARINE Brand name GR MU 2 ENERGREASE MP-MG 2 MULTIFAK EP 2 SPHEEROL SX 2 DURA-LITH GREASE EP 2 EPEXA 2 BEACON EP 2 MOBILUX EP 2 ALVANIA R 2 MULTIFAK EP 2 CERAN WR 2 en / 29.

These requirements can only be met by proper prepared. depending on the evaporation loss. 100 max.Regulations and care Cooling Water M20-M601C A4. even a short period of operation may result in damages due to corrosion. well water) .2008 BA000198 1/2 . clean water.Natural water (deep well-.8 Chemicals 0 . monitored and maintained cooling water.1.condensate and .8 0 .chemical corrosion inhibiting agent (chemicals) exact dosing of the corrosion inhibiting agent • Requirements for the cooling water Always use clear. Three decisive facts are to be considerd for a proper treatment: • • Suitable fresh water effective corrosion inhibiting agent .10*** pH value ** at 20 °C Chloride ion content mg / l total chloride + sulphate ions mg / l max.fully de-ionized water.2 12 6. soluble . Modern Diesel engines put particular requirements on the recirculating cooling water due to the increased power desity and the consequently increased heat to be dissipated.09.05.00 Recirculating Cooling Water The cooling system consists of a closed cooling water circuit with a cooling water volume which must be kept constant by topping up. Suitable are: .corrosion inhibiting oil.Hardness * ° dGH 0. 200 en / 03.alkaline earths mmol / l . monitoring and maintenance work are not carried out properly.03. The values for the fresh water analysis must be within the following limits: corrosioninhibiting oil total .5 .5 3 2. If the the preperation. The checking of the recirculating cooling water level has to occur at the expansion tank.

9 USA hardness **) pH value: Concentration of hydrogen ions < 7 = acid. Magnesium sulfate ° (Mg SO4) should be used for this purpose. ***) In general.03).05. Condensate and fully de-ionized water should be hardened up to 3° dPH.09.05. > 7 = alkaline.Regulations and care Cooling Water M20-M601C A4. Water with a hardness of > 12° (10°) dGH must be brought within the specified range by mixing with condensate or fully de-ionized water (by ion exchange).03.25° British hardness 1° dGH = 17. Dosing: For 1° dPH 21.18° mmol/l 1° dGH = 1.0).4 g Mg SO4 per ton of water are required.00 *) Water hardness: Water which does not fulfil the above requirements must be hardened or softened. 7 = neutral.79° French hardness 1° dGH = 1. the corrosion inhibiting effect of chemicals shows the best results with low water hardness values (. what may result in precipitations and in reduction of the inhibiting effect. see Diagram I (A4.09. en / 03. At higher hardness values and with missing hardness stabilization the chemicals may react with water contents. if corrosion inhibiting oils are used.2008 BA000198 2/2 . ° German total dGH = = Permanent hardness dPH + + Carbonate hardness dKH Comparison with other values: 1° dGH = 0.

2 or they have proven effective over a long period of operation.Regulations and care Treatment of cooling water M20-M601C A4. Treatment of cooling water with corrosion inhibitors Anticorrosive agents to be used in MaK/CAT engines must have been tested for their effectiveness according to the rules of the “Forschungsvereinigung Verbrennungskraftmaschinen e.1 Safety note: No anti-corrosion oil emulsion must be used in case of systems heating living quarters by engine cooling water or in case of shell cooling! In this cases use only chemicals! Anti-corrosion oil The fresh water is mixed outside the engine with anti-corrosion oil to form a stable emulsion. No liability for the anticorrosive agent used will be accepted because MaK/CAT is unable to control the recipe and treatment.01 1. This 10 % emulsion is added to the cooling circuit which is already filled with 75 % of the necessary cooling water amount. For the initial filling or after cleaning the coolant circuit a 1.09. en / 23. V.5 % emulsion should be used and for the subsequent filling a 1. MaK/CAT will issue a recommendation on the basis of the results of the test. via the expansion tank. MaK/CAT has received positive test results for the agents mentioned in 1. For initial fillings take so much water that a 10 % emulsion can be prepared with the required amount of anti-corrosion oil.1 and 1. ~ 1. Topping up can be done with the engine running.0 % emulsion should be used. The following anti-corrosion oils are known to us to be effective (alphabetical order.25 °C) and stir vigorously.05.2005 BA020912 1/3 .11. not complete): BP: Castrol: Esso: Shell: FEDARO-M SOLVEX WT3 Kutwell 40 Dromus B Shell Oil 9156 The preparation of the emulsion can generally be carried out as follows: Add oil to the water (15 .” (Research Association for Internal Combustion Engines Inc).

2005 Safety note! Chromates are not recommended despite of their good properties due to their poisonous nature! Using and checking procedures must be obtained from the manufacturers. Attention: It is important to avoid too low concentration. A chemical anticorrosive agent is added to the delivery scope (fittings) of some stationary engines.1500 — 1500 800 500 1000 750 750 750 1500 1500 1500 — 1500 2500 2250 1100 700 2000 1000 1000 1000 2500 2500 2500 2100 Bedia Rohm + Haas Bedia Liquid BL1 Dia-Prosim RD 11 Dia-Prosim RD 25 Ashland (Drew Ameroid) DEWT-NC (Schiff) CWT-110 (Land) Maxigard Liqui dewt Maritech Nalfleet Marisol CW 9-108 9-111 Nalcool 2000 Unitor Dieselguard NB Rocor NB Liquid Vecom Arteco Marichem Marigases CWT Diesel / QC2 (D99) Havoline XLI DCWT Non Chromate ~ Note: en / 23.Regulations and care Treatment of cooling water M20-M601C A4.01 1. taking particular care not to use any poisonous substance it fresh water plants are connected into the cooling circuit. g.09. no danger of sludge formation due to breaking down of the emulsion and are simplier to prepare and control. BA020912 2/3 . In any case. because this may result in crevice corrosion! As far as we know. the following materials are being used in MaK/CAT Diesel engines at the moment: Manufacturer Additive Limit value of nitrite content as NO2 in mg /l 1200 1400 .11.05. a filling with this chemical is to be implemented prior to commisioning.2 Chemical corrosion inhibitors The chemical corrosion inhibitors have some advantages over the anti-corrosion oils e.

A concentration check of the chemical corrosion inhibitors under consideration of the limit values (see 1. After a freshening up of the concentration mix well with engine running! en / 23. possibly incorrect measurement In case the measured values are higher than 1.1 % >1% – – – – Cooling water change and cleaning necessary.09.2005 BA020912 3/3 . 2.09.09. test again with fresh sample water. a correction of the emulsion is necessary. Pour off oil which rises to the surface.04) and refill the circuit with conditioning water. see A4. 2. Emulsion freshening in case of concentration too low Mix required amount of oil according to diagram II (A4.05.09.04) with conditioning water to a highly concentrated emulsion.5 . 0% < 0. also possible with engine running.g.05.2 Chemical corrosion inhibitors. Always add oil to water Fill in the mixed emulsion via the compensator reservoir.05.1 Checking and care of the treated water Anti-corrosion oil A daily check of the coolant level in the sight glass on the expansion tank is just as important as checking the anti-corrosion oil contents every 750 operating hours.01 2. If the result is confirmed.5 % 0.02 Emulsion freshening required Emulsion in order Concentration too high. The maintaining of the determined concentration is of decisive importance for a proper corrosion protection.5 %. Carry out emulsion test e.2) is to be carried out with the relevant testing equipment every 150 h in accordance with the instructions of the supplying companies. Take the emulsion sample out of the supply line from expansion tank to pump and let it stand for 1 h.11.05. During prolonged operating breaks. with hand refractometer (specialist shop laboratory equipment) . a monthly check should be made. Emulsion correction in case of concentration too high Drain cooling water emulsion according to diagram II (A4.Regulations and care Treatment of cooling water M20-M601C A4.

1 Changing the cooling water Anti-corrosion oil emulsion The anti-corrosion emulsion must be changed at the latest every 7500 operating hours.11.09.04) prepare a highly concentrated emulsion.2005 BA020059 1/2 . Remove water inlets on the crankcase and flush out any sludge which may have formed.05. Henkel 0. Stop engine and let it cool down to 30 °C.05. P3T 308 from Messrs. g. Drain the cleaning solution and flush engine thoroughly with fresh water. Fill engine with an alkali solution (e. First drain expansion tank with floating oil then drain the entire system. 1.02 1. Attention: Always add oil to water! Add the emulsion to system via the expansion tank. 1. Then put in 90 % of the required amount of water. With the remaining 10 % and the required amount of anti-corrosion oil (according to diagram II: A4.09.1 Cleaning the cooling water chambers before changing the emulsion Stop engine and let cooling water cool down to 30 °C.2 Chemical corrosion inhibitors When recirculating cooling water has chemical corrosion protection the cooling water does not need changing.Regulations and care Changing the cooling water M20-M601C A4. at least annually if the 7500 operating hours are spread over a period of more than one year due to long breaks in operation.1. 1. en / 23.5 % solution) and run it for approximately 12 hours.

3. The firm which supplies the anti-corrosion material will usually be able to offer a good cleaning agent for scale.02 2. The highest concentration is 50%. Havoline XLC. For summer operation. such as: Drew Chemical: Rohm + Haas: SAF . In cases of doubt MaK should be contacted.2005 BA020059 2/2 .09. Only an anti-freeze agent with a corrosion protective effect may be used. a 30 % concentration is necessary. To obtain adequate corrosion protection. Cleaning the cooling water chambers Before badly scaled cooling water chambers can be cleaned. This will remove loose foreign matter such as sand and sludge which may have been deposited at places where the water flow speed is low. they must be precleaned as described and flushed well with water under pressure. for example BASF Glysantin G48.ACID RD 13 M Attention: Keep to the manufacturer´s instructions!Improper use of the cleaning agents may cause damages to your health! Flush cooling water chambers or cooling system with a 1 % sodium carbonate solution after draining off the cleaning agent. a reduction in cooling efficiency must be expected.05.Regulations and care Changing the cooling water M20-M601C A4. When an anti-freeze agent is used. This agent must be changed annually. GlycoShell AF 405. it is advisable to drain off the cooling water with anti-freeze in it and replace it with cooling water with chemical corrosion protection in order to guarantee adequate radiator performance at higher ambient temperatures. en / 23. BP Antifrost X 2270. Afterwards flush the water chambers with fresh water. Cooling water with anti-freeze agent In case of temperatures at or below the freezing point of the cooling water an anti-freeze agent must be added to the coolant.11.

en / 28.05.09.Regulations and careÿ Diagram I M20-M601C A4.1200 = 1100 litres of condensate or fully de-ionized water.1996 BA000210 Hardness = dGH 1/1 .03 Diagram I Determining the cooling water mixture for 10° dGH ° amount used (litres) Cooling system capacity (litres) Example: Cooling system capacity: Hardness of available fresh water: 2300 l 19° dGH To determine the fresh water mixture.06. proceed from the abscissa “Cooling system capacity” (2300 l) via the intersection of the 19° dGH line to the ordinate “Amount used” and read off the amount of water with 19° dGH which is to be used and which is to be mixed with the difference of 2300 .

04 Diagram II Emulsion freshening for weak concentration measured oil concentration in vol.Regulations and care Diagram II + III M20-M601C A4.06. % amount of cooling water in circuit m3 amount of oil to be added in litres to obtain a 0.1996 BA021428 1/1 .7 % oil concentration Diagram III Emulsion freshening for excessive concentration measured oil concentration in vol.09.05. % amount of cooling water in circuit m3 amount of cooling emulsion to be drained off water to be added in m 3 en / 28.

2008 AA000026 1/1 .Maintenance - A5 Maintenance en / 24.04.

01.05.01.05.01.00 A5.02.01.09.05.02.00 A5.51 A5.51 A5.52 A5.01.01. cylinder head Valve Clearance Rocker Arm Bracket Valve Rockers Valve Rocker Bush Valve Rotator Valve Guide / Oil Scraper Ring Media guiding system Cylinder Head Nozzle sleeve Relief Valve In and Outlet Valve Cone Valve Cones Valve Seat Ring Valve Seat Ring (Inlet/Outlet) Starting Valve Starting Valve Cylinder Head Cylinder Head Cylinder Head Engine.01.03.01 A5.01.04.00 A5.05.05.Table of Contents - A5.01 Maintenance Table of Contents Introduction Safety instructions Periodical schedule Heavy fuel Engine.01.70.02 A5.05.01.05.01.01.00 A5.03.05.05.01.51 en / 24.01.03 A5.05.01.01.05.50.51 A5.01.05.01.02.10.05.02.00.03.02.02.02 A5.00 A5.05.01.11.02.02 A5.02.05.05.01 A5.05.08.04.05.07.02.06.01.02.06.05.05.05.01.01.05.05. gear Running Gear / Engine Timing Crank Web Deflection Bearing Shells and Bearing Bushes Bearing Shells Big-end bearings Big-end bearings Crankshaft bearing Crankshaft thrust bearings/crankshaft be Crankshaft thrust bearing A5 A5.02.00 A5.09.01 A5.01.53 A5.01 A5.02.01 A5.05.01.03.04.01.01.01.05.01 A5.07.01.51 A5.02.02 A5.01.04.02.08.05.01.05.50 A5.03 A5.05.03.10.05.01.05.01 A5.05.03.50.06.05.01.2008 AA020041 1/3 .02.05.02.01.02.00 A5.01.08.05.01 A5.02.00 A5.01 A5.05.00 A5.01 A5.01.05.00 A5.

03 A5.05.03 A5.08.09.05.04.00 A5.05.05.50 A5.05.04.05.02.05.01.03.05.05.05.08.06.01.02.01.01.00 A5.05.01.07.05.04.05.04.02.03 A5.00.09.08.02.02.52 A5.01.04.51 A5.01 Piston Piston Crown Piston Replace Piston Rings and Grooves Piston pin Small-End Bush Piston Engine.00 A5.01.06.51 A5.04. exhaust gas system/supercharging Exhaust Manifold Charge air drain A5.04 A5.02.01 A5.05.Table of Contents - A5.01.00 A5.04 en / 24.05. control Camshaft Bearing Camshaft Bearing Bottom part for Valve Mechanism Camshaft Timing Gear Train Governor Drive Vibration Damper on Camshaft Engine.05.09.08.05 A5.06.07.05.02.02.06.05.05.53 A5.02.09.01.10.06.05.05.51 A5.50 A5.01.50 A5.52 A5.03.00 A5.01.04 A5.04.01.03.02.03.05.01.00.05.04.05.05.01.00. regulation Control shaft bedding Starting Valve Control shaft Compressed Air System Control Valves Compressed-Air Filter Engine.03.03.06.50 A5.05.01.06.03.02.01.05.04.00 A5.04.02 A5.52 A5.05.50 A5.02.01. housing Cooling water distributor housing Cylinder Liner Cylinder liner Cylinder Liner Engine Bolting and Unions Engine.00 A5.04.02.02.05.2008 AA020041 2/3 .01.05.05.52 A5.05.09.05.04.05.01.05.01.06 A5.05.01 A5.05.05.

11.12 A5.03 A5.01.08.11. starting system Starting Air Distributor Stop cylinder Engine control equipment Pressure Switches RPM Switch Pressure Switch Pressure Switch Crankcase Monitoring Device Engine auxiliary units Vibration Damper Vibration Damper Turning Device A5.05.09.11.05.10.07.05.05.03.01 A5.02.00.05.03.15.00 A5.05.07 A5.08.00 A5.05.08.01.05.00 A5.06.05.05.05.00 A5.10.51 A5.02 A5.01.05.05.07.01 Engine.08.07.04.08 A5.01.06. fuel system Injection Pump Injection Pump Fuel Injector Fuel Injector Fuel Injector Fuel Distributor Manifold Engine.07.05.05.51 A5.09.02.01.03.10 A5.08.11 A5.02 A5.Table of Contents - A5.00 A5.03 A5.05.08. lubricating oil system Lubricating oil pump Protective Lube Oil Filter Oil pressure control valve Oil pressure control valve Prelubricating pump/Prelubrication Engine.03.05.05.07.52 en / 24.02.07.05.11.01.05.07.52 A5.05.05.03.04.05.12.10.01.05.11.05.56 A5.05.2008 AA020041 3/3 .03 A5.12.01.04.01.03 A5.01.01.12.05.01.05.05.01.05.08.00 A5.06.02 A5.02 A5.02.02 A5.01.01.04.

No claims can be raised owing to missing instructions in the maintenance documents.1 Explanation of the maintenance system Scheduled maintenance Without “Scheduled maintenance” the economic operation of supercharged engine is in the long run not possible at today's state of art. fuel qualities and their care. The “Scheduled maintenance” is thereby supported by inspections according to fixed deadlines. It is recommended to consult MaK with regard to extended intervals in order to maintain the guarantee. General It is assumed that the engine room personnel has the necessary knowledge and experience required for the proper maintenance and servicing of diesel engines. 2. For this reason and in the interest of clearness we did not go too much into details in the maintenance documents. But in any case a sufficient safety margin . 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 of individual components is highly influenced by environmental and operating conditions. but it is left to the user to modify the maintenance schedule in accordance with own experiences.02. 2. These inspections are decision criteria for the need and extend of maintenance and servicing.is to be calculated in order to cover the always occurring variations. It is the purpose of the maintenance to replace parts subject to wear and tear or to repair these parts before they are damaged. en / 27. The information given by us gives no rise to legal claims.Introduction M20-M601C A5. Therefore the present interval schedule shall not be considered stringent in the long run.even if the mean wearing levels are well-known . The explanations are used to make the user of this engine plant familiar with the existing maintenance system of MaK and to interest and deepen the understanding of the user for the problems and importance of the “Scheduled maintenance”. All information refers to the date of printing. if damage is caused by improper handling.2008 AA000021 1/5 .02 1.

Introduction M20-M601C A5.02.2 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 or repair shall be carried out.2. • Periodic maintenance work A list of all recurrent inspection. depending on equipment condition. the job cards indicate the manner in which the work is to be carried out. maintenance and repair work occurring up to 90. Other values may be obtained. operating and maintenance conditions.02 2.1 Work interval schedule The work interval schedule shall provide for a quick summary of all intended inspection. 2.000 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. maintenance and repair work to be carried out at the scheduled date. • Maintenance work to be carried out independent of deadlines List of work which may be required in the scope of scheduled work which cannot be allocated to a deadline.2008 AA000021 2/5 . The indicated intervals are statistical mean values. * will be handed over by the MaK service department for commissioning of the engine en / 27.

nn.01.2220 1 Pers.01. repair and safety check.nn.2 Job cards The job cards are instructions for inspection. ¬ Title of the job card Maintenance work Activity Discharge valve Inspection / Dismounting and mounting A5.nn B1.01.02.05.000 Engine type Register Main maintenance group 01 See also: Spare parts list: Time requirement: Personnel qualification: Operating medium: 01. A operating instructions Subchapter Job cards A5. 01. B1.02 2.03 Main maintenance group Maintenance group Subgroup Variant Job cards Document number en / 30.05.05.91 Date of issue IB000003 1/1 Registration number Language Page/number of pages en / 27.7.000 / 12.Introduction M20-M601C A5.2104. 01.01. maintenance.05.04.7.01.01.2008 AA000021 3/5 .09.08.02.04.03 Operating hours/maintenance deadline M 551 / M 552 6.01.01.2. / 3 h skilled engine hand Heavy fuel and destillate fuel Breakdown Chapter maintenance Vol. 01.01.

indicating other design details in the illustrations. Cylinder head Driving mechanism Engine housing Engine control Regulation Exhaust gas system/ supercharging Fuel system 08.02 The job card number consists of the index breakdown (A5. 02. the pair of digits on the right margin has been set as register 01 . 05. if necessary. B “Spare parts catalogue”. The fourth pair of digits indicates the type of variant. 06.02. Note: Gives the personnel information which optimize the work process. 12. 03. 09. 07. See job card: Reference is made to other job cards required for maintenance work. • The first pair of digits indicates the engine main maintenance group: 01. Spare parts sheets: For easy finding of necessary comsumables and spare parts for the maintenance group in Vol. ~ in order to draw special Attention: Marking technical regulations or measures to be strictly observed in order to avoid damage or destruction of equipment or components of the engine plant or other material.03). 13. The third pair of digits in the index breakdown in the spare parts number indicates the main group/register. 04. • • • • Fuel: Documenting the sold type of fuel of the engine plant (see also: introduction A0.05) and the maintenance number (bold) subdivided into four pairs of digits. • • • • The second and third pair of digits indicates the subgroups of the main group and the titles of the job card where maintenance work is required. 10. Lube oil system Cooling water system Starting air system Monitors Auxiliary generator sets and tools Additional installation In order to facilitate the finding of the engine main group. Safety note: Each safety note is additionally marked with a symbol attention to the text (see A5.02).Introduction M20-M601C A5. en / 27. 11. At this point the types of variants (fourth pair of digit) are marked “nn”.2008 AA000021 4/5 .

Typical consumption parts which are replaced routinely or any time mounting is carried out (Oring seals. It would be useful to mount the plan on a wall.Introduction M20-M601C A5.3 Maintenance schedule (Periodic maintenance work) A large-scale plan showing all maintenance work up to the largest maintenance interval clearly indicating all occurrences and the future work expenditure for the individual components. red = damage/replacement of parts.: green = no defects/o. e.2.02 • • • • • In the maintenance sheets the checks. Not all of these tools are included in the normal scope of supply.2008 AA000021 5/5 .02. The work already carried out will be countersigned in fields intended for this purpose. Wherever the required working time depends on the number of cylinders the indicated time of the maintenance sheets refers to one cylinder unit only. O-rings etc. 2. clearances). Different colours can be used to differentiate between the results. maintenance. * The map will be handed over by the MaK service department for commissioning of the engine en / 27.) are not considered defective parts.. 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. cleaning and repair works of the maintenance sheets are briefly designated Under the designation "tools (W)" only special and additional tools are listed with the MaK tool No. yellow = readjustment/correction (e. Together with the engine type it will be indicated for what engine the job card is valid.k.g. it has to be folded and filed in the map “maintenance forms” *. The indicated time is based on estimated mean values which may deviate according to the equipment of the plant and its maintenance conditions.g. The indicated personnel and time requirement does not define the working time of the individual person. when this is not possible for space reasons.

however it should not be exposed to temperatures above 300 °C.Safety instructions M20-M601C A5. since above 325 °C a thermal decomposition and the formation of hydrofluoric acid can occur. it should be taken care that this material is not overheated even by accident e.03 1.1 Work safety symbol ~ 1. and above all. With normal engine operation this material is completely harmless. the following is to be observed: • Seals made of VITONR have been used at various locations in the engine.1999 AA000022 1/4 . If this should however has happened. Skin contact with decomposed VITONR is to be avoided at all times.12.e.2 All texts marked with this symbol in the maintenance sheets are safety instructions which have to be observed in all cases in order to eliminate danger to life and limb of the user or of third parties! General safety instructions The provisions of the relevant accident prevention regulations of the appropriate employer's liability insurance association are to be observed any time operation and repair work is carried out. the gases emitted must not be inhaled. during combustion and welding operations. • Replaced seals should be disposed of immediately. i. In addition. Maintenance and repair work must only be carried out by skilled and authorized personnel! Use personal protective equipment as far as necessary or as required by the regulations! • • en / 01.g. Safety instructions 1. saturated with calcium hydroxide. it is essential that neoprene gloves are worn during the clearing up operations. After a fire with VITONR. • Any residues have to be neutralized before their disposal.

fuel! Clean the engine parts.03 • When work is being carried out on engines and systems.Safety instructions M20-M601C A5. grease.1999 AA000022 2/4 . fuel or preservatives before carrying out maintenance/repair (disassembly. e. Shut-off valves are to be secured by a plate “Do not open”! Mounting openings are to be protected! Perfect hoists. the switch-on devices have to be switched off and protected. platforms. cooling water. hydraulic oil. oil. the specially designed or safety-oriented climbing aids are to be used only! • • Do not use engine/plant parts for climbing on! Keep all handles. ladders free from dirt. starting and control air) must be depressurized. assembly)! • • Never use aggresive detergents and preservatives! • • Use non-fuzzy cleaning rags! Pressurized plant components (lube oil. fuel. individual parts and large assemblies are to be carefully fastened and secured on hoists to avoid risks of accidents! • • • Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity! • • Never work or stand under suspended loads! When carrying out overhead assembly work. especially connections and threaded unions of any traces of oil.12. steps. During replacement work. tools and devices are to be used only! Observe all indicating labels attached to the engine! • • • en / 01. In order to prevent reconnection. handrails.g. the engines and systems have to be marked with a plate “Do not switch” or an appropriate pictogram plate! Re-install removed guards and protecting devices on completion of work.

shut off at the power supply and provided with the notice “Do not switch on” or the corresponding warning sign! • • • 1.Safety instructions M20-M601C A5.if prescribed .12.4 Working with hydraulic devices • Operating instructions.1999 AA000022 3/4 .5 Checking and adjustment of injection valve • 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 .3 Working on electrical equipment • Work on the electrical equipment of the engine/plant must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician in accordance with the electrical engineering rules and regulations! Use only original fuses with the specified current raiting! Switch off the engine/plant immediately if trouble occurs in the electrical system! The electrical equipment is to be inspected/checked at regular intervals. thermal or chemical influences! Replace hydraulic hose lines at regular intervals. even if no safety relevant defects are detectable! • • • • 1.03 1. tightening torques and setting dimensions specified in the appropriate job card are to be carefully observed! Do not place parts of your body above/below pressurized hydraulic tools! The minimum bending radii r = 130 mm of the high-pressure hoses are to be strictly observed! The hose lines are to be protected against damage caused by external mechanical. Defects such as loose connections or scorched cables must be rectified immediately! Engine or plant parts on which inspection and maintenance work is being carried out have to be .respiratory mask! • en / 01.

safety gloves and safety glasses are to be worn in order to avoid injuries.12. birth defects. observe the accident leaflets including first-aid actions for dangerous substances in accordance with the regulations for dangerous substances! • • 2.6 Handling of liquid nitrogen or carbon dioxide snow • When handling liquid nitrogen or carbon dioxide snow.7 Cleansing agents/chemicals • • Use only cleansing agents with a flash point above 65 °C! Observe instructions for use in accordance with DIN safety data sheet of the regulations for dangerous substances! Observe the specialist disposal of all cleansing agents and chemicals in accordance with the regulations for dangerous substances! In case of accident. and other reproductive harm.03 1. The non-observance of the safety instructions may cause danger to persons and failure of important functions of engine/system! 3. safety shoes. Observe protection against cold! 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! • 1. en / 01. California / USA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer.Safety instructions M20-M601C A5.1999 AA000022 4/4 .

06 Temperature A1.05 A3. Temperature rise at rated output see also A1.05.05.02 Intervall Designation / Work to be carried out Remarks Doc-Nr.06.10 Fuel Upstream pumps Charge air Upstream charge air cooler.00 A3. rating Lubricating oil Engine inlet.10 Cooling water Engine inlet.05 Pressure Pressure A1. downstream charge air cooler Charge air Upstream charge air cooler.08.00 A3.05 A1. downstream charge air cooler Exhaust gas After cylinder.05 A1.10 Pressure Pressure Lube oil system Cooling water system Fuel system Pressure air en / 24.04.10 Temperature Pressure A1.10.10 Temperature A1.04.05.10 Cooling water Upstream engine see also A1.05 Pressure A1. Temperature rise at rated output see also A1. Daily inspection and monitoring procedures (if it is not automated) -------------------------------------------------------------------------------------------------------------------------------General Engine operating data Compare with acceptance test records: Speed.06 Temperature A1.10 Cooling water Upstream charge air cooler.Periodical schedule Heavy fuel M32 A5. downstream turbocharger Lubricating oil At the main bearing or at the camshaft bearing see also A1. downstream charge air cooler Control air Starting air Lube oil circulation tank Check of the lube oil level Expansion tank Check of the cooling water level Day tank Check of the fuel level Air bottles Drain AA020752 A1.10 Temperature A1.00 1/9 .00 A3.09.10 A1.2008 A1.07.

04. First inspection and maintenance procedures Work to be carried out after the first commissioning or after major repairs.00 150 h 150 h A5.05.06.51 150 h Engine bolting and unions Inspection/Checking Tight fitand leaks Compressed air strainer Maintenance/cleaning Exhaust gas turbocharger Function check see book C A5.07.09.05.04.Periodical schedule Heavy fuel M32 A5.00 en / 24.05.08. -------------------------------------------------------------------------------------------------------------------------------24 h Lubricating oil safety filter Inspection/Cleaning A5.02 Intervall Designation / Work to be carried out Remarks Doc-Nr.03.2008 AA020752 2/9 .05.01.04.03.

11.06.01 A5.52 1.01.04 150 h 150 h 150 h Valve rotor Inspection/Evaluate Cylinder head Inspection/Checking Prelubricating pump/Prelubrication Maintenance/Checking A5.01 A5.09.01.11.04 A5.08.01.05.03 A5.01.04.12.05.00.05.03.00 A5.01.06.05.09.05.03 en / 24.02 Intervall Designation / Work to be carried out Remarks Doc-Nr.09.08.500 h Valve clearance Inspection/Adjust Starting valve Inspection/Checking Control shaft bearings Maintenance/Checking Oil mist detector Inspection/Checking A5.01.Periodical schedule Heavy fuel M32 A5.500 h 1.05.09.05.00 A5.00.05.05.10.02.05.10.05.00.06.05.00 A5.01.06.05.00 A5.500 h 1.01.01.05.01.09.00 A5.01.01.500 h 1.05.00 A5.06.03.04.05.05.01.09.00 A5.05.00 750 h 750 h 750 h 750 h 750 h 750 h Cooling water system Inspection/Corrosion inhibitors Compressed air system Inspection/Adjust Charge air drain Cleaning Stop cylinder Inspection/Checking Oil mist detector Inspection/Checking Turning device Maintenance/Disassembly and reassembly A4.2008 AA020752 3/9 .00. Periodical maintenance procedures -------------------------------------------------------------------------------------------------------------------------------24 h 24 h Compressed air strainer Maintenance/Cleaning Charge air drain Inspection A5.10.01.

00 en / 24.08.05.09.05.500 h A5.500 h 7.05.05.12.500 h A5.01.00 A5.05.04.00 A5.09.05.00 A5.01.11.00 A5.08.52 3.01.07.750 h 3.750 h 3.03. 1.05.750 h 3.2008 AA020752 4/9 .02 Intervall Designation / Work to be carried out Remarks Turning device Maintenance/Disassembly and reassembly Governor Governor behaviour/governor control rod see book C Doc-Nr.07.04.01.12.Periodical schedule Heavy fuel M32 A5.500 h A5.06.07.750 h Running gear/engine timing Inspection/Checking Timing gear train Inspection/Checking Pressure switch Inspection/Adjust Turning device Maintenance/Disassembly and reassembly Governor Oil change see book C Monitors Checking of alarm and safety system see book C A5.07.01.05.52 3.01.03 7.500 h Inlet and exhaust valve cone Inspection/Disassembly and reassembly of one cylinder unit Piston rings and grooves Inspection/Checking of one piston Starting valve Maintenance/Disassembly and reassembly Control shaft Maintenance/Disassembly and reassembly Compressed air filter Maintenance/Cleaning Exhaust gas line Inspection/Checking Injection pump Inspection/Disassembly and reassembly of one pump Fuel injector Repair/Disassembly and reassembly A5.01.500 h 1.08.08.04.05.01.05.01.05.750 h 7.01.52 A5.01.500 h A5.03.02 7.06.01.02.05.02.01.500 h 7.05.02 A5.500 h 7.05.01.05.500 h 7.01.51 A5.03 7.05.750 h 3.02.

000 h 15.04.01.04.03.01.00 A5.04.01.05.05.500 h 7.01.05.11.04.000 h 15.05.09.000 h 15.500 h A5.500 h 7.08.12.01.08.01.04.500 h 7.51 A5.05.000 h 15.05.05.01.50 15.01.000 h A5.01.03 A5.51 A5.05.01.08.01.000 h Valve guide/Oil scraper ring Inspection/Replace Nozzle sleeve Maintenance/Disassesmbly and reassembly Inlet and exhaust valve cones Inspection/Disassembly and reassembly Starting valve Maintenance/Disassembly and reassembly Cylinder head Maintenance/Cleaning Big-end bearings Inspection/Disassembly of one big-end bearing Main bearings Inspection/Disassembly of two main bearings Cylinder lining Inspection/Measuring at one cylinder unit Camshaft bearing Inspection/Checking of one bearing Camshaft bearings Maintenance/Disassembly and reassembly Timing gear train Inspection/Checking Governor drive Inspection/Disassembly and reassembly AA020752 A5.02.51 en / 24.01.03.000 h A5.02.000 h A5.000 h A5.52 A4.05.01.07.04.03.02 Intervall Designation / Work to be carried out Remarks Lubricating oil safety filter Inspection/Cleaning RPM-switch Inspection/Adjust Oil mist detector Inspection/Checking Turning device Maintenance/Disassembly and reassembly Anti-corrosion oil emulsion Change Doc-Nr.Periodical schedule Heavy fuel M32 A5.11.09.05.01.06.01.02 A5.08.05.05. 7.10.000 h 15.53 15.03.05.05.500 h 7.000 h 15.05.03 15.05.01 A5.01.52 15.05.51 A5.000 h 15.05.01.50.03 A5.01 A5.05.02 A5.04.02.2008 5/9 .05.04.01.02.02 15.09.

01.12.05.04.01 A5.53 30.000 h A5.50 en / 24.07.03.05.05.06.000 h 15.02.01.000 h 15.01.11.05.52 30.09.05.08.01.02.05.04.05.nn A5.05.05.05.01 A5.01.04.02.03 30.01.05.Periodical schedule Heavy fuel M32 A5.04.05.01.000 h 30.05.03 15.07.000 h 15.05.03.03 30.03.05.02.04. 15.09.00 A5.01.500 h Pressure switch Inspection/Replace A5.03.51 A5.01.05.05.000 h A5.02 Intervall Designation / Work to be carried out Remarks Vibration damper on camshaft Repair/Disassembly and reassembly Control valve Inspection/Checking Injection pump Inspection/Disassembly and reassembly of all pumps Oil pressure regulating valve Maintenance/adjust Starting air distributor Maintenance/Disassembly and reassembly Vibration damper Inspection/Disassembly and reassembly Doc-Nr.01.000 h 15.05.000 h A5.52 A5.02.000 h 30.05.000 h Valve rockers Maintenance/Disassembly and reassembly Relief Valve Maintenance/Replace Big-end bearing Inspection/Disassembly exchange of all big-end bearings Main bearings Inspection/Disassesmbly exchange of all bearings Main thrust bearings Inspection/Disassembly Piston rings and grooves Inspection/Checking of all pistons Small-end bush Maintenance/Measuring Cylinder lining Inspection/Measuring at all cylinder units Cylinder liner Maintenance/Disassembly AA020752 A5.02.000 h A5.000 h A5.06.05.05.70.02.05.02 30.2008 6/9 .05.01.00 A5.09.000 h 30.000 h 30.04.10.00 A5.01.02.000 h A5.02.51 22.

50 30.05.52 A5.01.12.01.05.02.51 A5.000 h 30.04.52 45.04.000 h Vibration damper Maintenance/Replace A5.04.02.00 90.000 h A5.000 h 30.05.51 60.000 h 30.06.02.04.01.06.05.2008 AA020752 7/9 .12.12.05.05.05.02.04.04. 30.08.04.00 A5.Periodical schedule Heavy fuel M32 A5.000 h Piston Maintenance/Replace A5.09.05.05.01.00 en / 24.01.05.04.02 Intervall Designation / Work to be carried out Remarks Camshaft bearings Inspection/Checking at all bearings Camshaft bearings Maintenance/Disassembly and reassembly Control valves Inspection/Checking Vibration damper Maintenance/Disassembly and reassembly Turning device Maintenance/Disassembly and reassembly Doc-Nr.000 h Piston Maintenance/Replace A5.000 h A5.

05.05.05.05.50 en / 24.50.03.05.04 A5.51 A5.02.01.02.07. Non-interval dependent maintenance procedures -------------------------------------------------------------------------------------------------------------------------------Valve rocker brackets Maintenance/Disassembly and reassembly Valve rocker bush Inspection/Replace Media guiding system Maintenance/Disassembly and reassembly Cylinder head Maintenance/Disassembly Inlet and exhaust valve cones Repair/Checking Valve seat ring Repair/Checking Valve seat ring (inlet/outlet) Repair/Replace Cylinder head Repair/Reassembly Crank web deflection Inspection/Checking Bearing shells and bearing bushes Inspection/Evaluate Bearing shells Inspection/Evaluate Big-end bearings Inspection/Reassembly Main thrust bearings and main bearings Maintenance/Reassembly Pistons Maintenance/Disassembly Piston crown Maintenance/Replace Piston pin Inspection/Disassembly and reassembly A5.00 A5.01.02.05.01.08.01.02.02.03.03.01.02.05.00 A5.04.01 A5.01.00 A5.01.02.05.06.02.04.2008 AA020752 8/9 .05.05.51 A5.08.05.01 A5.01.50 A5.05.05.02.11.08.01.05.02.05.00 A5.08.02.01 A5.01.05.03.01.05.02.51 A5.06.04.02.05.51 A5.01.03.01.01.01.02.Periodical schedule Heavy fuel M32 A5.06.53 A5.02.01 A5.02 Intervall Designation / Work to be carried out Remarks Doc-Nr.

04.00 A5.02 A5.01.15.03.02.07.06.05.03 A5.2008 AA020752 9/9 .01.05.02.06.11.08.03.07.05.07.04.00.05.05.50 A5.01.05.01.52 A5.06.02.06.01.05.52 en / 24.00 A5.07.05.03 A5.02 A5.07.07.05.09.08. A5.01.04.02 Intervall Designation / Work to be carried out Remarks Piston Maintenance/Reassembly Cooling water distributor housing Maintenance/Disassembly and reassembly Cylinder liner Maintenance/Reassembly Camshaft Repair/Disassembly and reassembly Charge air blow-off equipment Inspection/Checking Jet assist system Inspection/Checcking Injection pump Repair/Disassembly and reassembly Fuel injector Maintenance/Disassembly and reassembly Fuel injector Maintenance/Adjust Injection valve Repair/Disassembly and reassembly Fuel distributor/collection pipe Repair/Disassembly and reassembly Lubricating oil pump Maintenance/Disassembly and reassembly Pressure switch Maintenance/Adjust Crankcase monitoring device Inspection/Checking Vibration damper Maintenance/Disassembly and reassembly Doc-Nr.11.02.05.01.Periodical schedule Heavy fuel M32 A5.50 A5.01.09.04 A5.01.03 A5.04.56 A5.06.05.05.04 A5.12.02.04.04.00.05.06.03.00.52 A5.10.05.05.

500 hours and adjusted.01.3 1.01. i.01.nn B1.00 1500 02.50 h See also: Spare parts list: Time requirement: 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: The valve clearance is to be checked every 1. Turn the crankshaft until the piston of the cylinder to be adjusted comes into the ignition dead center position. Tools: Feeler gauge * not available as figure W2 * 1.9075-003 Note: The valve clearance should only be measured with warm engine.1 1. 15 minutes after shutting down the engine. Remove cylinder cover hoods without damaging the gaskets. if required.05.2107 1 Pers. 1/S): Inlet: Outlet: 0. Open indicator valves./ 0.Valve Clearance Inspection / Adjust M32 A5.05.e.4 + 0. en / 14.1 mm A readjustment of the valve bridge position to the valve spindles must be carried out before every valve clearance adjustment during scheduled inspections or due to work being carried out on the valve drive components.9.4 Adjust valve bridge.2 1. Sequence of operations: 1.1 + 0. Engage the barring gear.01.01.2006 IB020905 1/2 .1 mm 1. Valve clearance (Fig.09. 1. 01.

00 1500 Release valve bridge of rocker arm (Fig. Afterwards adjust valve clearance „S“ as per instruction. 01. Turn the valve adjusting screw (2) until the stipulated clearance has been attained.5 01 1.3 2.09. 1/1).2. Thereby press the pushrod down.1 2.2 2. Disengage the barring gear and close the indicator valves.01.2006 IB020905 2/2 . At this position of the valve bridge screw in setting bolt (4) until contact at „Y” without any clearance is reached.8 1.2.2. Correct clearance "S". Enlarge clearance „S“ and/or flap back rocker arm (1).9 Check absence of clearance at „X“ and „Y“ with feeler gauge of 0. Adjust valve clearance.6 1. 2. 1. Loosen counternut (5).Valve Clearance Inspection / Adjust M32 A5. Valve bridge must not be tited. 2/3) and unsrew setting bolt (4) until a contact in „X” without clearance is reached.5 Check clearance again after countering. Hold tight setting bolt (4) and tighten locknut (3) with M = 150 Nm.7 1.2.05. Tighten the counternut (5) with M = 250 Nm in order to fix the position of the adjusting screw.2 2. Release locknut (Fig. en / 14.02 mm (W2). Measure the clearance (Fig.2.4 2. 1/S) with a feeler gauge.01. 2.1 2.

en / 18. 1. Place rocker arm bracket (3) with rocker arm shaft (2) and rocker arms by means of stud bolts on the cylinder head and align in such a way that the adjusting screws sit in the middle of the valve bridges.2 1.9459-030 Auxiliary material: Molykote paste "G-Rapid Plus" ** ** or a product of equal standard Sequence of operations: 1.3 Disassembly Engage the barring gear.01.400 Nm Ring wrench SW30 * not available as figure W1 * W2* 1.3 1.01. rocker arms are unloaded.05. Dismount the cylinder head cover.01 See also: Spare parts list: Time requirement: 01.01. Turn piston to TDC.1 1.01.Rocker Arm Bracket Maintenance / Disassembly and reassembly M32 A5.05.02./ 0.9. Inlet and exhaust valves are closed. Blow through oil overflow holes with compressed air.4 1.1 2. Remove rocker arm bracket (3) with rocker arm shaft (2) and inlet and exhaust valve rocker.2005 IB022290 1/2 .2 2.nn B1.5 2.02. 2.20 h 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench 100 . 01. Reassembly Clean the supporting surfaces of the rocker arm bracket (3).2107 1 Pers.9454-400 1. Remove fastening nuts (1).

6 2.4 Apply a thin film of Molykote paste "G-Rapid Plus" to thread and nut contact face and tighten nuts (1) alternately in steps with a torque of M = 300 Nm 01 2.nn).02. Disengage the barring gear.02.01.01. Check the oil flow. Mount cylinder head cover (check gasket!).Rocker Arm Bracket Maintenance / Disassembly and reassembly M32 A5.8 Adjust valve clearance (01.01.7 2.5 2.2005 IB022290 2/2 .05. 01. en / 18.01 2.

Blow out oil bores with compressed air and check to ensure that they are clear. 1/4) and thrust washers (5) from the rocker arm shaft (3).05. Molykote paste may not be used for installing the bushings.05.01 30000 01.20 h skilled engine hand Heavy fuel and distillate fuel See also: Spare parts list: Time requirement: Personnel qualification: Operating medium: 01 ---------------------------------------------------------------------------------------------------------------------------------Maintenance: Disassemble intake and exhaust rocker arms and check bearing clearance every 30. Remove the intake valve rocker arm (1) and the exhaust valve rocker arm (2) from the rocker arm shaft (3).02.03.02. Procedure: 1.02.01.nn.02. 1. 01.nn B1./ 0.01.Valve Rockers Maintenance / Disassembly and reassembly M32 A5. 2. Clean all parts and check for damage.000 h Note: The liners may only be lubricated with oil.2001 IB022284 1/2 . 01.9.06. 1.2107 1 Pers. en / 12.2 Note: All additional maintenance work is identical for the intake and exhaust valve rocker arms.1 Disassembly Remove securing rings (Fig.

Reinstall the rocker arm bracket and rocker arms on the cylinder cover (01. Replace parts as necessary. 1/3) and replace the bush when the clearance meets or exceeds the wear limit (01.159 Wear limit (mm) 0. 3. New clearance (mm) 0.Valve Rockers Maintenance / Disassembly and reassembly M32 A5.01. Assembly Note: Rocker arm shaft must be undamaged and may have no burrs or scratches. 1/1) and exhaust rocker arms (2) and the rocker arm shaft and slide the rocker arms onto the shaft carefully.05. 2 /13) and shaft (Fig.02 .2001 IB022284 2/2 . 01 ~ 4. 01.02. Attention! Note and follow all safety instructions when handling liquid nitrogen.03.1 5. en / 12. Cool ball pins to -195 °C with liquid nitrogen and slide into place.nn) and check the oil flow through the components. Measure the rocker arm bush (Fig.02.02. 5.01 30000 Check the bearing surfaces of the ball pin (Fig.0. 2/10) and the adjusting screw (12) for wear and damage.nn).02.06.25 5.2 Oil the contact surfaces of the intake (Fig. Do not tilt the rocker arms.

1 2. en / 12.01 See also: Spare parts list: Time requirement: Personnel qualification: Operating medium: 01.02.05. Be careful not to damage the plastic coated contact surface.02.2107 1 Pers. Oil the new bush lightly and press into rocker arm.2 Measure the rocker arm bush (1) and (01. 0. 2.01.02. Attention: Note the position of the oil bores (2) and the separating joint (3) when pressing the new bush into place./ 0.40 h skilled engine hand Heavy fuel and distillate fuel 01 -------------------------------------------------------------------------------------------------------------------------------Tools: Copper punch * no picture W1 * Note: The liners may only be lubricated with oil.nn. Replace. The rokker arm must protrude past the liner (Z) s = ca.nn).nn B1.06.01.05. 2. Molykote paste may not be used for installing the liners. 01. Drive out the bush (1) with the proper copper punch (W1).02.9.03. 01.02.2 mm on both sides.2001 IB022287 1/1 .02. Procedure: 1.Valve Rocker Bush Inspection / Replace M32 A5.

1 Lubricate the valve rotator with some drops of lubricating oil/gas oil mixture (mixture ratio 1:1) if a considerable deceleration of rotation is detected in comparison to the new condition. 2.00 150 01. 1/1). 01. 2.01.05.07.11.05.01. Open lock cap of cylinder head cover and check valve rotation.03.nn.10 h See also: Spare parts list: Time requirement: 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: of the valve rotator every 150 h Note: Check the rotational speed of the valve versus engine speed when taking the new or repaired cylinder cover into service.Valve Rotator Inspection / Evaluate M32 A5.05. Attention: Do not apply too much lubricating oil/gas oil mixture.2107. Fig.01. the valve rotator must be replaced. B1. if a uniform engine speed-dependent rotation can be detected.1998 IB002320 1/1 . Use this rotational speed for further reference.nn B1.9. The valve rotator works properly. 01. See mark "X" on spring plate (Fig.00.01.1 If at nominal engine speed the rotational speed goes down to approx. Remedy: Inject a gas-oil/lubricating oil mixture drop by drop onto the valve stem.2225 1 Pers. Sequence of operations: 1. Danger of lubricating oil dilution! en / 02. n ≤ 1 min-1.10. Note: Deceleration of the valve rotation can also be caused by hard motion of the valve stem in the valve guide.9./ 0.

nn. clean stem thoroughly. 1.01. Lubricate new O-ring slightly and carefully place in groove. Fig.06. Remove the O-ring (Fig.01 15000 01.3 1./ 0.05. 01.2 Replacement of oil scraper rings (O-rings) Dismount valve cone. 1 en / 29. 1/1) from the groove with a sharp-angled wire.4 Clean groove.01.01.05.nn.20 h See also: Spare parts list: Time requirement: 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: of valve guide clearance of inlet and outlet valves after 15.01.01.1 1. 1 1 Attention: The O-ring is used to adjust the lubricant quantity and must only be replaced by a new original MaK spare part.2000 IB020926 1/2 .07. 01.Valve Guide / Oil Scraper Ring Inspection / Replace M32 A5. 01.9.02. The ring must not be twisted in mounting position.nn.nn B1.2107 1 Pers.000 h Auxilary material: Molykote paste "G-Rapid Plus"** ** or product of equal standard Sequence of operations: 1.01.01.05. 01. 1.05.

05.2000 IB020926 2/2 .11 . Measure the inside diameter of the guide bush in traverse direction of the engine.0.0.35 Measurement of the valve guide clearance Measure the outside diameter of the valve stem in the guide zone of the bush.35 0.17 Limit clearance (mm) 0. en / 29.Valve Guide / Oil Scraper Ring Inspection / Replace M32 A5. Replacement of the valve guide Note: If possible. replace the valve guide during cylinder head maintenance in the workshop of an MaK dealer. 2.01 15000 01 2. 01.24 0.18 . 0.2 2.05.01.1 2.3 Normal clearance (mm) Outlet Inlet 3.05. There is a risk of damaging the cylinder cover when the old valve guide is knocked out.

01.Media guiding system Maintenance / Disassembly and reassembly VM32 A5.1 Safety note: The system must be depressurized before assembly! Loosen the cheese head screws (fig.06.01. 01. 01. en / 20.2002 IB022850 1/4 .02.nn B1.01.05.51 See also: Spare parts list: Time requirement: 01. Disassembly ~ 1.25 h 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Auxiliary material: Vaseline * * or a product of equal standard Sequence of operations: 1.nn.01.50.9.05. 2/10) and disassemble the connecting flanges (fig./ 0. 3) together with the sleeves (11). 07.2144 1 Pers.03.nn.11.05. 1/2.

3).05.2 1.03.Media guiding system Maintenance / Disassembly and reassembly VM32 A5. Insert the O-rings in the grooves using Vaseline and making sure that they are not twisted! Check the gaskets (16) for the connecting flanges (2. Clean the sealing surfaces.50. 01. 3) as well as the gaskets for the connecting flanges (fig.3 Pull the sleeves (fig. 1/4 and 5) and the blank flanges (1). 01 1.05.2002 IB022850 2/4 . 2/11) out of the connecting flanges (2. Check the O-rings (15). Replace faulty O-rings (15).4 en / 20.51 1.

Replace O-rings (32).7 1.2002 IB022850 3/4 . Remove media block (31 and 35). 01 en / 20.Media guiding system Maintenance / Disassembly and reassembly VM32 A5.03.8 Pull the sleeves (fig.05.50. 3/30) out of the media block (31 and 35).05.6 1.51 1.5 1. 01. Replace O-rings (33) and clean all sealing surfaces.

2 and 3. Put the connecting flanges (4 and 5) onto the sleeves (30) and mount them. Mount the alarm probe.4 Reassembly Mount the connecting flanges (fig. Identification of the defective fuel delivery pipe in the event of a "leak fuel" alarm. Insert sleeves (30) with new O-rings (32). 2. Replace faulty gaskets (fig. leak fuel is found on cylinders 1.01. but not on cylinder 4.2 When a "leak fuel" alarm is given. remove the screw (fig.50. en / 20. Hinweis: Leak fuel can result from a defective fuel delivery pipe or a faulty gasket between the fuel delivery pipe/injection pump or the fuel delivery pipe/injection nozzle.3 Mount the screw (12) with a new gasket (13). refit the connector and dip the tip of the alarm probe into a medium. 2/16) beforehand. 01.1 4. 3. then replace the fuel delivery pipe for cylinder 3 ((07. 3/31 and 35). 2/2 and 3) with inserted sleeves (11).1 2. Replace faulty gaskets (16) beforehand. Check the bore in the connecting flange (2) for leak fuel. If. acknowledge the alarm and. If an alarm is triggered. beginning with cylinder 1. 01 Attention: Make sure that all gaskets (16) are centred properly by the dowel pins (17)! 3. 3/20). for example. 1/1).2002 IB022850 4/4 .05. 2/12) with gasket (13) on each cylinder. If no alarm is triggered. 3. 4.3 2.2 2.nn). Dismantle the alarm probe.02. acknowledge it.51 2.1 Functional check of the alarm probe for leak fuel (fig. Replace faulty gaskets (16) beforehand.2 4.05. Mount the blank flanges (fig. replace the alarm probe and repeat the test. 4. Mount the media block (fig.Media guiding system Maintenance / Disassembly and reassembly VM32 A5.03.

9203-112 0.01.nn. The devices are to be stored protected against corrosion.05.9.9203-221 0.9203-110 9.01.9213 C 0.Cylinder Head Maintenance / Disassembly VM32 A5.01. remove cylinder head cover and pump covering.9203-004 0. 3.01.nn B1. Use only hydraulic oil. set of devices consisting of High-pressure pump High-pressure hose (1 m) Hydr. turn the piston to top dead center.01.06.01. Secure the engine against accidental starting.50 h 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Hydr.9205 B 0.05.nn.nn. 06. Drain the cooling water: Close the stop cocks of the corresponding cooling water feed lines and open the corresponding stop cocks of the drainage lines.9203-211 0. 03.06.9221 D Attention: The actual bending radius of the high-pressure hoses must not fall below the minimum bending radius r = 120 mm. Safety note: Do not place any parts of the body over pressurized devices.2107 1 Pers. 4. en / 30. 1/3) of the respective cooling water distributor housing and drain the residual cooling water.02.9204 D 0.9203-106 0. ~ 1.2002 IB023645 1/5 .51 See also: Spare parts list: Time requirement: 01.01. Loosen the connecting flange (1) / blank flange (2) of the media guide of the cylinder head which is to be dismantled and remove if necessary. 02. 01.04. Sequence of operations: Open indicator valves.01./ 0. jack Distributor Support ring Threaded sleeve Support ring Threaded sleeve Pin Eye bolts M16 (3x) Cylinder head lifting device * not available as figure W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 * 0. Loosen the screw plug (fig. 2.

7. Loosen clamp ring on the exhaust pipe (06. Loosen the six cylinder head nuts with the hydraulic tightening device. 8.01. Disassemble rocker arm bracket (01.nn). the complete rocker arm bracket must be disassembled.51 01 5. 01.06.05.nn). 3/10) must not be project above upper edge of the cover.01. Loosen the union nut of the fuel delivery pipe on the injection pump. Remove covering cap between exhaust pipe and cylinder head. en / 30. Loosen union nut of nozzle holder one turn and turn 90° to the right.Cylinder Head Maintenance / Disassembly VM32 A5.01.01. 6.01. Note In order to avoid damages and ensure trouble-free assembly and disassembly.02. Attention: Stroke limit indicator (Fig.2002 IB023645 2/5 .

3/12) with pin (W9).Cylinder Head Maintenance / Disassembly VM32 A5.5 mm of the threaded sleeve to top edge of jack (W3) has been reached. Screw threaded sleeve (W6) onto cylinder head screw (11) until a step S = 3. Turn round nuts back by at least eight holes.05. 01 8.01.6 8. 2/W3) connected with support ring (W5) and threaded sleeve (W6) over round nut (Fig.7 Loosen round nuts (Fig.3 Place hydraulic jacks (Fig. en / 30. 2/W3) connected with support rings (W7) and threaded sleeves (W8) over round nuts (Fig. Make sure the slits (13) are easily accessible.5 Connect hydraulic jack (Fig.2002 IB023645 3/5 .51 8.01.2 8. Screw threaded sleeves (W8) onto cylinder head screw (11) until a step S = 3. 3/12) setzen.5 mm of the threaded sleeve to top edge ofjack (W3) has been reached. 4/W3) and distributor (W4) to high pressure pump (W1) via high pressure hoses (W2).1 Place hydraulic jack (Fig. Make sure the slits (13) are easily accessible. 01. 3/12).4 8. Close valve (Z) on high-pressure pump (W2) and extend all six cylinder head screws simultaneously and stepless with a hydraulic pressure of p = 850 bar 8.06. 8.

In the case of a further pressure increase. there is a risk of the round nut getting stuck due to the expansion of the bolt thread. remove hydraulic devices and unscrew round nuts.51 Note: If a loosening of the round nuts is not possible.01.8 Relieve jacks. 01 8.01. then the pre-stressing of the cylinder head screw can be increased by 50 bar.Cylinder Head Maintenance / Disassembly VM32 A5. en / 30.06.2002 IB023645 4/5 . 01.05.

fuel delivery pipe and charge air connecting piece.01. 01.06. 10.2002 IB023645 5/5 . 5/W10)into the cylinder head and attach to the lifting device (W11). pushrods. cylinder head screws. Screw the eye bolts (Fig.51 9. en / 30.Cylinder Head Maintenance / Disassembly VM32 A5.01. Place the cylinder head on wooden base. Lift the cylinder head with crane.05. Pay attention to pushrod guide! 01 Attention: Risk of damage to transfer ports.

/ 0.06.05.07.9.9220 C 1.9023-017 Auxiliary material: Vaseline ** Adhesive and sealant “ Loctite 510 “** ** or a product of equal standard 5* Sequence of operations: 1.50 h See also: Spare parts list: Time requirement: 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Replacement of O-rings every 15. Place wrench (5) with bush (6) on nozzle sleeve (1) so that nozzle sleeve and wrench (5) are engaged. 01. consisting of: wrench bush torque wrench 100 .nn.00 15000 01.1 Dismount nozzle sleeve (1). Attach torque wrench (W4) with reducer (W5) and extension (W6) to wrench (5) and unscrew nozzle sleeve until the threads of nozzle sleeve and cylinder head (2) are exposed.9454-400 1. 07.2107 1 Pers.01. 1.Nozzle sleeve Maintenance / Disassembly and reassembly M32 A5.2 2 * = W1 en / 30.nn B1.000 h Tools: Dismounting and mounting device.05.400 Nm reducer extension brass mandrel * no illustration W1 W4* W5* W6* W7* 9.2007 IB020933 1/2 .06.50.01.01. 6* 3 4 1 1.05.

insert O-ring in groove (3) and make sure the O-ring is not twisted.06. Attention: Do not exchange the position of the O-rings. Mount the nozzle sleeve (1). Apply a film of vaseline to the new green O-ring. en / 30. Apply a film of vaseline to the new blackish brown O-ring.4 Apply a film of “Loctite 510 “ to the threads of the nozzle sleeve.3 1. 01. 01 1.2 Use a brass mandrel (W7) and carefully drive out the nozzle sleeve. 2.3 2. Remove O-rings (3 and 4).05. 2.50.Nozzle sleeve Maintenance / Disassembly and reassembly M32 A5.2007 IB020933 2/2 .1 2. Insert the nozzle sleeve and tighten it by means of wrench (5) at a torque of M = 300 Nm. observe the mounting instructions.05.00 15000 Attention: The threads of nozzle sleeve and cylinder head must be exposed.insert O-ring in groove (4) and make sure the O-ring is not twisted.4 2.

70.000 h Auxiliary Material: High-temperature thread paste “Dag S 5080“ * * or a product of equal standard Sequence of Operations: 1. Remove cover (2). en / 09./ 0.2001 IB023036 1/2 . 2.05.00 30000 01.01.nn B1.2107 1 Pers. 01.9.20 h See also: Spare parts list: Time requirement: 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Replacement of relief valve every 30.01.Relief Valve Maintenance / Replace M32 A5.03.06.05. Unscrew hexagon nut (1).06.

Mount new relief valve (3) with new joint ring (4). Firmly tighten the relief valve by means of a wrench. 5.Relief Valve Maintenance / Replace M32 A5. 01 en / 09. 3. In doing so mind disc spring (5). 8. Firmly tighten hexagon nut (1).03. Lubricate the thread of the new relief valve with high-temperature thread paste “Dag S 5080“. 01.00 30000 Slacken relief valve (3) by means of a wrench and remove it.70.06. 7. 6. Mount cover (2).05. 4.2001 IB023036 2/2 .

50 h See also: Spare parts list: Time requirement: 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: of the in and outlet valve cones of a cylinder unit as regards contact reflection and deposits after 7.01.02 15000. Dismantle rocker arm (01.500 h Maintenance: of all in and outlet valve cones after 15.nn) and lift valve bridge.02.2 Disassembly Dismantle cylinder head (01.08.06.2001 IB022833 1/2 .9222 A Auxiliary material: Molykote paste "G-Rapid Plus" ** ** or product of equal standard Note: The service lives of the valve cones depend on the fuel quality.03. en / 22. if necessary.01.08.nn.05.nn). 01.08. remilled. Sequence of operations: 1.02. 01.01.nn.nn). 7500 01.01.05.01.In and Outlet Valve Cone Inspection / Disassembly and reassembly M32 A5. every time the valve cones are dismantled (01.05.nn B1.1 1.01./ 0. 1.000 h Tools: Valve spring clamping device W1 9.01. 01. 01.06.01. 01. For this reason the user must stipulate the repair intervals depending on the conditon of the inspected valve cones.2107 1 Pers. The seat geometry is to be checked.nn.9.02.07.nn. operating conditions of the plants and the quality of the repaired valve cones/seat rings and therefore differ from plant to plant.01.

2001 IB022833 2/2 .05. Note: Valve cones with signs of heavy wear in the clamping area as well as cone clamp halves on which heavy burr has formed must be replaced by new parts.08. Carefully unload valve spring (3). 1.07.02.8 1. renew O-rings (01. Repairing valve cone/valve seat (01.4 01 Note: The receptacle of sleeve (5) must engage in the groove of valve stem (9) 1. After putting in the cone clamp halves.5 Coat the contact surface (X) of the valve spring clamping device (W1) with „G-Rapid Plus“Molykote paste before use. Remove circlip (10). 7500 Screw off clamping sleeve (5) by hand until it can be placed on valve stem (9).08. 1. valve spring (3) as well as the valve turning device or valve spring disk from the cylinder cover. spring plate (2).9 Safety note: Spring tension Lift off valve spring clamping device (W1). Screw down by hand clamping sleeve (5).01. 01. The re-assembly is effected in a reverse dismantling sequence.3 2.01.02 15000. Lubricate burr-free valve stem before fitting and put in valve cone screwing so that the O-ring is not damaged.nn). en / 22.In and Outlet Valve Cone Inspection / Disassembly and reassembly M32 A5.nn).4 Reassembly Check valve guide clearance.nn/01.03. Compress valve spring (3) and remove cone clamp halves (4).7 ~ 1.1 2. 2.6 1.3 1.2 2. 2. Place valve spring clamping device (W1) on spring plate (2) and with the clamping screw (6) fit the clamping block (7) into the clamping sleeve receptacle (8). Projecting burr must be removed before dismantling such valve cones.01. slowly unload the valve spring and make sure that the cone clamp halves are sitting properly. Pull valve cone out of cylinder head.05.

9.00 See also: Spare parts list: Time requirement: 01. using illuminated magnifying glass (8-fold magnification) or powderspraying procedure (Met L'Check) and/or in the flux procedure.nn.02. damaged sealing faces. Sequence of operations: 1.08. 1.01.08.1 Checking of condition Valves may be reused without refinishing when • the circumference of the valve cone face is bright metallic • the valve cone face does not indicate carbon pockets with blow holes • by inspecting cracks. Refinishing of the valve cones (according to operating sequence 3) may be necessary in the following cases: • • after extended operating times.00 h 01 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Valve refacer W1 6.g. 01.2107 0 Pers.9224 B Auxiliary material: Diamond paste Dp 30/10 . in case of negative result.07.1998 IB002338 1/5 . uneven contact reflexions of valve cone/seat.nn B1.01. no crack formation is established at the valve cone face. 01.05. e.Valve Cones Repair / Checking M32 A5. deep scars.15 µm * Thinner F25 * * or a product of equal standard Note: New or refinished or undamaged used in and outlet valve cones are to be ground before mounting in accordance with operating sequence 4.05.02./ 0. en / 02.01.

08. blowholes) exceeds • the wear caused by corrosive material >2% of the valve head diameter (compare with new valve) • concave burns "s" caused by high temperature corrosion on the underside of the valve head exceeds > 1.1998 IB002338 2/5 . 2 indicates severe pitting (formation of socalled "paving stones") in zone of the valve stem.05.08 AB 20 20 A s 0. the stem transition and valve head s • the underside of the valve head • corrosion pits and mechanical damage • excess of limit dimension for refinishing.04 0. 1). Measuring range "s" = 390 mm A B 01 = contact points for test device • when the radial runouts of the valve cone do not exceed the following values: — 0. en / 02. 01.02.01. 1 1. 2) Fig.Valve Cones Repair / Checking M32 A5.03 AB B — 0.00 • when the deviation from the straightnesss does not exceed the following values (Fig.006 Fig.5 mm (Fig.2 The valves cannot be reused in the following cases • the valve cone face is damaged (cracks.

nn). inlet valve). 3).08. 3a 3. 3.2 = Fig. The valve cone is to be resplaced when the actual dimension falls below the minimum dimension (Fig. 3a Fig.g. Cleaning with sharp-edged tools as well as pickling with inorganic acids (hydrochloric acid. The dimension between the visible edge of the base metal arm ring "X" and the outer edge of the seat is to be determined upon completion of the grinding process. Fig.Valve Cones Repair / Checking M32 A5. sulphuric acid etc. 3.) is not allowed.1998 IB002338 3/5 . 3 = Fig. 3 The appropriate information of the grinding machine manufacturer is to be observed when grinding is carried out.3 3. 3. outlet valve.1 Regrind sealing surface in accordance with the prescribed angle (Fig. Do not refinish existing concave fillets.01. en / 02.08. Repairing (refinishing of the sealing surface) Note: In all cases the refinishing must be carried out professionally on precision spindle grinding machines. Fig.05. 3a. If no such machine is available. blasting with glass beads.02.02.00 01 2. Cleaning Clean the valve spindles e. Outer edge rounded with stone. Outlet valve cone Inlet valve cone 3.4 Attention: When the valve cone is refinished. the valve seat ring must also be refinished (01. the valve cones should be taken to a MaK workshop for regrinding. 01.

Insert the lubricated valve stem into the guide.Valve Cones Repair / Checking M32 A5. 4). 4. 4 Fig. Fasten the device (Fig.02. 01. 6/a) which is visible due to the light grinding process should not exceed 30 .00 01 4. 5 en / 02.1998 IB002338 4/5 . The contact reflexion (Fig.1 Maintenance (Checking contact reflexion/grinding) Apply small dots of diamond paste Dp 30/ 10 .08.2 Fig.01. the seat ring surface is to be sprayed with a thinner (F25) belonging to the diamond paste for dilution and in order to increase the grip.50 % of the seatwidth "b" starting from the outside diameter.05.15 µm with a syringe to the fitting surface of the new or remachined valve cone and distribute the paste evenly (Fig. 5/W1) to the valve head and grind the valve cone face and seat by hand applying a moderate pressure. Thereafter. rotating the device. 4.

3 When the contact reflexion is poor. 5.05. Clean valve cone/seat thoroughly and check the sealing surfaces with an illuminated magnifying glass (8-fold magnification) for cracks in the armouring and in the adjacent area.00 01 4. 01.Valve Cones Repair / Checking M32 A5.2 a b a Fig.4 5. both sealing surfaces are to be refinished by machine. 6 en / 02.02. however.1998 IB002338 5/5 . Final check Ensure that the refinishing limits are maintained. the valve must not be reground anymore.1 5. Ensure that the components (valve cone and seat ring) refaced to one another stay together. 4.01.08.

01. both sealing faces must be refinished.2001 IB002340 1/5 .05.9224 YY 9.nn. 01.2107 0 Pers.g. 01.07.08.07.00 h 01 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Precision seat grinding machine Valve seat milling machine * not available as figure W1 * W2 1.02. deep scars.15 µm ** Diluting agent DIAPLASTOL ** ** or product of an equal standard Note: In the case of irregular contact reflexions or scars being shown on the sealing faces of valve seat/ valve cone.9224 A Auxiliary material: Illuminated magnifying glass (8-fold magnification) Diamant paste Dp 30/10 .00 See also: Spare parts list: Time requirement: 01. e. en / 05./ 0. 1 and 2).nn B1. New or refinished valve seats are to be ground in accordance with operating sequence 4. uneven contact reflexions of valve seat/cone (Fig.05.9.08.Valve Seat Ring Repair / Checking M32 A5.01.01. damaged seat face. Refinishing of the seats may be necessary: • • after extended operating times in case of negative result.

2001 IB002340 2/5 . Carbon desposits are therefore a normal indication and not hazardous if good cooling is present (Fig. with regard to the valve cone. en / 05. Checking of condition The hardness of the valve seat is designed in such a manner that a certain adaptability is present.08.07.05.00 01 Sequence of operations: 1.Valve Seat Ring Repair / Checking M32 A5. 4 and 5). 3.02. 01.

Unnecessary material removal is to be avoided.1. • cracks are present in the seat face • burn holes are present • the refinishing limits have been exceeded.02. Insert centering disk (4) with guide mandrel (5) and tighten with star handle (6). 3. en / 05.2001 IB002340 3/5 .08. 01.2 The valve seat rings are not re-usable when spraying procedure (Met L'Check) and/or in the flux procedure no crack formation is established at the seat face. hard touchdown can also damage the valve seat face. carbon pockets are only to be repaired. cutters are sensitive to impact.00 1.05.Valve Seat Ring Repair / Checking M32 A5. if they are present in the contact area.1 3. 2.1.2 Remilling of the valve seat Clean the valve seat ring thoroughly in the contact area (3) of the centering disk (4) in order to ensure an absolutely centrical fixing of the guide mandrel (5). Refer to special operating instructions. Alternatively.1 The valve seat rings are re-usable without refinishing when 01 • the circumference of the seat face is bright metallic • no carbon desposits with blowholes or visible wear are present • by inspecting cracks using an illuminated magnifying glass (8-fold magnification) or powder1.07. 3. Maintenance (refinishing of valve seat rings) Note: Remachining is to be carried out professionally with the MaK precision seat grinding machine (W1). 6/W2).1 3. Remove O-ring from guide bush. Attention: Handle the cutter head (2) with care. Cleaning Remove residues from the seat faces. the seats may be refinished by means of the MaK valve seat milling device (Fig.

1.1.5 Prior to finishing the cutting process. 01 3.2 a = no material removed Outlet valve seat ring Inlet valve seat ring = Fig. 7): 107+0. 7 = Fig. screw in knurled screw (1) until resistance can be felt. 6/2) on greased guide mandrel.2001 IB002340 4/5 .00 3. Set the contact pressure according to touch.1.02. 6 Fig. slowly unscrew the knurled screw (1).4 Attention: The machine will rattle when the contact pressure is too low and/or the cutting speed is too high. Rotate valve seat clockwise uniformly and slowly and remill the seat in one operation pass. at the same time rotating the cutter head. 7a Fig.6 Maximum permissible dimension Ø (x) for refinishing (Fig. 3. The cutting of the cutters has to be noticeable.1.08. 01.07. 7 Fig. 7a en / 05.05.3 Place cutter head (Fig.Valve Seat Ring Repair / Checking M32 A5. 3.

01. Grind sharp edges with fine emery cloth.Valve Seat Ring Repair / Checking M32 A5.01. Fasten the device (W1) (01. 01. the cutter head is to be sent to the MaK for refinishing.08.7 3. Thereafter.08.08. Ensure that the components (valve cone and seat ring) reface to one another stay together.50 % of the circumferential seatwidth "b" starting from the outside diameter (01. spray the total surface of the seat ring with diluting agent DIAPLASTOL (01. the valve must not be reground anymore. Final check Check whether the refinishing limit dimensions are observed.2 When the contact reflexion is poor.08. 4. The contact reflexion "a" which is a visible due to the light grinding process should not exceed 30 . however.01.02.3 4.15 µm with a syringe to the seat face of the new or refinished valve spindle and distribute the paste equally.00 01 3.1. rotating the device. 5.2 en / 05. 4.8 4. both sealing faces must be refinished by machine.2001 IB002340 5/5 .05.nn).nn) to the valve head and grind the cone and seat by hand applying a moderate pressure.1 5.07. Checking of contact reflexion/grinding Apply small dots of diamond paste Dp 30/10 . Clean valve cone/seat thoroughly and check the sealing face with an illuminated magnifying glass (8-fold magnification) for cracks in the arm ring and in the adjacent area. Insert the lubricated valve stem into the guide bush.1.nn). 4.4 5.1 When the milling cutters are blunt. Dismount the milling device.

Connect cone and seat ring with welding bead around total circumference (electro welding unit).9./ 1.05. Insert the valve cone into the valve seat ring and hold in the shown position. with a serated disk (260).02. Clean the bore where the new insert is to be fitted by hand using a 120 grain emery cloth or in the case of heavier fouling. Fig. 1/1) and bevel the resulting cutting surface (2) to avoid buckling. Turn valve head to approx.nn B1. the cylinder head to 130 ° C. 83 mm (inside diameter of seat ring). 01. Shrink the new seat ring in. 4.07.1998 IB002354 1/2 .08.02.nn.9222 C Auxiliary materials: Diamond paste Dp 30/10 .01.01.01.1 en / 02. Grease cylinder cover bottom outside of seat ring in order to prevent damage by spraying of welding beads.06. 01.Valve Seat Ring (Inlet/Outlet) Repair / Replace M32 A5.00 See also: Spare parts list: Time requirement: 01.nn. Drive the valve seat ring out by striking the valve spindle forcefully. Cool the seat ring to at least -20 ° heat C.05.03.15 µm * Molykote paste “G-Rapid“ * * or a product of equal standard Sequence of operations: 1. 01.2107 1 Pers. Cut off the unusable valve cone at the shaft end (Fig. 4.00 h 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Pressure applying device W1 9. 3. 1 1 2 2.08.

2/1) with Molykote paste “G-Rapid“. Grind the valve cone lightly with diamond paste Dp 30/10 .2 Carefully insert the seat ring with the help of a valve cone to the bottom of the cylinder head bore by means of light hammer blows.nn). Tighten nut (1) with M=150Nm .05. e.g. 2 en / 02. Slightly refinish the seat ring. 01. 01 5.08. W1 1 Fig. 6.15 µm and check the contact reflexion (01.00 4. hold the seat ring in this position with the pressure applying device (W1) until the cylinder head has cooled down.08. Slightly grease thread and contact face of nut (Fig.02. Fit valve cone.03.02.Valve Seat Ring (Inlet/Outlet) Repair / Replace M32 A5. with valve seat grinding machine or valve seat milling machine.1998 IB002354 2/2 . After that.

en / 29. Tighten fixing screws (1). Note: Do not move spindle (5) by turning locknut (6). the treatment / dehumidification of the starting air should be checked. bank A all 1. vent lines.09. The piston and spindle should move freely when doing so. Push down piston (4) and spindle (5) approx. 01./ 0. Ensure that the piston und spindle return to the original position quickly and easily. block start valve. Loosen fixing screws (1) and remove cover (2) with sealing ring (3). 2.05.01.9.01. lubricate the piston (4) and guide in the cylinder head with engine oil.01.Starting Valve Inspection / Checking M32 A5. Fit cover (2) with new sealing ring (3). 4. 7 mm using the handle of the hammer.20 h See also: Spare parts list: Time requirement: 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Check: Check starting valve for easy movement For V-engines only on cyl.00 1500 01. rust.01. dirt or other soiling between the cover (2) and piston (4). If the parts do not move freely. Note: If there is moisture.2000 IB020953 1/1 . Procedure: 1. 1 2 3 6 4 3.500 h Attention: When performing work on starting system close main valves on compressed-air bottles.05. 5 5.05.nn B1.2107 1 Pers.

01.9224 C Aid: Molykote paste "G-Rapid" ** ** or equivalent product Attention: When performing work on the starting system close main valves on compressed air bottles. 01. 01.50 h See also: Spare parts list: Time requirement: 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Remove starting valves. dismantle and if necessary.11.nn.01./ 0.nn B1.05. Procedure: 1.06.03 15000 01.9.9227-001 9.02. block start valve and engage turning unit.09.2107 1 Pers.05.Starting Valve Maintenance / Disassembly and reassembly M32 A5. en / 29.1 1. vent lines.2000 IB020969 1/3 .000 h Tools: Insertion ring for starting valve piston Starting valve reseating tool * not shown W1 * W2 9. 1.01. 1/10) and remove cover (1) with sealing ring (2).05.2 Disassembly Loosen fixing screws (Fig. regrind every 15. Loosen locknut (3) while holding valve spindle (4) with spanner.

Loosen adjusting screw (20) on reseating tool (W2). spring block (8).6.2000 IB020969 2/3 .4 1. Then tighten adjusting screw another 1/4 turn to set cutting pressure. Carefully clean all parts in gas oil. Tighten adjusting screw (20) until a slight resistance is felt.6. Rework starting valve seat with reseating tool (Fig. and valve spindle (4) from cylinder head. Check step piston (6). Insert reseating tool in valve guide and fix with spanner (21).Starting Valve Maintenance / Disassembly and reassembly M32 A5.09.05.6. 1/5).3 1.5 1.05. sealing rings (11) and valve seat (9). Carefully clean valve seat and guide of valve spindle. 1.1 1.02. 2/W2).2 1.6 1. Carefully smooth of scored step piston (6) with fine emery cloth. spring (7).03 15000 Remove disk (Fig. 01.3 01 21 20 W2 2 en / 29. step piston (6). Lightly oil valve canon.

6. repeat steps 1.5. ° If the appearance of the bearing surface is not satisfactory. To do so.1 2.6. 2. apply a thin layer of try-out paste to valve spindle. 01.Starting Valve Maintenance / Disassembly and reassembly M32 A5.05. 3/X).02.09. distribute ring joints evenly around periphery.2 Assembly Lightly rub in Molykote paste "G-Rapid" on step piston.6. 1.6.03 15000 Turn reseating tool evenly and slowly without additional pressure.5 1. Press valve spindle onto valve seat and turn through max. Replace sealing ring (2). 90°.05. Maximum size for rework (Fig. Tighten locknut (3) until a frictional connection between the valve spindle (4) and locknut (3) is obtained.4 01 1.6 2. Check using ° M = 50 Nm en / 29. Insert piston using insertion ring (W1).6. Repeat process until valve seat is clean.2000 IB020969 3/3 . Turn reseating tool evenly and slowly without additional pressure. Then tighten with a rotation angle of 45°. Repeat process until valve seat is clean.1 to 1.

07.01.00.nn). 1 en / 02.11.01. Observe conformability of valve movement.01. 2.Cylinder Head Inspection / Checking M32 A5. In case of lubeoil leakage. In case of leakage at the wedge parts of the media supply.01.06.nn). If a proper sealing cannot be obtained. 07. remove cylinder head .05.02.1998 IB002636 1/1 .01.clean sealing surfaces and check .05. cylinder liner and cooling water distributor housing at the inspection hole (1) for combustion gas leaks or cooling water leakage.01.9.11. Check the gasket between the cylinder head.nn. Check lube oil supply of valve lever and valve lever bearing. 3. In the case of leakage.10. check the retaining screws of the cylinder head cover for tightness and check profile rubber for damage. Irregularities can be seen better at low engine revolutions.2 3.nn.nn B1.3 3. if necessary and tighten according to regulation (01.1 3. loosen the cylinder head screws and tighten again according to regulation (01. Check function of the valve rotating device (01.nn).1 2.nn.03. Check valve springs for damage.01.11.50 h See also: Spare parts list: Time requirement: 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: of all cylinder heads every 150 h Sequence of operations: 1.replace with new O-rings. Remove cylinder head cover. 2.06. check retaining screws for tightness.03.2107 1 Pers. 01.01 150 01.01. 01.4 Check cylinder head externally for leakage.2 3. 01. 01.01. Replace seals if necessary. inspect cylinder head upper side./ 0.nn.

2000 IB020982 1/1 . especially at the valve webs.05. Sequence of operations: The following parts have been removed: Inlet valve.05.01. Do not damage seat recess.00 h See also: Spare parts list: Time requirement: 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------Note: Put the cylinder head bottom only on a wooden base. 3./ 1. 7.01.9.01. starting valve and rocker arm bracket. 01. 5. Clean the sealing surface for the injection valve. 1). for cracks. 2. en / 29. (especially leak fuel of pressure pipe monitor) Check the function of the alarm probe for fuel leakage in the distributor plate at the connecting piece of the media supply (cyl.Cylinder Head Maintenance / Cleaning M32 A5.09.2107 1 Pers.01 15000 01. injection valve.nn B1. 1. 01.nn.06. Check in and outlet holes of the media supply for free passage. Clean the inlet and outlet ports and the cylinder head underside (not the valve seats!) of carbon deposits with a wire brush or scraper. 6.02.01.nn. 01. Wash the cylinder head with a cold cleaner.05.10. Clean cooling water inlet ports and cooling water outlet.07.nn. outlet valve.01. 01. 4. Check underside of cylinder head.02.

01.05.11.01.nn.04.06. ~ Safety note: Do not place any parts of the body over pressurized devices.01.2002 IB023653 1/5 . Auxiliary material: High temperature bolt lubricant "Dag S-5080" * Molykote lubricant "G-Rapid Plus" * Vaseline * * or comparable product Caution: Do not exceed the minimum bending radius r = 120mm of the high pressure hoses. 01.nn.nn B1.9.2107 1 Pers.01. en / 30.01. 03.05./ 1.00 h 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: See maintenance sheet 01.06.nn. 06.01.01.Cylinder Head Repair / Reassembly VM32 A5.01.51 See also: Spare parts list: Time requirement: 01. Use only hydraulic oil as operating medium.

11. at the control air inlet and at the charge air inlet port (5). 01 en / 30.01.Cylinder Head Repair / Reassembly VM32 A5.nn).01.51 Sequence of operations: 1. 2.05. 01.2002 IB023653 2/5 . Check and clean sealing surface on exhaust pipe (06. Renew the following O-rings. Turn piston to ignition top dead center. on the cylinder head (3). 3.01. at the pushrod sleeve (4). Upper O-ring on cylinder liner collar (2).01. Insert new sealing ring (Fig. 1/1) into cylinder liner collar. at the cooling water connection to the starting air inlet. Clean sealing faces and contact surfaces of cylinder head and liner thoroughly and check for damage.

01. Caution: The indicator max.1 Install hydraulic pulling elements (Fig. 2 / W3) connected to backup rings (W5/W7) and threaded bushes (W6/W8) over round nuts (Fig.01.Cylinder Head Repair / Reassembly VM32 A5. 6.51 Note: Coat all O-rings with petroleum jelly or green soap and insert in the grooves without twisting.2002 IB023653 3/5 . Grease screw with high temperature bolt lubricant "Dag S-5080" and tighten by hand (no seal). Align connections for cooling water and starting air vertically in cooling water distributor housing and check completeness. 3/12). Tightening of the six (6) cylinder head screws together with the hydraulic tightening device. 3/10) should not project above cover upper limit. To do this.11. 6.05. Insert pushrods into cylinder head. Ensure good accessibility of slots (13) Install threaded bushes (W6/W8) on cylinder head bolts (11) finger tight.2 en / 30.01. 4. stroke (Fig. Caution: Before using the hydraulic equipment. install the round nuts (Fig. 3/12) with pin (W9) alternately fingertight. 01.01. 01 5. Mount clamping ring for exhaust pipe and hook in chain links (06. take care that the cylinder head is resting firmly on the cylinder liner. Ensure correct positioning towards rocker arm.nn). Carefully place cylinder head onto cooling water distributor housing using cylinder head lifting device (W11) and lifting gear. 6. Align cylinder head. Failure to do this can cause damage to the hydraulic equipment.

6 Tighten round nuts (Fig.51 6.01. otherwise a pulling error could occur.2002 IB023653 4/5 .4 Connect hydraulic pulling elements (Fig. 4/W3) and distributor (W4) to high pressure pump (W1) via high pressure hoses (W2). 3/12) with pin (W9). en / 30.3 6. 01. Make sure parts move easily. 6.01. Close valve (Z) on high pressure pump and extend all six cylinder head screws simultaneously and steplessly with a hydraulic pressure of p = 850 bar. 01 Caution: The pressure must remain constant when the pump is not used.5 6. Check the firm positioning of the round nuts. • reduce pressure by 50 bar. • it should no longer be possible to loosen the round nuts with the pin.7 Unload hydraulic pulling elements and dismantle.05.Cylinder Head Repair / Reassembly VM32 A5.11. 6.

nn) and mount pump compartment paneling.01. Venting at cooling water return flow pipe from turbocharger.01.01.05. 13. 11.nn).01. Check sealing of all connections after bringing engine into service.11.01. Tighten clamping ring for exhaust pipe.01. Make sure the tension pins are properly positioned.02. 01.51 7. 12. 8. 01 en / 30. The position of the clamping ring is fixed at the lower part by a retaining screw (06.nn). Mount the removed connecting flange of the media supply with new seals.2002 IB023653 5/5 . Assemble rocker arm bracket (01. Connect fuel pressure pipe with corresponding injection pump. 10. Adjust valve clearance (01. 9.01.Cylinder Head Repair / Reassembly VM32 A5. Insert the pushrods into the cylinder head. Mount the removed pressure gauge lines and fill up with cooling water. 14.

1 7. Check cylinder liner surface on engine side.01. 02. bearing metal particles.01. Check seals of all crank case and sealing lids and refit cover.03. corrosion.01. en / 28. Check crankshaft bearings and big end bearings for even and normal temperatures. cloths etc.08.05. Check lubricating oil flow for camshaft bearing and valve mechanism.01. 4./ 0.nn). The remaining tasks are to be carried out after allowing a period of ventilation.nn. Turn engine and check bearing surfaces of cams and rollers for scoring. 2.2 8. pitting or other damage. 7.1112 1 Pers. Sequence of operations: 1. 6.01.08.01.10. Open crank case cover approx.01. 10 min.nn B1.2003 IB020989 1/1 . Remove camshaft cover. Check screws of camshaft components and the lower valve mechanism for proper tightness. Carry out lubrication oil flow check and check oil delivery at bearing points. Check extent of soiling of the engine room (silt deposits.9.50 h See also: Spare parts list: Time requirement: 02 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Note: The temperature check for the bearings must be carried out with the engine at operating temperature after switching off the circulation system lubrication. 3.05. Open indicator valve and engage turning gear. 5. Check oil tray and crank case for left-behind tools. after shutting down the engine. Check wheel mechanism (04.nn. 04. detached paint).Running Gear / Engine Timing Inspection / Checking M32 A5. 01.01. Visually check screws and nuts.00 3750 03. 9. 7.

In the event of unpermissible changes. the installation must be realigned and the respective main bearings inspected. the rigidness of the foundation and the ship.01. Measurements should therefore be carried out when the engine is warm.1998 IB002366 1/4 . Depending on the location of the engine. 1).03.05.00 h 02 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: Measurements are to be carried out in the following cases: When there is suspicion or danger of deformation of the foundation.02. e.02.02./ 1. not in dock! Changes that suddenly appear or appear after a longer period under otherwise uniform conditions point to a deformation or subsiding of the foundation. with normal loading and even keel. 02.Crank Web Deflection Inspection / Measuring M32 A5.05.2520.g.1110 2 Pers.9.00 See also: Spare parts list: Time requirement: B1. Tools: Crank web measuring device W1 1.05. It is therefore suggested to collect the measurement sheets extra so that the chronological allocation of the values and changes are visible.: • after the collision of a ship • signs of the foundation subsiding • bearing or crankshaft damage • before and after docking of a ship.9. different values are given in comparison with loaded and unloaded condition of the ship as well as warm or cold engine. a) Initial position b) Negative deflection c) Positive deflection en / 02.9425-300 Note: Crank web deflection is the change in distance beween a web pair during one rotation of the crankshaft (Fig. B1.

Crank Web Deflection Inspection / Measuring M32 A5.TDC) (crank pin . 02 2.exhaust side) (crank pin .02. 02. 4.BDC camshaft side) en / 02. then at the stipulated measuring point. 2 1 2 3 4 5 = = = = = 1st measuring point 2nd measuring point 3rd measuring point 4th measuring point 5th measuring point (initial positon) (crank pin .01.00 Sequence of operations: 1. do not place the measuring tips on the centring marks. the purpose of the latter is only to indicate the space in which to use the measuring tips.camshaft side) (crankshaft pin . Watch the gauge continuously and read the values at the measuring points 2 .05. Turn the crankshaft. 2/1st measuring point).1998 IB002366 2/4 .5 . 3. If a higher value is read before or after the measuring point. Set the pointer to the scale value 20 on the measuring gauge: 1st measuring point (initial position).02. so that the crank pin turns in the direction of the exhaust side and the gauge towards the camshaft side. Where punch holes are found. Turn the crank pin from bottom dead center in the direction of the exhaust side so that the measuring gauge is placed as far out as possible between the webs and the con rod just passes the gauge (Fig. Fig. record this value.

00 Note: Crank web deflection is primarily a criterion for the alignment of the engine with the shafting.04 mm en / 02. The values given below must be observed if it is impossible to obtain the permissible limits for the plant from MaK. 02 Values for crank web deflection in mm: RM32/VM32 Cylinder 1 or last cylinder with additional load (flywheel/coupling) All cylinders without external load Permissible values for realignment of base frame mounted gensets in horizontal direction + 0.09 mm + 0.0.02. Values from a cold engine are of secondary importance.1998 IB002366 3/4 . 02. Only the values measured on an engine at operating temperature can be used for the assessment.02.05.0. This means that the permissible deflection is determined by the engine load.06 / .06 / .04 / .13 mm + 0.01. Heavy crank web deflection imposes additional loads on crankshaft and main bearings. A high load permits less deflection than a low one.Crank Web Deflection Inspection / Measuring M32 A5.0.

02.00 02 en / 02.05.02.01. 02.Crank Web Deflection Inspection / Measuring M32 A5.1998 IB002366 4/4 .

05.01.9. 0.05.03.05 and A1.nn.1110 0 Pers. They consist of a steel back (layer strength up to 10 mm thickness) and a running-in layer of approx.1 mm thickness made of either: lead bronze (Fig.9.nn for recommendations of lubricating oil treatment See A4.03.01.. 02. 1. AlSn. B1.Sn) or aluminium/tin layer (Fig.nn for renewal/supplement of the lubricating oil (additives) When the engine is frequently started and stopped (mixed friction)..01.05.06 for specifications of the lubricating oil temperature and pressure See A4./ 0.2601.01 See also: Spare parts list: Time requirement: 02.07.Bearing Shells and Bearing Bushes Inspection / Evaluate M32 A5. 02.04.08. solid foreign matters and water are the cause of 85 % of all cases of bearing damage. 1.08.nn. 02.09. the bearing shells must generally be replaced in pairs (top and lower bearing shell)! Note: Corrosion-resistant two-metal bearings are employed at normal loaded bearings.03.05.03..) en / 02.02..nn B1.nn for recommendations of the lubricating oil brand (viscosity classification) See A4.7 to 1.00 h 02 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Note: Contaminated oil. the bearings may be more rapidly worn so that they must be renewed sooner.02. CuPb. Dirt is the enemy to all bearings! To avoid restrictions in the service life consider the following: • • • • See A1.08.nn. Attention: When replacing the bearings in the drive unit.1998 IB002410 1/2 .05. 02.05.05.

Replacement of the bearing only after .Flash 3 µm Lead bronze or AlSn.05.02. only for AlSn bearings)..03..heavy scratches.1998 IB002410 2/2 .1 mm Steel back Steel C. Shell thickness up to 10 mm en / 02.03.7 . 02.Bearing Shells and Bearing Bushes Inspection / Evaluate M32 A5..07. bearing Corrosion protection flash Sn . 02 Layer configuration of two-metal bearings Lead bronze bearing / AlSn. 3 µm) is already passed after a short running time.exceeding of a possibly specified limit value or .according to the specified evaluation criteria (02.nn. .1.01 The corrosion protection flash of the bearing (approx. layer 0.03.

/ 0.nn. 02. both bearing shells are to be replaced.07.01. 3 The contact pattern is evenly developed over the total bearing surface.05. If the depth of these scratches is neither measurable nor feelable. Fig.05. Assessment catalog: Criteria for reuse Fig. the bearing shell may be reused.1998 IB002418 1/4 . The contact pattern is evenly developed over the total bearing surface.nn B1.9.00 h 02 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Note: The following assessment catalog shows different degrees of wear.03. depth and a big extent of the scratches impede the development of a lubricating film.05. 2 Fig. 02. 02.01 See also: Spare parts list: Time requirement: 02. the bearing shells must generally be replaced in pairs (top and lower bearing shell)! en / 02. The scratches in running direction are caused by small foreign matter particles in the lubricating oil.1110 0 Pers.03.05.05. caused by mechanical wear and overload of the bearing shells. This bearing shell may be reused. If the number.03. 1 The contact pattern is evenly developed over the total bearing surface.02. the scratch caused by foreign matter in the lubricating oil has negligible influence on the reliability of the plain bearing.03.nn. As experience shows.Bearing Shells Inspection / Evaluate M32 A5. This bearing shell may be reused. Attention: When replacing the bearings in the drive unit.

5 The contact pattern show a large area damage with differently developed gallings. 02 en / 02. Inspect further bearing shells. Fig.03. 02. Some bearing metal fragments may lay loosely in the effected area. both bearing shells have to be replaced. Fig. This bearing shell may not be reused. both bearing shells have to be replaced.01 Criteria for replacement Fig. This bearing shell may not be reused. The cause for the overload along the edges has to be found and corrected. The cause for the scaling is definitely to be found and corrected.1998 IB002418 2/4 .02. 6 The loaded area of the bearing shell shows bearing metal scaling caused by overload. 4 The contact pattern show heavily developed overload along the edges with galling areas in the aluminium alloy plated overlay. This bearing shell may not be reused.05.Bearing Shells Inspection / Evaluate M32 A5.07. The cause for this damage has to be found and corrected. Inspect further bearing shells. both bearing shells are to be replaced.

02.Bearing Shells Inspection / Evaluate M32 A5. 02.05.07.01 02 en / 02.1998 IB002418 3/4 .03.

05.02.Bearing Shells Inspection / Evaluate M32 A5.07.01 02 en / 02.03.1998 IB002418 4/4 . 02.

02. ~ Safety note: Do not position any parts of the body over pressurized devices! Secure the engine against unintentional starting! en / 25.06.9213 C 0. consisting of: Slide rail (22) Slide rail [extension (27)] Suspension (25) with spacers (26) Suspension (20) Stopper (24) Guide tube (28) Clamping device (2x) for con-rod W1 W2 W3 W4 W5 W6 W7 W8 0.9228 F Auxiliary material: Molykote paste "G-Rapid Plus" * * or a product of equal standard Attention: A minimum bending radius of r = 120 mm must be observed for the hydraulic hoses! Only use hydraulic oil for operating the hydraulic device.nn. 02.07./ 0.01.2001 IB023261 1/6 .9203-101 0.9228 G W9 9.9203-110 0.nn B1.02.50 h See also: Spare parts list: Time requirement: 02 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: of a big-end bearing of all big-end bearings every every 15.9.000 h 30. 15000 02.03. Store the hydraulic device protected against corrosion.nn.9203-209 0.04.000 h Tools: Hydraulic device consisting of: High pressure pump High pressure hose (1 m) Hydraulic tension element Support ring Threaded sleeve Pin Distributor Mounting / extraction device for big-end bearings.05. 02.03.9204 D 0.2601 2 Pers.52 30000.Big-end bearings Inspection / Disassembly VM32 A5.06.03.01.9203-004 9.05.9205 B 0.

02.nn). Turn the con-rod. New parts must be marked accordingly.2 Loosen the round nuts (2) by means of the hydraulic device. con-rod eye and con-rod are always marked on the corresponding control end (cylinder row A or B) according to which cylinder they belong (beginning at the clutch end) and must not be swapped. 15000 Note: The bearing cover. 1/2) must be freely accessible. The ring surface (a) of the threaded sleeve is then flush with the upper surface (b) of the hydraulic tension element. bearing shells.Big-end bearings Inspection / Disassembly VM32 A5.06. 3. Pay attention to good accessibility of the slits. Screw the threaded sleeve (W5) firmly onto the con-rod bolt (1) and then loosen by 3/4 of a rotation. 02 Sequence of operations: 1. Caution: After disassembly of the piston the engine may be cranked as described below with installed con-rod holder! 2.52 30000.2001 IB023261 2/6 .1 3.04. en / 25. Place the hydraulic tension elements (W3) with the support rings (W4) above the round nuts (2).01. Remove piston (02.06.05. The round nuts (fig. 3.01.

5.Big-end bearings Inspection / Disassembly VM32 A5. en / 25. Turn the round nuts back by at least 8 holes.01. 02.3 02 Attention: The pin (fig. 1/2) with the pin (W6). 2/6) on the high pressure pump and extend both con-rod bolts simultaneously and gradually at a pressure of p = 1200 bar + 25 bar. Close the valve (fig. maximum stroke indicator) must not be driven out of the hydraulic tension element (W3) when extending the con-rod bolt (1)! 4. 2/W3) and distributor (W7) to the high pressure pump (W1) via the high pressure hoses (W2). 15000 Connect the hydraulic tension elements (fig.05.2001 IB023261 3/6 . Loosen the round nuts (fig. 3.52 30000. 1/9.04.06.

06. en / 25.2001 IB023261 4/6 . then the con-rod bolts can be pretensioned at a higher pressure of p = 50 bar. The mounting/ extraction device for the big-end bearing (W8) can also be mounted mirror-inverted. 3/25) with spacers (26) and suspension (20). 2/6)on the high pressure pump (W1). W5 and W7).01.05. Turn the con-rod (fig.52 30000. 02. 7.Big-end bearings Inspection / Disassembly VM32 A5. Open the valve (fig. 15000 Note: If it is not possible to loosen the round nuts by means of the pin. W4.04. A further pressure increase could cause the round nut to clamp as a result of the con-rod bolt thread expanding! 6. Wait for the pressure to drop completely and then dismantle the hydraulic devices (W3. 8. Mount the suspension (fig. 9. 02 Note: The removal of a con-rod from cylinder row B using the mounting/ extraction device (W8) is described and shown in the following. 3/10) to a horizontal position with the con-rod shank division towards the center of the engine. The tension elements are relieved.

15. Dismantle the con-rod clamping device (W9).3 20. raise and suspend in suspension (20).2 20. 160 mm from the bearing.03.5 28 11 4 en / 25. Align the slide rail (22) with the clamp bolts (21). Unscrew the round nuts (2) and pull off the big-end bearing cover (11) approx. 4/28) in upper conrod bolt bore. if required. Turn the upper big-end shell (13) by 180° on the crank pin and pull it off. 11. Remove the lower big-end shell (12) from the crank pin.2001 IB023261 5/6 . 17. Loosen the lateral stopper fixing device (23) in such a way that the stopper can glide in the slots. 14.04. 10. Disassemble con-rod clamping device (W9).06. Pull out con-rod bearing cover (11) with bearing shell and place on a suitable surface. 20. 15000 Insert the slide rail (fig. Insert guide tube (Fig. 60 mm.03. It must lie flush on the con-rod (10) and the bigend bearing cover (11). Mount the stopper (24) and screw the con-rod to the stopper.52 30000.1 Disassemble con-rod (10) only. 02 Note: The con-rod bolts (1) are not removed for disassembling the bearing shells. 13.nn and 02.03. Stopper (Fig. Disassembly of con-rod: 20. Remove round nuts (2) and con-rod bolts.07.4 20. 3/22) via clamp bolts (21) in the crankcase.Big-end bearings Inspection / Disassembly VM32 A5. 16.01. 12. Check the condition of the big-end shells (02.nn).05. Pull the con-rod (10) off the bearing by approx. perform steps 1-11 to do so. 5/24) should only be mounted to con-rod in such a way that it intercepts the con-rod and rests freely movable on the slide rail. 18. 02. 20. 19.

01.06.6 20. Sling con-rod to crane and remove guide tube.05.04.8 20. Stabilize con-rod with guide tube and pull out from engine on guiding rail.52 30000.9 02 28 24 5 en / 25.7 20.Big-end bearings Inspection / Disassembly VM32 A5. 15000 Relocate guide tube Fig.2001 IB023261 6/6 . 5/28). Disassemble stopper (24). 20. lift con-rod and place on suitable surface. 02.

Do not tighten it. Insert big-end bolts (1) with washer (5) and assemble stopper (24) on connecting rod (10).2. 02.2. 2/10) to a crane by means of a sling.2.9. If necessary.2601 2 Pers. bearing shells. Assemble washer (5) with chamfer pointing towards bottom end of connecting rod. 02. 1.51 See also: Spare parts list: Time requirement: 02.06. 60 mm in front of the crank pin.03. New parts must be marked accordingly. Do not remove the sling! Preassemble the lateral stopper fixing device (23).03.nn. 1. Place the con-rod on the slide rail (27) of the mounting / extraction device (W8) in such a way that the locating hole (4) for the dowel pin (3) is located on the corresponding control end (cylinder row A or B).01.2 1.01.2 1. attach the disassembled con-rod (fig.1 1.04. Sequence of operations: 1.3 Attention: The bearing shells each have a locating projection (fig.nn.nn B1.3 1.2001 IB023265 1/5 . 1/X) at different positions to fix them in the con-rod/big-end bearing cover.07.04.1 Reassembly of the bearing shells Clean and lubricate the crank pin.nn Note: The bearing cover.04. The bearing shells must be mounted with the locating projections towards the corresponding control end (cylinder row A or B)! en / 25. 02.4 1.05.Big-end bearings Inspection / Reassembly VM32 A5.03.02. Lubricate the bearing shells on the inside and outside./ 0.50 h 02 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Tools W1 .02. con-rod eye and con-rod are always marked on the corresponding control end (cylinder row A or B) according to which cylinder they belong (beginning at the clutch end) and must not be swapped.2.W9 refer to 02.05. Push the con-rod to approx.

Attention: Pay attention that the bearing shell halves on the exhaust side and control side align axially. 2/4. en / 25. 2/23).8 Insert the lower bearing shell (fig. 02. without holes) on the crank pin and turn it under the con-rod by 180°.4 1.04. Remove the sling from the con-rod. Carefully press the con-rod against the bearing shell. There must be no offset between the bearing shell halves in an axial direction.2001 IB023265 2/5 . Attention: Pay attention to the allocation of the locating hole (fig.51 1. 02 1.06. con-rod) and dowel pin (3. 1/b) paying attention to the locating projection (x).05.02.5 Place the upper bearing shell (a. Carefully push the big-end bearing cover (fig. The projection on the bearing shell must be positioned exactly in the recess on the bigend bearing cover. 2/11) against the bearing shell and the foot of the con-rod.6 Mount the con-rod clamping devices (W9). Align it and press it into the base bore. They must be located at the corresponding control end (cylinder row A or B)! 1.7 1. The locating projection on the bearing shell must be positioned exactly in the recess on the con-rod.Big-end bearings Inspection / Reassembly VM32 A5. bigend bearing cover). Tighten the lateral stopper fixing devices (fig.

Both round nuts (2) must be freely accessible.Big-end bearings Inspection / Reassembly VM32 A5. see position illustrated (fig. Dismantle the mounting / extraction device for the big-end bearing [(fig.51 1. Assemble round nuts (fig. 3/2) and fasten finger-tight. 3/2) by means of the hydraulic device. Check the con-rod shells on the exhaust side for any offset in an axial direction. slide rails (27. 20) and stopper (24)]. Eliminate any offset by aligning the bearing shells. 2/W8). 02. Tighten the round nuts (fig. 3).1 Safety note: Do not place any parts of the body above pressurized devices! Secure the engine against unintentional starting! Turn the con-rod with the con-rod division downwards by approx.10 1. 15-30°.06. en / 25.2001 IB023265 3/5 . 02 ~ 2. 22) with suspensions (25.04.9 1.05.02.11 2.

2 2.Big-end bearings Inspection / Reassembly VM32 A5.9 Close the valve (fig.05. 5/W3) at pin side (camshaft side) to the high-pressure pump (W1) via high-pressure hose (W2). Connect both hydraulic tension elements (W3) and the distributor (W7) to the high-pressure pump (W1) via high-pressure hoses (W2). 4/9). 02 2. Screw the threaded sleeves (W5) hand-tight onto the con-rod bolts (1).04. 02.7 2. maximum stroke indicator) must not be driven out of the hydraulic tension element (W3) when extending the con-rod bolts (1)! The pressure must be kept constant if the hydraulic pump is not used otherwise tightening will be faulty! 2.2001 . 5/6) on the high pressure pump (W1) and extend both con-rod bolts IB023265 4/5 en / 25. The tension elements are relieved. 4/W3) together with the support rings (W4) above the round nuts (2). Attention: The pin (fig.8 Firmly tighten the round nut (fig.4 2.6 2.06. Open the valve (fig. 4/2) with the pin (W6). Pay attention to easy action.02.3 Place the hydraulic tension elements (fig. Close the valve (6) of the high-pressure pump (W1) and stretch the big-end bolt at pin side (camshaft side) steplessly with a pressure of p = 50 bar.51 2. Pay attention to good accessibility to the slits (8).5 Connect the hydraulic tension element (fig. 2. 5/6) of the high pressure pump (W1).

11 Firmly tighten the round nuts (fig. It must no longer be possible to loosen the round nuts with the pin.10.nn).13 3.06. Mount the piston (02.10 2. W5 and W7). 2.02. The tension elements are relieved. W4. 2. Wait until the pressure has dropped completely and then remove the hydraulic devices (W3. 5/6) of the high pressure pump (W1).01.51 simultaneously and gradually at a pressure of p = 1200 bar + 25 bar. Pay attention to easy action. 4/2) with the pin (W6).2001 IB023265 5/5 . Open the valve (fig. en / 25.05.Big-end bearings Inspection / Reassembly VM32 A5. Check firm seating on the round nuts 02 • • 2.12 Reduce the pressure by 50 bar.04. 02.

07.nn.9204 D 0.9203-107 0.01.1110 2 Pers.03. en / 05.53 30000. 15000 02.9203-209 0. Store the hydraulic device protected against corrosion. 02.9203-101 0.9213 C 0.05.9.9203-119 0. consisting of: Mechanism W11 Carrier W12 Mounting device W13 * Feeler gauge * for assembly only ** not illustrated W14** 1.00 h See also: Spare parts list: Time requirement: 02 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: a) of two crankshaft bearings Number of cylinders 12 16 every Bearing number 4 ans 6 5 and 7 15./ 2.000 h b) exchange all crankshaft bearings every 30.03.9213 M 0. 02.06.03.9205 B 0.03.05.9214 B Mounting / extraction device for crankshaft bearing.000 h Tools: Hydraulic device consisting of: High pressure pump High pressure hose (3 x 1 m) Pin Hydraulic tension element (lateral waisted studs) Hydraulic tension element (crankshaft bearing bolts) Support ring (lateral waisted studs) Support ring (crankshaft bearing bolts) Threaded sleeve (lateral waisted studs) Threaded sleeve (crankshaft bearing bolts) Distributor W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 0.9203-110 0.9075-003 Attention: A minimum bending radius of r = 120 mm must be observed for the hydraulic hoses! Only use hydraulic oil for operating the hydraulic device.Crankshaft bearing Inspection / Disassembly VM32 A5.9203-004 9.05.2000 IB021847 1/9 .nn B1.

2000 IB021847 2/9 . checked and measured within the specified interval in the event of: Distortion of the foundation or Changes in the crank web deflection 5 6 7 8 after suffering sea damage Sequence of operations: 1.1 1. 2/W4) with the support rings (W6) above the round nuts (7). Unscrew the protective caps (8).3.2 1 1. Screw the threaded sleeves (W8) firmly onto the waisted studs (6) and then slakken again by half a rotation.05. New parts must be marked accordingly.06. The round nuts (fig. Use the hydraulic device to loosen the round nuts (7) on the lateral waisted studs (6). 15000 ~ Note: 02 Safety note: Do not position any parts of the body over pressurized devices! Secure the engine against unintentional starting! The bearing cover and bearing shells of the crankshaft bearings are always marked on the righthand side of the engine (cylinder row B) and are not allowed to be swapped.05.Crankshaft bearing Inspection / Disassembly VM32 A5.53 30000.3. 1/23) of the crankshaft bearing bolts (22) must be freely accessible.1 Dismantle the crankshaft bearing.3 W3 W4 1. 02. The crankshaft bearings must also be removed. Pay attention to good accessibility to the slits (11).3. The ring surface (a) of the threaded sleeve must then be flush with the upper surface (b) of the hydraulic tension element (W4). 1. Place the hydraulic tension elements (fig. The retaining pin of the lower bearing shell points towards cylinder row B. Open the respective power unit cover at the clutch end on both sides of the engine (cylinder row A and cylinder row B) Turn the crankshaft to a favourable position.2 11 1.01. 23 22 1.3 7 a W6 6 W8 10 b 2 en / 05.

Turn the round nuts back by at least 8 holes. 02.06. en / 05.53 30000.5 Close the valve (fig. 2/7) with the pin (W3). 2/10. 1.3.3.2000 IB021847 3/9 .05. 15000 Connect the hydraulic tension element (fig.01. 3/W4) and the distributor (W10) to the high pressure pump (W1) via high pressure hoses (W2).05.4 02 Attention: The pin (fig. 1. maximum stroke indicator) must not be driven out of the hydraulic tension element (W4) when extending the waisted studs (6)! W2 W2 W10 13 3 W1 1. 3/13) on the high pressure pump (W1) and extend both waisted studs simultaneously and gradually at a hydraulic pressure of p = 680 bar.Crankshaft bearing Inspection / Disassembly VM32 A5.6 Loosen the round nuts (fig.3.

8 1.01.2000 .10 1. 4/W11).06.9 1. If the pressure is increased even further then there is a risk of the round nuts jamming as a result of the bolt thread expanding! 1. 02 W7 3 20* T W5 15* 19* W9 W11 T 16 * = W11 19* 24* 4 1.4 Open the valve (fig.05.3. Refer to 1. 2/W8). The tension elements are relieved. Only loosen the round nuts (7) on the lateral waisted studs (6) on the adjacent crankshaft bearing by means of the hydraulic device.3.3. hydraulic tension elements (W4) and support rings (W6).Crankshaft bearing Inspection / Disassembly VM32 A5. Loosen the waisted studs (fig.53 30000.3.4.3.05. 02.1 Move the mechanism to the lowest position (stopper) by means of the IB021847 4/9 en / 05. Wait for the pressure to drop completely.3.1 to 1. 3/13) on the high pressure pump (W1). 1/6) and unscrew them completely. 15000 Note: If it is not possible to loosen the round nuts with the pin. Insert the mechanism (fig. then the waisted studs can be pretensioned at higher pressure of p = 50 bar.8. Remove the threaded sleeves (fig.7 1.

5. 7/W5) and the distributor (W10) to the high pressure pump (W1) via the high pressure hoses (W2). 6/27).2 W11 16 Attention: When driving up.3 U 3 U 23 22 19 21 1. Drive the mechanism (W11) upwards until the support rings (W7) make contact with the crankshaft bearing cover (3). Pay attention to good accessibility to the slits (fig. Connect the hydraulic tension elements (fig. The ring surface (a) on the threaded sleeve is then flush with the upper surface (b) of the hydraulic tension element (W5).5. 4/W5) together with the support rings (W7) flush on the bearing block (19) and pull outwards up to the stoppers (24).53 30000. 1.5 20 1.5. 02.01. 1.4 en / 05. Place the hydraulic tension elements (fig. pay attention that the round nuts glide properly into the support rings! Align the table accordingly if necessary! 17 5 1. 02 1. Remount the table on the bearing block (19). 15000 threaded rod (fig. 4/15). Loosen the round nuts (23) on the crankshaft bolts by means of the hydraulic device.3 Screw the threaded sleeves (W9) firmly onto the crankshaft bearing bolts (22) through the bearing block from below and loosen them again by half a rotation. 5/17) engages in the reinforcement (16). Lift the mechanism (W11) on the respective crankshaft bearing into the cylinder crankcase and place it in the oil sump.5.2 Disassemble the table (20). The holder (fig.05.05.1 1.2000 IB021847 5/9 .06.Crankshaft bearing Inspection / Disassembly VM32 A5. Push the mechanism under the crankshaft bearing and align it.4.4.

53 30000. 1.2000 IB021847 6/9 .01.05. 6/23) with the pin (W3).5.06.5 Close the valve (fig. 7/30) on the high pressure pump (W1) and extend both crankshaft bearing bolts simultaneously and gradually at a pressure of p = 1025 bar.05.5. 22 26 b a 6 W9 W5 W2 W2 W10 30 W1 7 en / 05. maximum stroke indicator) is not allowed to be driven out of the hydraulic tension element (W5) when extending the crankshaft bearing bolts (22)! 23 W7 W3 27 02 W5 1. Turn the round nuts back by at least 8 holes. 02. 6/26.Crankshaft bearing Inspection / Disassembly VM32 A5. 15000 Attention: The pin (fig.6 Loosen the round nuts (fig.

7/30) on the high pressure pump (W1). The tension elements are relieved.05.11 Turn the upper bearing shell towards the left-hand side of the engine (cylinder row A) and remove it. Drive the mechanism with the crankshaft bearing cover and lower bearing shell down to the stopper. Drive the mechanism onto the crankshaft bearing cover and remove the round nuts.03.6 1.nn and 02. 02 Note: If the crankshaft bearing cover does not come off. 02.7 1. Refer to 02.9 1.1 1. 15000 Note: If it is not possible to loosen the round nuts with the pin. Push the carrier (fig. 1.nn.07. If the pressure is increased even further. Measure the gap.01. Drive the mechanism down to the stopper.2000 IB021847 7/9 .53 30000.2 1. Wait for the pressure to drop completely.6. Assess the bearing shells.03. 1. then screw the table (fig.8 Open the valve (fig. then there is a risk of the round nuts jamming due to the bolt thread expanding! 1.12 W11 8 en / 05. then dismantle the threaded sleeves (W9).03. Refer to operation sequence 2. 5/21) to the crankshaft bearing cover (3) using counter sunk screws and drive the mechanism (W11) with the crankshaft bearing cover down to the stopper.06. then the waisted studs can be pretensioned at higher pressure of p = 50 bar.Crankshaft bearing Inspection / Disassembly VM32 A5. Attention: Only turn when the mechanism (W11) has been driven down to the stopper! W12 1. 8/W12) down to the stopper in the oil bore of the crankshaft.10 Remove the lower bearing shell. Remove the support rings and the hydraulic tension elements.05.6.

05.87. 02.05.3. 1.actual dim.05 mm. Wear = dimension when new . 2.1 Measure gap. 15000 Check the wall thickness wear at measuring points in the main strain zone (fig.3 up to an including 1. K A K S 6 10 23 en / 05.015 mm Attention: If the inspection results in the bearing shells having to be changed.13 02 1.2000 IB021847 8/9 . 10/6) of the respective crankshaft bearing on both sides of the engine (cylinder rows A and B).06. then the adjacent bearings should also be inspected.53 30000.01. Refer to operation sequence 1. 2. Remove the waisted studs (fig.10.14 The bearing shells must be replaced if the wear is > 0. New dimension = 8.0. 9/X) by means of a micrometer gauge.Crankshaft bearing Inspection / Disassembly VM32 A5.

Crankshaft bearing Inspection / Disassembly VM32 A5.1.00 .1 02 2. Loosen the round nuts further but do not move them.5.25 Service limit value mm 0.3 en / 05.4 and 1. 15000 Loosen both round nuts (fig. 02.6. Use a feeler gauge to measure the gap "K" between the cylinder crankcase and crankshaft bearing cover on both side of the engine (cylinder rows A and B) and add the two measured values.01.1.2000 IB021847 9/9 .1. Drive the mechanism (W10) downwards.05. Then tighten the round nuts evenly and alternately by hand until the surfaces of the bearing shells just make contact. Refer to 1. Relieve the hydraulic extraction device and remove it.05.53 30000.06.2 2. K = KA + KS Gap "K" mm 1.1. 10/23) hydraulically according to operation sequence 1.80 2.

Crankshaft thrust bearings/crankshaft be Maintenance / Reassembly VM32 A5.50 See also: Spare parts list: Time requirement: 02.05.00 h 02 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Tools W1 .9459-033 Auxiliary material: Molykote paste "G-Rapid Plus" ** ** or a product of equal standard Attention: A minimum bending radius of r = 120 mm must be observed for the hydraulic hoses! Only use hydraulic oil for operating the hydraulic device set.nn 100 .W14.05. New parts must be marked accordingly.03./ 1.2008 IB003361 1/8 .05.400 Nm torque wrench 1/2 Changeover ratchet * not illustrated W15 * W16 * 1. en / 26.05. Damaged crankshaft bearing bolts and round nuts must be replaced together.01.01. 02. The locking pin of the lower bearing shell points towards cylinder row B. Store the hydraulic device set protected against corrosion.9454-400 1.1110 2 Pers.nn B1. Refer to maintenance sheet 02.02.05. ~ Note: Safety note: Do not position any parts of the body over pressurized devices! Secure the engine against unintentional starting! The bearing cover and bearing shells of the crankshaft thrust bearing/crankshaft bearings are always marked on the right-hand side of the engine (cylinder row B) and are not allowed to be swapped.03.9.

7 Drive up the mechanism (W11) and remove the round nuts (23). Attention: The locating nose on the upper bearing shell points towards the left-hand side of the engine (cylinder row A).50 Sequence of operations: 1.2 1. 1/W12) in the oil bore pushing it down to the stopper. 1. Slowly drive the mechanism (W11) up until the mounting device (W13) lies on the bearing block (x). W12 1 W11 1. Pay attention that the bearing shell is centred correctly. 1. The locating nose must glide into the guide groove in the bearing block. Tighten the round nuts (23) finger-tight.05.4 X 1. 02 Note: The upper bearing shell has a lubrication groove and oil bores.5 W13 Attention: Only turn the crankshaft when the mechanism (W11) has been driven right down to the stopper! 23 1. The mounting device (W13) is clamped. Fit bearing shells.1 Lubricate the running surface of the upper crankshaft bearing shell.3 Insert the carrier (fig.05. Place the mounting device (W13) in the crankshaft bearing cover. en / 26. Reinsert the upper check plate segments if they have been removed (only in the case of the crankshaft thrust bearing).02.2008 IB003361 2/8 . Drive the mechanism (W11) down again and remove the carrier (W12) as well as the mounting device (W13). Drive the mechanism (W11) down 1.Crankshaft thrust bearings/crankshaft be Maintenance / Reassembly VM32 A5.03. Pay attention to the lateral stopper. 02.6 Turn in the upper bearing shell. The bearing shells are marked on the right-hand side of the engine (cylinder row B). Dry the back of the bearing and turn the bearing shell as far as possible into the bearing.

Crankshaft thrust bearings/crankshaft be Maintenance / Reassembly
VM32

A5.05. 02.05.02.50

1.8

Lubricate the running surface of the lower crankshaft bearing shell (fig. 2/4). Dry the back of the bearing and fit the shell in the crankshaft bearing cover (3).

02
1 4 2

Attention:
The locating nose on the lower bearing shell must point towards the right-hand side of the engine (cylinder row B).

3

1.9

If they have been removed, put the lower check plate segments (1; on crankshaft thrust bearing only) back onto the dowel pins (2). Preassemble the round nuts (fig. 3/23) for the crankshaft bearing bolts. Drive the mechanism (W11) together with the crankshaft bearing cover (3) up to the stopper. Do nor damage the crankshaft bearing bolts (22) when doing so! Align the table (20) with the crankshaft bearing cover if necessary. Screw the round nuts (23) onto the crankshaft bearing bolts (22) and tighten fingertight by means of the pin (fig. 5/W3). If used, loosen and remove the countersunk screws (fig. 3/21).
2

2. 2.1

U
3

U
23 22 19

21

2.2

20

2.3

W11 24

Note:
Measure the gap "K" (02.05.01.nn) after fitting new bearing shells. The axial clearance must also be measured (02.05.01.nn) after replacing the check plate segments (fig. 2/1) or the bearing shells on the crankshaft thrust bearing. 2.4 Lower the mechanism (W11) down to the stopper. Do not dismantle!

3

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Crankshaft thrust bearings/crankshaft be Maintenance / Reassembly
VM32

A5.05. 02.05.02.50

3.

Mount the lateral waisted studs (fig. 4/6).

5

6 7 8

02

Note:
The waisted studs for the crankshaft thrust bearing (crankshaft bearing cover 1) must be fitted with a new O-ring (5). 3.1 Coat the threads of the waisted studs (6) with Molykote. Screw them in and tighten them at a torque of M = 150 Nm. 3.2 3.3 Screw the round nuts (7) finger-tight onto the waisted studs. Place the hydraulic tensions elements (fig. 5/W4) with the support rings (W6) over the round nuts (7). Pay attention to good accessibility to the slits (11). Screw the threaded sleeves (W8) fingertight onto the wastes studs (6). Connect the hydraulic element (fig. 6/W4) on B-side via the high-pressure hose (W2) and the distributor (W10) to the high-pressure pump (W1).
4

3.4 3.5

W3

W4

11

Attention:
The pin (fig. 5/10), maximum stroke indicator) must not be driven out of the hydraulic tension element (W4) when extending the waisted studs (6)!

7 10

W6

6

W8

5

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Crankshaft thrust bearings/crankshaft be Maintenance / Reassembly
VM32

A5.05. 02.05.02.50

3.6

Close valve (fig. 6/13) of the high-pressure pump (W1) and stretch the stud steplessly with a pressure of p = 150 bar + 50 bar

02

W4

W2

W2

W10

13
6

W1

Attention:
The pressure must remain constant if the hydraulic pump is not used otherwise the tightening will be faulty!

3.7 3.8 3.9 3.10

Firmly tighten the round nut (fig. 5/7) using the pin (W3). Open the valve (fig. 6/13) of the high-pressure pump (W1), the element is relieved. Connecthe hydraulic element (W4) on B- and A-side via the high-pressure hose (W2) and the distributor (W10) to the high-pressure pump (W1). Close valve (13) of the high-pressure pump (W1) and stretch both studs steplessly with a hydraulic pressure of p = 680 bar - 25 bar.

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5/8

Crankshaft thrust bearings/crankshaft be Maintenance / Reassembly
VM32

A5.05. 02.05.02.50

Attention:
The pressure must remain constant if the hydraulic pump is not used otherwise the tightening will be faulty!

02

3.11

• Reduce the pressure by 50 bar • It must no longer be possible to loosen the round nuts with the pin.
Open the valve (13) on the high pressure pump (W1). The tension elements are relieved. Wait for the pressure to drop completely before removing the threaded sleeves (fig. 5/W8), hydraulic tension elements (W4) and support rings (W6). Tighten the round nuts (fig. 4/7) on the lateral waisted studs (6) on the adjacent bearing(s) by means of the hydraulic device. Refer to operation sequence 3.2 to 3.10. Screw the protective caps (8) onto the waisted studs. Tightening the round nuts on the crankshaft bearing bolts. Place the hydraulic tension elements (fig. 7/W5) together with the support rings (W7) flush on the bearing block (fig. 3/19) and pull outwards up to the stoppers (24). Drive the mechanism (W11) up until the support rings (fig. 7/W7) lies on the crankshaft bearing cover. Pay attention to good accessibility to the slits (27). Screw the threaded sleeves (W9) fingertight onto the crankshaft bearing bolts (22) through the bearing block from below. Connect the hydraulic tension elements (fig. 8/W5) and distributor (W10) to the high pressure pump (W1) via the high pressure hoses (W2).

Check firm seating of the round nuts

3.12 3.13 3.14 3.15 4. 4.1

23 W7 W3

27

W5

4.2

22 26

4.3

4.4

W9
7

Attention:
The pin (fig. 7/26, maximum stroke indicator) must not be driven out of the hydraulic tension element (W5) when extending the crankshaft bearing bolts (22)!

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Crankshaft thrust bearings/crankshaft be Maintenance / Reassembly
VM32

A5.05. 02.05.02.50

4.5

Close the valve (fig. 8/30) on the high pressure pump (W1) and extend both crankshaft bearing bolts simultaneously and gradually at a hydraulic pressure of p = 1025 bar.

02

Attention:
The pressure must remain constant if the hydraulic pump is not used otherwise the tightening will be faulty!

4.6 4.7

Firmly tighten the round nuts (fig. 7/23) with the pin (W3). Pay attention to easy action.

• Reduce the pressure by 50 bar • It must no longer be possible to loosen the round nuts with the pin.
Open the valve (fig. 8/30) on the high pressure pump (W1). The tension elements are relieved. Wait for the pressure to drop completely before unscrewing the threaded sleeves (fig. 7/W9). Drive the mechanism (W11) down to the stopper. Remove the support rings and hydraulic tension elements. Dismantle the table (fig. 3/20) and remove it. Remove the mechanism (W11) and remount the table. Check the lubricating oil flow. Mount the power unit cover on both sides of the engine (cylinder rows A and B) as well as the cover under the gear drive.

Check firm seating of the round nuts

4.8 4.9 4.10 4.11 4.12 4.13 4.14

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Crankshaft thrust bearings/crankshaft be Maintenance / Reassembly
VM32

A5.05. 02.05.02.50

02

W5 W2 W2

W10

30 W1
8

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Crankshaft thrust bearing
Inspection / Disassembly
VM32

A5.05. 02.05.05.51

30000 02.03.03.nn, 02.03.07.nn B1.05.03.9.1110 2 Pers./ 1,00 h

See also: Spare parts list: Time requirement:

02

Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel

-------------------------------------------------------------------------------------------------------------------------------Inspection:
Crankshaft thrust bearing every 30.000 h

Tools:
Hydraulic device consisting of: High pressure pump High pressure hose (3 x 1 m) Pin Hydraulic tension element (lateral waisted studs) Hydraulic tension element (crankshaft bearing bolts) Support ring (lateral waisted studs) Support ring (crankshaft bearing bolts) Threaded sleeve (lateral waisted studs) Threaded sleeve (crankshaft bearing bolts) Distributor W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 0.9204 D 0.9205 B 0.9203-110 0.9213 C 0.9213 M 0.9203-119 0.9203-209 0.9203-107 0.9203-101 0.9203-004 9.9214 B

Mounting / extraction device for crankshaft bearing, consisting of: Mechanism W11 Carrier W12 Mounting device W13 * Feeler gauge * for assembly only ** not illustrated W14**

1.9075-003

Attention:
A minimum bending radius of r = 120 mm must be observed for the hydraulic hoses! Only use hydraulic oil for operating the hydraulic device. Store the hydraulic device protected against corrosion.

~

Safety note: Do not position any parts of the body over pressurized devices! Secure the engine against unintentional starting!

en / 05.06.2000

IB021892

1/9

Crankshaft thrust bearing
Inspection / Disassembly
VM32

A5.05. 02.05.05.51

30000

Note:
The crankshaft thrust bearing consists of the 1st crankshaft bearing (clutch end) and four check plate segments which limit the axial play of the crankshaft. The two lower check plate segments (fig. 1/1) are locked in position on the crankshaft bearing cover (3) by means of dowel pins (2), the two upper check plate segments are inserted in the grooves on the cylinder crankcase. The bearing cover and bearing shells of the crankshaft thrust bearing are always marked on the right-hand side of the engine (cylinder row B) and are not allowed to be swapped. New parts must be marked accordingly. The retaining pin of the lower bearing shell points towards cylinder row B. The first crankshaft bearing must also be removed, checked and measured within the specified interval in the event of: Distortion of the foundation or Changes in the crank web deflection after suffering sea damage

02

Sequence of operations:
1. 1.1 Measure the axial clearance "s". Open the cover below the geared drive and the first propulsion unit cover on both sides of the engine on the clutch side (cylinder row A and cylinder row B). Measure the axial clearance "s" (s1 and s2) by means of the feeler gauge. Axial clearance "s": s = s1 + s2

s1

s2

1.2 1.3

1

2

1

3
Clearance when new mm 0,3 - 0,5 Limit mm 0,8

The check plate segments and bearing shells must be renewed pair-wise when the clearance limit is exceeded. Refer to operation sequence 2, disassembly of crankshaft thrust bearing.

1

en / 05.06.2000

IB021892

2/9

The round nuts (fig. 2/23) on the crankshaft bearing bolts (22) must be freely accessible. Screw the threaded sleeves (W8) firmly onto the waisted studs (6) and then slakken again by half a rotation The ring surface (a) of the threaded sleeve must then be flush with the upper surface (b) of the hydraulic tension element (W4). 02. 3/W4) with the support rings (W6) above the round nuts (7). maximum stroke indicator) must not be driven out of the hydraulic tension element (W4) when extending the waisted studs (6)! 7 a W6 6 W8 10 b 3 en / 05. 5 Turn the crankshaft to a favourable position. 6 7 8 2.05.4 Connect the hydraulic tension elements (fig.05.2 23 22 2 2. 4/W4) and the distributor (W10) to the high pressure pump (W1) via high pressure hoses (W2). Pay attention to good accessibility to the slits (11).2.05.1 2.51 30000 Attention: Make sure the check plates are marked before disassembly for inspection purposes to avoid the parts being mixed up by mistake. Then remount the parts without delay! 02 2. 2.2. 2.Crankshaft thrust bearing Inspection / Disassembly VM32 A5.2.06.1 Disassemble the crankshaft thrust bearing. Place the hydraulic tension elements (fig.2000 IB021892 3/9 . 3/10.2 2.2. Use the hydraulic device to loosen the round nuts (7) on the lateral waisted studs (6): Unscrew the protective caps (8).3 W3 W4 11 Attention: The pin (fig.

5 02 2.05.51 30000 Close the valve (fig. 3/7) with the pin (W3).05.6 Loosen the round nuts (fig.06.7 Open the valve (fig. 02. The tension elements are relieved. Turn the round nuts back by at least 8 holes.2.2. Note: If it is not possible to loosen the round nuts with the pin.2000 IB021892 4/9 . 2. W2 W2 W10 13 4 W1 en / 05.Crankshaft thrust bearing Inspection / Disassembly VM32 A5. 4/13) on the high pressure pump (W1). 4/13) on the high pressure pump (W1) and extend both waisted studs simultaneously and gradually at a hydraulic pressure p = 680 bar.2. then the waisted studs can be pretensioned at higher pressure of p = 50 bar. If the pressure is increased even further then there is a risk of the round nuts jamming as a result of the bolt thread expanding! 2.05.

3 2. 2. 3/W8).8.05.10 2.2. The holder (fig.3. Push the mechanism under the crankshaft thrust bearing and align it.05.2.2 Only loosen the round nuts (7) on the lateral waisted studs (6) on the adjacent crankshaft bearing by means of the hydraulic device. Remount the table on the bearing block (19). 02.51 30000 Wait for the pressure to drop completely.8 2. Disassemble the table (20). 2/6) and unscrew them completely. 6/17) engages in the reinforcement (16). Lift the mechanism (W11) on the crankshaft thrust bearing into the cylinder crankcase and place it in the oil sump. Inserting the mechanism (fig.1 to 2.05.2000 IB021892 5/9 . Remove the threaded sleeves (fig.2. Refer to 2. 5/W11): Move the mechanism to the lowest position (stopper) by means of the threaded rod (15). hydraulic tension elements (W4) and support rings (W6).9 02 Note: Replace the O-ring (5) during assembly! 2.2.1 2. Loosen the waisted studs (fig.2. 2.3.06.3.3 W7 3 20* T W5 15* 19* W9 W11 T 16 * = W11 19* 24* 5 en / 05.Crankshaft thrust bearing Inspection / Disassembly VM32 A5.

Drive the mechanism (W11) upwards until the support rings (W7) make contact with the crankshaft bearing cover (3). The ring surface (a) on the threaded sleeve is then flush with the upper surface (b) of the hydraulic tension element (W5).4. maximum stroke indicator) is not allowed to be driven out of the hydraulic tension element (W5) when extending the crankshaft bearing bolts (22)! W5 22 26 b a 7 W9 en / 05.1 U 23 22 19 21 20 2.4. 7/27).05.51 30000 Loosen the round nuts (23) on the crankshaft bolts by means of the hydraulic device. Pay attention to good accessibility to the slits (fig.Crankshaft thrust bearing Inspection / Disassembly VM32 A5.4 U 3 02 2.2 Attention: When driving up. Connect the hydraulic tension elements (fig.4.06. 17 6 23 2.3 Screw the threaded sleeve (W9) firmly onto the crankshaft bearing bolts (22) through the bearing block from below and loosen them again by half a rotation.05.2000 IB021892 6/9 . 8/W5) and the distributor (W10) to the high pressure pump (W1) via the high pressure hoses (W2).4.4 27 W7 W3 Attention: The pin (fig. 7/26. 5/W5) together with the support rings (W7) flush on the bearing block (19) and pull outwards up to the stoppers (24). 02. 2. Place the hydraulic tension elements (fig. pay attention that the round nuts glide properly into the support rings! Align the table accordingly if necessary! W11 16 2.05.

4. Turn the round nuts back by at least 8 holes.6 Loosen the round nuts (fig.05.51 30000 Close the valve (fig. 2. then there is a risk of the round nuts jamming due to the bolt thread expanding! 2. 7/23) with the pin (W3).05. 8/30) on the high pressure pump (W1) and extend both crankshaft bearing bolts simultaneously and gradually at a pressure of p = 1025 bar. 02. then the waisted studs can be pretensioned at higher pressure of p = 50 bar If the pressure is increased even further.06.Crankshaft thrust bearing Inspection / Disassembly VM32 A5. 8/30) on the high pressure pump (W1).05.5 02 2.5 Open the valve (fig. W5 W2 W2 W10 30 W1 8 en / 05.2000 IB021892 7/9 .4. The tension elements are relieved. Note: If it is not possible to loosen the round nuts with the pin.

Push the carrier (fig. 9 2. 9/W12) down to the stopper in the oil bore of the crankshaft Attention: Only turn when the mechanism (W11) has been driven down to the stopper! W12 2.05.06. Measure the gap. Remove both lower check plate segments (fig.51 30000 Wait for the pressure to drop completely. 2.6 2.8 2.0.nn and 02.11 2.12 W11 2. Drive the mechanism onto the crankshaft bearing cover and remove the round nuts. 02.10 Turn the upper bearing shell towards the left-hand side of the engine (cylinder row A) and remove it.07.05. Refer to operation sequence 1.Crankshaft thrust bearing Inspection / Disassembly VM32 A5.nn.7 02 Note: If the crankshaft bearing cover does not come off.015 mm en / 05. Refer to 02. 7/W9). 2. 6/21) to the crankshaft bearing cover (3) using countersunk screws and drive the mechanism (W11) with the crankshaft bearing cover down to the stopper.03. Dimension when new = 8. Refer to operation sequence 3.13 The bearing shells must be replaced if the wear is > 0. 10/x) by means of a micrometer gauge. Measure the wall thickness at measuring points in the main strain zone (fig. Drive the mechanism with the crankshaft bearing cover and lower bearing shell down to the stopper.actual dim. Wear = dimension when new .1 2. Drive the mechanism down to the stopper.2 2. 1/1) and only replace them if excessive axial play has been discerned.9 Remove the lower bearing shell.2000 IB021892 8/9 .87.5.03.03. Only remove the upper check plate segments if a replacement is to be made. Remove the support rings and the hydraulic tension elements. then screw the table (fig.5. Assess the bearing shells. then dismantle the threaded sleeves (fig.05 mm.05.

10. Refer to operation sequence 2. Then tighten the round nuts evenly and alternately by hand until the surfaces of the bearing shells just make contact.3 en / 05.2000 IB021892 9/9 .06.1.2 up to and including 2.Crankshaft thrust bearing Inspection / Disassembly VM32 A5.2. Drive the mechanism (W11) downwards. 3. 11/6) of the crankshaft thrust bearing on both sides of the engine (cylinder rows A and B). then the adjacent bearings should also be inspected.4.00 .1 Loosen both round nuts (23) hydraulically according to operation sequence 2.05.5.1.51 30000 Attention: If the inspection results in the bearing shells having to be changed.3 and 2.05.25 Service limit value mm 0.1.05. 02 3. 02. Refer to 2. K = KA + KS Gap "K" mm 1.2 3. K A K S 6 11 23 3.1 Measure gap. Loosen the round nuts further but do not move them. Use a feeler gauge to measure the gap "K" between the cylinder crankcase and crankshaft bearing cover on both side of the engine (cylinder rows A and B) and add the two measured values.80 3.1. Remove the waisted studs (fig. Relieve the hydraulic extraction device and remove it.

05.9223-001 9.06./ 0. consisting of: Spacer blocks (2x) Crosspieces (2x) Lever (assembly/disassembly rig.53 See also: Spare parts list: Time requirement: 01.2 W2 W3 W4 W5 W6 W7 W8 W9 W10 9.nn.01.01. 02.05.nn. en / 27.9223-004 9.9. 03. cylinder liner) Piston rod clamping rig (2x) Cylinder liner retainer Pistoin rod eye holder Torque wrench 100-400 Nm Reversible ratchet 3/4“ Flexible head wrench 3/4“ Extension 3/4“ Disassembly rig for gauging ring W1 W1.9495-036 9.9216-001 9.9223-003 1.9217 B 9.9454-400 1.07. disassembly rig.01.30 h 02 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Assembly.2601 1 Pers. 02.nn.01.9228 F 9.9216 H Note: In order to prevent the cylinder liner (Fig.1 W1. 1/3) from loosening while the cylinder head is lifted or during turning.11.06.2000 IB022760 1/4 .04.02. the cylinder liner must be held in place with the cylinder liner retainer (W4) at all times. 02.50.Piston Maintenance / Disassembly VM32 A5.nn B1. piston.05.9223 B 9.

12. 7. 11. 6. Do not damage the cylinder liner surface. Turn the piston to TDC and rethread the threaded holes (Fig.nn). M12. 20° before TDC. 3. Note: The crane and lever must remain connected! en / 27.2000 IB022760 2/4 .01.05. 1/1.53 Procedure: 1. Attach the crane to the lever (W2) and bring the piston to BDC.1) into the crosspiece and mount the lever (W2) with the extension.11.06. Turn the upper piston edge to just below the gauging ring (Fig. 3/W1. Open the indicator valves. Insert disassembly rig (W10) so that the recess is inside the gauging ring. 02. Bolt the crosspiece (Fig. 9. remove the crankcase cover for the respective cylinder on both sides and remove the cylinder head (01. 8. 5.Piston Maintenance / Disassembly VM32 A5. Clean carbon deposits from the area above TDC for the 1st piston ring up to the gauging ring. 11 mm deep) in the piston crown. 4. 10. Press out and remove the gauging ring by turning the engine to raise the piston. Remove the disassembly rig (W10).06. 02 2. 2/4).01. Bolt the spacer blocks (W1.2) to the piston crown. Turn crank journal to the control side to ca. Tighten the disassembly rig slightly by turning the spindle nut.

2 13. 02 en / 27. Use the additional extension (W9) on the inside of the V. 13. 02.06.53 13. Bolt the flexible head wrench (Fig. Secure the wrench above the holder with set collars.3 Split the connecting rod shank. 4/W8) to the piston rod cap on both sides with the holder.01. Mount the piston rod clamping ring (W3) on the counterweight to secure the piston rod (22).2000 IB022760 3/4 .11.05.Piston Maintenance / Disassembly VM32 A5. Place the flexible head wrench on the uniform strength bolts (20).1 13.

nn). Place the piston on a suitable surface.Piston Maintenance / Disassembly VM32 A5.4 13. moving the crane as required.11. 15. Remove the uniform strength bolts (20) with the segments (21). 02 13. en / 27. 02. Pull the piston (4) carefully.53 Note: The engine may not be turned with the piston rod clamping rig (23) in place.5 14. Place the holding device (Fig.03.01. Note: Remove the connecting rod eye (Fig.01. 3/W5) for the piston rod eye (12) on the connecting rod shank with the opening towards the middle of the engine and lock into place into the piston bottom.05. 3/12) if the piston will be stored for a longer period of time to prevent vibration damage in the small end bearing bush area. 16.06. Seal off the oil bore in the piston rod shank split with a protective cap. Loosen the uniform strength bolts (20) with the torque wrench (W6) and reversible ratchet (W7). Measure the wear of the cylinder liner (03. 17.2000 IB022760 4/4 .

06.9.08.01. 02.2601 1 Pers.nn. Carefully turn piston and place on suitable base.nn).07. Disassembly of piston crown Attach lifting gear for piston (W1.01. 02. Mount second lifting gear for piston (W1) to connecting rod boss (1) and attach to second crane.nn) and evaluate (02.01.1 1.01.03. lift piston.08.3 2. Attach crane to lifting gear for piston (Fig.9223-001 1.04.02.1 2./ 0. connecting rod shank division) to crane. 1.04 See also: Spare parts list: Time requirement: 02.nn).01. 1.2 en / 18.02.06.nn.05.Piston Crown Maintenance / Replace M32 A5. 02. 1/W1). remove piston pin (2) (02. Measure small-end bearing (3) (02.nn B1.2006 IB025305 1/3 .9454-020 Auxiliary material: Molykote paste "G-n plus" ** ** or a product of equal standard Sequence of operations: 1.05. 2.70 h 02 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Lifting gear for pistons (2x) Torque wrench 20 .2 Turn piston.03.90 Nm * not available as figure W1 W2 * 9.09.

02. Determine length projection (IÜ) of piston screws (7) from contact surface. 02.Piston Crown Maintenance / Replace M32 A5.04 2.04.05.2006 IB025305 2/3 . 02 Attention: Check contact surfaces for friction scars and signs of cold welding.6 2. Pay attention to cleanliness of contact surfaces of piston parts. remove sliding block (10).3 2. Check and clean oil bores and sliding surfaces on sliding block (10) as well as piston lower part (12). contact Caterpillar/ MaK customer service if necessary.7 Remove locking ring (9). 2/5) and remove with piston lower part (12).5 mm en / 18.06. replace piston screw if IÜ > 129. 2.4 Loosen hexagon nuts (Fig. Clean piston crown (8) and piston lower part (12).5 2.

02.14 Tighten up tapering of piston screws (7) in piston crown.15 Tighten hexagon nuts (5) crosswise with a torque of M = 35 Nm and finally turn through an angle of 90°.8 2.9 Mounting of piston Screw piston screws (if removed) into piston crown and tighten with a torque of M = 10 Nm.16 Check: It should not be possible to turn the hexagon nuts any further at a torque of M = 100 Nm! en / 18.11 Mount piston lower part (12).10 2.Piston Crown Maintenance / Replace M32 A5.02. centering hole and dowel pin (11) must coincide. torque: M = 10 Nm 2.05. 2.2006 IB025305 3/3 .12 Tighten hexagon nuts (5) crosswise with a torque of M = 30 Nm 2. Coat inner thread and contact surfaces of the hexagon nuts (5) with Molykote paste.04 2.06.13 Loosen hexagon nuts again. ° 2. 2. 02 2.04.

A5.05. 90000 02.05. A5. 02.nn.10.2007 IB025688 1/1 .nn = Piston (disassembly).01. A5.01.nn = Piston rings and grooves (disassembly and assembly).02.02.nn.04./ 0. 02.nn = Piston pin (disassembly and assembly).08.05.06.10.01.08.01.06. A5.01.02.01.09.00 60000.nn B1.nn = Piston (assembly).nn.05.9.02. 02.000/ 90.06. A5.00 h See also: Spare parts list: Time requirement: 02 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Note: We have to point out that this maintenance sheet was prepared only for the purpose of maintenance planning.000 hours deadline.02.nn.07. 02.2601 0 Pers. Please contact the Caterpillar/ Kiel Customer Service in time before reaching the 60.08. Action: Replacement of all piston skirts (lower part) Replacement of all piston crowns (upper part) every 60 000 h every 90 000 h See also documents no.nn = Piston crown (disassembly and assembly).07.05. 02.05.01.01.02.02.Piston Maintenance / Replace M32/VM32 A5. en / 25.06.01.05.

01.9. the engine must be driven in according to the driving-in regulation A3. en / 30.03 30000. 7500 02. all piston rings free and no heavy wear can be detected.3 Piston inspection (7. 1. During inspection. but not beyond a maximum of 30.06. Check the running surfaces of the cylinder liners from the crank chamber.9227 B Note: If the running surfaces of all liners are without scores or high spots or any other damage. the check of the other pistons can be postponed to a later date.01. ring tension. pay special attention to any sharp edges of the rings.10.05.2617 1 Pers. Do not remove the graphite coating on the piston skirt.1 1.04. 02.000 operating hours.01. Sequence of operations: 1.nn! Built up pistons with chromium-plated first ring groove must only be reconditioned by MaK or MaK contract workshops. rings sticking due to carbon deposits.06.2 1. After fitting new piston rings. if the piston rings are stuck or burnt.500 h Maintenance: of all pistons and their rings after 30.05. Draw the other pistons too.nn).Piston Rings and Grooves Inspection / Checking M32 A5. and if the parts of the drawn piston are in proper condition.07.nn B1.02.50 h See also: Spare parts list: Time requirement: 02 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: of one piston and its rings after 7.000 h Tools: Piston ring expander W1 6./ 0.500 h) Open all crankcase covers. Draw the piston from the liner with the worst running pattern (02.2001 IB021136 1/3 .01.

10 hN1 = new hN2 = worn en / 30.05.07.03 30000.04.7 1.01. 2) in the front area of the groove in the longitudinal and transverse directions of the engine. 02.4 02 1. Check the chromium layer for wear.6 1. Record position of ring gaps in regard to the installation position of the piston on measuring sheet. Measure the ring thickness hR (Fig. 2) at 4 opposite lying points.8 1.Piston Rings and Grooves Inspection / Checking M32 A5. Clean the piston rings. If the chromium layer of one ring has been worn. check the rings of all pistons. ring grooves and oil return holes for the scraper ring. In case of heavy damage or deep scores renew the piston. Renew all rings of this piston if there is no chromium visible in some spots.5 1. 1. 1.2001 IB021136 2/3 . Measure the groove width hN (Fig. Smooth light friction and seazing marks with a fine oily emergy cloth or a fine carborandum stone. 7500 Remove piston rings only with the piston ring expander (Fig. particularly at the cut and the opposite side. 1/W1). When exceeding the limits. have the grooves reconditioned by MaK.9 Clean the piston.

45 10. Fit all pistons (02. 1/W1).01.5 0.2001 IB021136 3/3 . If the chromium layer is worn away in some places.nn).4 2.7 en / 30.6 2. Check the state of lubrication and appearance of the running surface of the piston and clean it.2 Limit hN2 . 3/X) upwards and with the ring gaps alternately opposite in engine longitudinal direction in the ring grooves.hR mm 0. 2.06.5 0.6.000 h) Draw all pistons (02. Measure the groove width hN according to operation sequence 1.01.1 2.9. Clean all ring grooves and check wear of the chromium layer. Remove the piston rings with the expander (Fig.1 2.45 6.05. Ring thickness hR Nominal mm 8 6 10 Groove width hN2 Wear limit mm 8.nn).11 02 Groove 1 2 3 1.03 30000. 7500 Calculate the limit tolerances and check according to the chart for standard piston ring sets.07.2 2.10. 2.Piston Rings and Grooves Inspection / Checking M32 A5.12 Insert piston rings with inscription upwards (Fig. Maintenance (30.3 2. Record the position of the ring gaps in regard to the installation position of the piston on the measuring sheet. 02.3 1.01. 3/X) and with the ring gaps lying alternately opposite in the ring grooves in engine longitudinal direction. Insert piston rings with inscription (Fig.5 2.04. send the piston to MaK for reconditioning. Replace oil scraper ring and all compression rings.

5 W10 W1. consist of: Spacer Cross-piece Turning gear Lever (mounting/extraction device.3) on the con-rod eye (5) and attach to a second crane. 02.1 1.Piston pin Inspection / Disassembly and reassembly VM32 A5.3 Mount turning gear (W1.nn.00 h 02 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Mounting/extraction device.2 4 1.9.50 See also: Spare parts list: Time requirement: 02. con-rod eye W1 W1.01.2 Turn the piston.05.09.1 W1. Attach the crane to the lever (fig.01.2 W1.2601 2 Pers.1996 IB003363 1/4 . piston. Mount with the opening towards the corresponding control side and lock it again in the piston.1 Attention: The holding device (W10) must lie on the piston base when being turned and must support the con-rod eye (5)!! W1.nn B1.11.06.9223 A Sequence of operations: 1. W2 W1.02. 1. 02.3 1 en / 15.08.3 W2 W10 9. cylinder liner) Holding device.01./ 1. Extract holding device (W10) for con-rod eye.05. 1/W2) and lift the piston.

2 2.Piston pin Inspection / Disassembly and reassembly VM32 A5.2) with the spacers (W1. piston (4) and piston pin (31) for assembly on the correct side. 2/5). It is possible that the clearances are insufficient in a cold condition in the case of new parts. 2.1996 IB003363 2/4 .3 2.5 Only rotate the piston around the tip of the lever (fig. The piston pin can usually be fitted and removed without heating up the piston. 02 W10 W1.7 2. extension to control side) on the piston. 02.11.01. heat up the piston to 80 °C in an oil bath.05. Mark the con-rod eye (fig. Remove the locking rings (32).6 1.50 1. Push the piston pin (31) out of the piston bore and small end bearing bush (30) without using force. The overall clearance is only given at operating temperature.08.4 1. Dismantle the cross-piece (W1.1) and lever (W2). Mark the installation position of the lever (W2. Place the piston on a suitable base and secure it! Disassemble the piston pin. Raise the con-rod eye slightly to relieve the piston pin.1 A 4 5 31 2.4 32 A Note: If the piston pin cannot be pushed out by hand.3 1. 1/W2) in the direction shown. A-A 30 5 31 32 2 en / 15.

Turn the piston to the installation position. small end bearing bush and piston pin bore in the piston (02. Lubricate the piston pin (31) and push it into the piston and small end bearing bush according to the side mark and without tilting it.3 Check the piston pin surface for cracks and damage.4 4.2 Secure the piston pin with the second locking ring (32).1 3. Insert the con-rod eye (5) in the piston (4) in such a way that the piston bore and small end bearing bush are flush.01. 02. 2/W1.50 2.Piston pin Inspection / Disassembly and reassembly VM32 A5.05.1) and lever (W2) according to the mark on the piston. Measure the piston pin. 2/32) in the piston bore.01.11. 3. heat up the piston to 80 °C in an oil bath/freeze the piston pin.5 2. Note: When mounting the lever pay attention that: the extension of the lever (W2) and the cylinder mark (fig.3) or to a second sling and raise the piston.08. Reassembly Fit a locking ring (fig. 3/40) face towards the control side! 5 40 3 en / 15.1 4. Attach the crane to the turning gear (fig.2) with spacers (W1. 4. 3.6 3. 02 Note: If necessary. Mount the cross-piece (W1.1996 IB003363 3/4 .nn).2 3.09.

1.11.4 Attach the crane to the shackle on the lever (fig.08.1996 IB003363 4/4 . Mount it with the opening towards the middle of the engine and lock it again in the piston base). 02 Attention: The holding device (W10) must lie on the piston base when being turned and must support the con-rod eye (5)! 4.01.Piston pin Inspection / Disassembly and reassembly VM32 A5.6 en / 15. 1/W2).05. 02. Dismantle the turning gear (12) and place the piston on a suitable base. 4.50 4.5 Extract the holding device (W10) for the con-rod eye. Rotate the piston in the opposite direction shown in fig.3 4.

the relevant wearing parts are to be exchanged.9.09. If possible.000 h if any criteria for exchange is reached Note: Exactly inserting a small-end bush is hardly possible with conventional on-board equipment. see 02.05.02. Determine axial clearance [piston boss distance (size D) and measure bearing thickness (size X)].2000 IB021149 1/3 . Sequence of operations: 1.nn B1. A small-end bush must be replaced only in cases of reaching a clearance limit or the clearance limit will probably be exceeded by the next overhaul. 02. 1) are reached.03. 1.1 1.05. The small-end bush in the connecting rod boss is equipped with a galvanic plated overlay.01. this work should be carried out by the MaK works or a contractor. small-end bush (2) and piston bosses and measure the sizes A./ 1.2601 2 Pers.nn.2 Measure small-end bush Clean piston pin (Fig.03.03. The clearance limits are in general decisive for assessment of the small-end bush (see table).Small-End Bush Maintenance / Measuring M32 A5. In case the clearance limits (see Fig.00 h See also: Spare parts list: Time requirement: 02 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance/repairing: Measure clearance: Renew small-end bush: every 30. en / 13.g. and C with suitable measuring device e.03. external or internal micrometer gauge. 2/1). B.09.01 30000 02.

05.2 Clearance max.09. 1 D B 2 A Z Z X 1 C Fig.12 0.06 0. 2 en / 13.2000 IB021149 2/3 . (mm) 0. (mm) Piston boss Ø (A) Piston pin Ø (C) Bush Ø (B) Piston pin Ø (C) Boss distance (D) Bush width (X) 0.182 0.09.005 0.01 30000 02 Clearance min. 02.Small-End Bush Maintenance / Measuring M32 A5.01.029 0.25 1.1 Fig.8 Limit mm 0.

the disassembly is carried out with a minimum of force.09. 3/Y).01 30000 02 2. the dimensional accuracy and the position of the oil bores and oil grooves are to be checked. 80 °C (consider the safety provisions!).2 3. 02. corrosion pits or other damages. Use a suitable crack testing equipment as Magna-Flux and a magnifying glass.1 Assemble the small-end bush Cool a piston bush by means of CO2 snow to approx. Connecting rod bosses with damaged bore surface may never be reused without prior reconditioning. examine the bore surface of the small-end bush carefully for cracks. To be carried out on bord in the emergency case only! 2.1 When disassembling the small-end bush make sure. 3 Attention: It is decisive to make sure that the surface of the small-end bush bore in the connecting rod boss is not damaged! After taking out. it has to be made tensionless by careful sawing or milling at the marked position (Fig. remove carefully possible piled-up materials. Prior to testing.05. 3. en / 13. After reaching the normal temperature.Small-End Bush Maintenance / Measuring M32 A5. Disassemble small-end bush Y Note: The following work should be carried out by MaK works or a contractor. The small-end bush must not be pressed out. Fig. 3. Attention: • Make sure the small-end bush in the connecting rod boss is at the right place! • The lateral projection (Fig.3 Insert bush into the connecting rod boss.01.09. -60 °C and heat the connecting rod boss in clean oil bath to abt. A reconditioning by MaK is generally possible. 2/Z) of the bush has to be equal on both sides! 3.2000 IB021149 3/3 .

4/W4)! After mounting a new piston or new piston rings the engine has to be run-in according to the running-in instructions (A3.nn.1998 IB004703 1/5 .01.50 h 02 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Tool W1 .01.e.06./ 0.06.10.nn.nn.01. 02. 02. Mark the mounting position of the lever (W2.Piston Maintenance / Reassembly VM32 A5.2 en / 27.11. Dismantle lever (Fig.nn B1.52 See also: Spare parts list: Time requirement: 01.50.9. if necessary. 2/W2) together with cross-piece (W1.01.1).W10 siehe 02.05.01.2601 1 Pers. 1.05. 02.9220 A Auxiliary material: Molykote paste „G-Rapid Plus“ * * or a product of equal standard Note: To prevent the cylinder liner from coming loose when turning the engine (before the cylinder head is mounted) the cylinder liner always has to be secured by means of the cylinder liner hold-down.10.9220 B 9. they are to be at 180° opposite each other)! Thoroughly lubricate piston rings and piston on the outside. Insert the new piston rings and arrange them so that every other ring joint points to an alternate end of the engine (i. 02.07.01.nn Piston mounting ring Piston guiding device (sheet-metal sleeve) W11 W12 9.02. (Fig. 1.1 Replace piston rings. extension towards camshaft side) on the piston and remove the piston rings.07.05.nn)! Sequence of operations: 1.2) and spacers (W1.

Attention: When you tighten the tension bolt make sure the piston rings do not rest on the outer edge of the ring groove.Piston Maintenance / Reassembly VM32 A5. Check by turning if the piston guiding device (W12) can still be moved around the piston. 7.2) with spacers (W1.05. Mount the piston mounting ring (Fig. Slightly beat on the piston guiding device to remove possible deformations.07. Loosen the tension bolt (Fig. 02. Place the piston guiding device (Fig. 7.1) and lever (W2) with extension on the piston in accordance with the piston marking. 4. W2 5.10.01. 2/ W11). 02 3.1 W1. Mount the piston mounting/extraction device (W1) on the piston as follows: Mount cross-piece (W1.1998 IB004703 2/5 . W11 6.1 W1. Grease the thread and the bolt contact surface of the tension bolt (1) with Molykote paste „G-Rapid Plus“.52 2. 1/ W12) above the piston ring zone and tighten the tension bolt (1).2 4 12 5 2 W5 en / 27. 1/1) until the piston guiding device (W12) is relaxed and can be guided freely above the piston rings.

02.1998 IB004703 3/5 . Carefully insert the piston into the cylinder liner. 12 13 14 21 20 Attention: Remove the protective cap from the oil bore of the con-rod. Carefully place piston with small end on the con-rod (22) and remove the holding device (W5)! In case the cylinder liner hold-down (Fig.07. 4/W4) was removed. 9. 3/13) are pointing towards camshaft side 02 Attach a crane to the lever (Fig. the piston must not be tilted in the cylinder liner. 13. If necessary. mount it again on the cylinder liner and screw the hexagon socket screw (6) against the engine block (5) only hand-tight. If necessary. 3/14) are inserted in the bores of the small end (12). Check the position of the holding device (W5). 12.01. Lower the piston. 14. 1/W12) onto the piston mounting ring (Fig. 2/W2) and lift it up. Place the piston guiding device (Fig. en / 27. the extension of the lever (W2) and the cylinder marking (Fig. align the piston with the lever (W2) and follow up with the crane. mount it with the opening pointing towards engine centre and engage it in the piston end again. pull off the small-end holding device (W5). 2/W11) so that the guiding device is level. On camshaft side it must rest against the inside of the piston (opening pointing towards engine centre) and support the small end (12).52 Note: When you mount the lever.05. 11.Piston Maintenance / Reassembly VM32 A5. make sure: 8.10. 3 22 10. Carefully lower the piston until the parallel pins (Fig.

01. Place the segments (21) upon the shank partition. insert the tension bolts and tighten the tension bolts alternately with a torque of M = 50 Nm.52 15. 15. At the side pointing towards the inside of the Vee use an extension (W9) additionally.3 15.07. 02 15.4 15. Screw the flexible head spanners (W8) at both sides onto the big-end bearing cap with the strap.5 Mark the positions of the tension bolts with chalk.1998 IB004703 4/5 .10.2 Mounting of piston and con-rod.Piston Maintenance / Reassembly VM32 A5. A B 3 20 W4 6 5 W8 W8 W6 21 W3 22 W7 W9 4 en / 27.1 15. 3/20) with Molykote. Remove the con-rod clamping devices (Fig. 4/W3).05. 02. Grease the threads and contact surfaces of the tension bolts (Fig.

01. Mount the cylinder head (01. Remove the flexible head spanners (Fig. 50° + 10°. 2/W1) and lever (W2) with extension. Dismount piston extraction/mounting device (Fig. 18. 1/W12) and piston mounting ring (Fig. Turn the piston to TDC position whilst following up with the crane. 19. 4/W4).7 Tighten the tension bolts alternately with a torque of M = 250 Nm. 02.07.11. It must have reached an angle of rotation = approx.05. 21. 20. Dismount the cylinder liner hold-down (Fig. 5/2) in the cylinder liner collar (3).8 Check the position of the tension bolt marking visually. Lower the piston and insert new calibrating ring (2). 17.52 15. piston guiding device (Fig. 2/W11). 2 3 4 5 en / 27.6 Put the flexible head spanners onto the tension bolts (20). 15. mount the crankcase doors and close the indicator valves.01.10. Clean the calibrating ring contact surface (fig. 4/W8) and the extension (W9) together with straps and set collars.nn). Fix the spanners above strap by means of set collars. 02 Attention: Do not turn the engine with spanners put on! 15.1998 IB004703 5/5 . ° ° 15.9 16.Piston Maintenance / Reassembly VM32 A5.

nn B1.01.nn.04./ 0.50 h 03 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Replace O-rings Tools: M16 ring bolt * not illustrated W1* Auxiliary material: Vaseline ** ** or a product of equal standard Sequence of operations: Attention: It is only possible to remove the cooling water distributor housing (fig.02.01. 2/6) when the cylinder liner (03.00.nn) has been removed.nn.50 See also: Spare parts list: Time requirement: 01.Cooling water distributor housing Maintenance / Disassembly and reassembly VM32 A5.04. 03.10.06.04. Y V 1 X X W Z 2 1 en / 28.9.02.01.nn.03. 01.1110 1 Pers.04.05.1998 IB003365 1/4 . 03.05.01. 03.

Dismantle the corresponding cylinder head and retainer for the exhaust pipe (fig. control air duct) into the adjacent cooling water distributor housing (1).2 Disassembly of the cooling water distributor housing. Remove the hexagon bolts (fig. 3/ 20).05.1 1.3 Remove the hexagon bolts (fig. 03 12 1 13 14 10 11 1. 03. Screw the ring bolts (W1) into the cooling water distributor housing and lift the housing off by means of a crane.1998 IB003365 2/4 . Push the sleeves (16. 3/23) on the cooling water distributor and collecting pipeline (24). Remove the cheese head screws (fig.5 15 24 Y 25 26 20 W1 20 21 22 23 1 27 20 Z 20 W1 16 14 12 3 en / 28.04. Follow up with the crane accordingly! Remove the O-rings (25) on the cooling water distributor and collecting pipeline connection. 1 1.02. 1.00. 2/11). 2/10) together with the washers (11).50 1.4 15 16 2 1.Cooling water distributor housing Maintenance / Disassembly and reassembly VM32 A5.

3/14) and the opposite cooling water outlet (26) Fig. 5/40) on the push rod leadthrough (fig.3/21) on the cooling water distributor housing. 2/12. air charge transfer Fig.00. 2/13. The sealing ring (fig.4/30) on the air charge opening and the O-ring (fig. 2/16) out of the adjacent cooling water distributor (1) housings and replace the O-rings (15). 5/44) and O-ring (43) on the cylinder liner collar as well as the O-rings 27 24 25 Fig. 03. control air transfer are replaced when assembling the cylinder head! The sleeves (fig.6 Replace the O-ring (fig. 30 4 W 44 22 43 42 41 21 12 U 50 6 40 5 2. Reassembly of the cooling water distributor housing IB003365 3/4 en / 28. 03 V Note: Insert all O-rings in the grooves using vaseline and make sure they are not twisted. 6/50.Cooling water distributor housing Maintenance / Disassembly and reassembly VM32 A5. 14 and 26) must be positioned vertically! The O-ring (fig.05.02. 5/41) is replaced when mounting the cylinder liner (42)! 1.7 Pull the sleeves (fig. 5/22.1998 . starting air inlet (fig.04. push rod leadthrough Fig.50 1. 4/27.

02.Cooling water distributor housing Maintenance / Disassembly and reassembly VM32 A5. 1/2).04.nn) and tighten the cheese head screws (fig.1 Clean the contact surfaces on the cylinder crank case and carefully lower the cooling water distributor housing with new O-rings onto the cylinder crank case by means of a crane.4 2. 3/23) on the cooling water distributor and collecting pipeline.3 2.02.nn).05. 03.6 2.7 Mount the cylinder liner (03.04. Push the sleeves (fig. 2.01. Remove the ring bolts (W1) and mount the cylinder head.50 Attention: Only mount the cooling water distributor housing (fig.1998 IB003365 4/4 . 3/20). 03 2. Insert the push rods in the push rod leadthrough (22). Tighten the hexagon bolts (fig. 2/16) of the starting air duct into the correct position and secure with the hexagon bolt (10) and washer (11).04.00. Follow up with the crane accordingly. en / 28. 3/1) when the cylinder liner has been dismantled (03.2 Press the cooling water distributor housing against the cooling water distributor and collecting pipeline (24) and tighten the cheese head screws (20) slightly. Attention: Final tightening of the cheese head screws only after mounting the cylinder liner! 2.5 2. Mount the retainer for the exhaust pipeline (fig.

05.2001 IB021192 1/2 .03.nn). Clean the cylinder liner internally (thoroughly cover the crankcase). Check the cylinder liner. 15000 02. ** 1.1110.000 h of all cylinder liners after every piston removal. B1. W1 1 Tools: Gauge ruler for cylinder liner W1 9.1 1. depending on the operating time and operating conditions (see Fig. 2 Note: Extreme wear can occur on the cylinder liners which has to be evaluated and measured. dimension Longitudinal direction Transverse direction Diagonal Diagonal en / 18. determined by the ruler gauge (Fig.05. 03.01.06. 03. 2).9.03.2084 A Precision inside micrometer W2 *.06.12./ 0.01.04.3 Pull piston (02. Measure the cylinder liner with the precision inside micrometer (W2) at the measuring points longitudinal.05. 3 1 1.01.9419 B * not available as figure ** or measuring instrument of equal standard Sequence of operations: 1.4 Wear Measuring point 1 2 3 Ref. 1/W1) and table (Fig.01.03.20 h See also: Spare parts list: Time requirement: 03 Personnel qualification: Chief engineer Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: of one cylinder liner after 15.nn B1. transverse and 2 x diagonal to the engine axis.Cylinder Liner Inspection / Measuring M32 A5.9.2 1. 3) 1.nn.03 30000.000 h of all cylinder liners after 30. before every removal and after every fitting of the cylinder liner.1611 1 Pers.

00 30.5 03 1. Cylinder liner wear chart Evaluation criteria Nominal Ø (new) 320.01. or other limit values indicated in the table are reached (Fig. Individual deep blow-through ducts in the area of the 1st piston ring (TDC). 5: canyon 1.03 3 90. Vertical and linear scores.0 + 0. 3 and Fig.00 3 180.05.12.reference dimension d3 etc.03 3 8. See also measuring sheet in the file "Forms for maintenance reports".00 0.Cylinder Liner Inspection / Measuring M32 A5. 2: pocket. out-of-round Wear Gusset height depth * max. normally in the area of the top dead center of the piston ring (TDC 1st ring). number length total width number length depth number length width ** depth * 0. 3 2 4 5 ***1 4 en / 18. Canyon Scores Pocket Irregular indentations. Reconditioning of the cylinder liners only by Caterpillar/MaK .03 30000. 03.057 Max.00 0.). 4: TDC 1st ring.02 Wear limit (mm) * ** *** Explanation Radius r ≥ 3mm In circumferential direction 1: gusset. 2) and thereafter determine the wear (d1 . replace the cylinder liner.03. 3: scores. When the wear limit.00 4. 15000 Enter the measured values in the table (Fig.00 0.6 TDC 1st ring Wedge-shaped indentation across the entire circumference.2001 IB021192 2/2 .00 8.30 1. 4). beginning frm the TDC of 1st piston ring.

03.nn.9.03.1 W1.01.50 30000 02. 1/3) must be protected against damage! Sequence of operations: 1.3 Measure the wear on the cylinder liner.2000 IB021905 1/2 ./ 0.06.3 W1.1 1.50 h See also: Spare parts list: Time requirement: 03 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Remove the cylinder liner Replace the O-ring every 30.05.05.03. 2/21) and O-ring (20) from the cylinder liner collar.01.05.01. en / 05. 03.06. 1.06.2 W1.nn B1. 03.Cylinder liner Maintenance / Disassembly VM32 A5.9.04.2 Disassemble the cylinder liner. B1. Remove the piston and cylinder liner holder (02. Remove the sealing ring (fig.1611 1 Pers.nn).1110.000 h Tools: Mounting /extraction device for cylinder liners consist of: Lever Clamping plate Tension rod Hexagon nuts W1 W1.01. Note: The sealing ring (21) and O-ring (20) are replaced when mounting the cylinder head! 1.4 Attention: All sealing surfaces of the cylinder liner (fig.

2) under the cylinder liner (3).6 1.2) and lever (W1.1 3 2 1. Follow up with the lifting gear accordingly. 1.1) if necessary. Check all sealing surfaces for damage. Place the cylinder liner on a suitable base and secure it.11 1.2000 IB021905 2/2 .1) together by means of the hexagon nuts (W1. Align with the lever (W1.8 1.4 W1. Remove the O-ring (fig.5 1.12 21 20 3 22 2 2 en / 05. 1/W1). Carefully clean the cooling water area on the cylinder liner collar.3 03 W1.4.4.01.50 30000 Mount the mounting / extraction device (fig.7 1.2 1.3).10 1. Do not tilt the cylinder liner.4 1. Fix the clamping plate (W1.3 1 1.1 1.04. Clean the cylinder liner support. Place the clamping plate (W1.2 W1.Cylinder liner Maintenance / Disassembly VM32 A5. To do so: Place the lever (1) with the extension on the cylinder liner collar.9 W1.06.4) and tension rod (W1.05. upper and lower fitting in the cylinder crank case. Carefully clean the sealing surface and groove for the O-ring and check for damage.4. 03. 2/22) in the cooling water distributor housing (2). Attach the lifting gear and carefully pull out the cylinder liner (3).

2000 IB003373 1/3 . Clean the inside of the cooling water manifold housing (fig.nn.03.11. 2. Fit a new O-ring (22) in the groove on the cooling water manifold housing.nn B1.1611 1 Pers.01.50 h 03 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Mounting/extraction device for cylinder liners consisting of: Lever Clamping plate Tension rod Hexagon nut W1 W1.05.4 Auxiliary material: Vaseline * * or a product of equal standard Note: After fitting a new cylinder liner.05. en / 24. measure the new cylinder liner before mounting the calibrating ring.02.03./ 0.05.2 W1.10. replace the O-rings on the push rod lead-through and the air charge opening to the cylinder crankcase (03. 1/2).Cylinder Liner Maintenance / Reassembly VM32 A5.9.01. 03.nn).00.01.04. 03.02. Observe the driving-in regulation (A3.1110. B1. If necessary.3 W1.04.50 See also: Spare parts list: Time requirement: 03.nn)! Sequence of operations: 1.9.1 W1.03.

5.05. 4. Mount the mounting/extraction device (W1) on the cylinder liner which is to be installed (03. Dismantle the mounting/extraction device (W1) from the drawn cylinder liner.1) to align it.04.04. Do not tilt the cylinder liner.1 en / 24. Attach lifting gear to the mounting/extraction device (W1) and guide the cylinder liner (3) into the cylinder crankcase (4).Cylinder Liner Maintenance / Reassembly VM32 A5. use the lever (W1.nn).11.50 Attention: Fit the O-ring in the groove using vaseline making sure it is not twisted! 03 3.01. 5. 03.2000 IB003373 2/3 . If necessary.02. Follow up with the lifting gear accordingly.

03.50 Note: Insert the cylinder liner in such a way that the marking (fig. 7. Dismantle the mounting/extraction device (W1) and measure the new cylinder liner.11. Attention: The cylinder liner must glide into the fitting on the cylinder crankcase (fig. 1/4) by its own weight! 6.05.2000 IB003373 3/3 .02.04. Mount the piston and calibrating ring. en / 24.Cylinder Liner Maintenance / Reassembly VM32 A5. 2/25) for the cylinder liners of Cylinder row A faces towards the side opposite the coupling and Cylinder row B faces towards the coupling side. 03 The marking (26) on the cooling water manifold housing can be used as an alignment aid.

/ 2. en / 05. Note: This precautionary measure has to be taken once to detect any leaks or slack screwed connections that may result from some parts or gaskets taking a set that could cause damage. 6. Check for good mounting and leaks of flanged connections. Ceck the expansion joints and screwed connections of the exhaust manifold for leaks and tight fit and the manifold itself for proper suspension (06.01.nn).00 150 02. thermostats and pipe clamps of the following systems: • cooling water • lubricating oil • fuel • starting air • exhaust gas • pneumatic control 2. 4.2001 IB002385 1/1 . Retighten the fixing bolts of the brackets of the injection pump control rods and check the locking washers and pins of the connection joints. Sequence of operations: 1. Check the monitoring and control equipment for good fitting.05.02.02.01. filters.01.01. 5. When starting up a new unit (150 h) or after big repairs the engine unions and screwed connections are to be inspected for good fitting and leaks.nn. Check the tight fitting of the suspensions and unions in the charge air manifold.nn See also: Spare parts list: Time requirement: 03 1 Pers. 03. 06.nn).Engine Bolting and Unions Inspection / Checking M32 A5.10. Torque values can be obtained at the MaK customer support. unions and screwed connections for good fitting and leaks.00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: of all bolts.01.01. 3.07. 7. Measure the crank web deflection after tightening slack foundation bolts (02. Check the foundation bolts and chocks by knocking.01. Check elastic bedding elements for damages. Cables and signal pipes must not scrab against any part.

1.01.04.37 Clearance limit mm 0. Measure clearance camshaft bearing / bearing neck. Check running surface of the bearing necks of the corresponding camshaft bearings.01.3123 1 Pers. en / 10.01.20 h See also: Spare parts list: Time requirement: 04 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: Bearing clearance of one camshaft bearing after Bearing clearance of all camshaft bearings after 15.50 30000. The load on the bearing occurs exceptionally in the lower contact area and is relatively heavy in this area. B1. 15000 02. 04.2001 IB022819 1/1 . Sequence of operations: 1.nn.1 1.3122.04.nn B1. Smooth overload along the edges is not unusual.23 .01.000 h Note: Camshaft bearings are not subjected to load changes.05. 04.9. New clearance mm 0.9.2 Check the camshaft bearing clearance.000 h 30.05.01.5 Note: With reaching the clearance limit the camshaft bearing is to be replaced (Caterpillar-customer support) and the clearance of all camshaft bearings are to be checked. Open corresponding inspection glass lid of the camshaft door.05./ 0.01.02.Camshaft Bearing Inspection / Checking VM32 A5.0.

01.04. Slight pressure on the edges is normal! Sequence of operations: Attention: Inform Carterpillar Customer Service for maintenance of the camshaft bearing between the camshaft gear wheel and the first cylinder.20 h See also: Spare parts list: Time requirement: 04 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Check the running surface of one camshaft bearing and the corresponding bearing journals from the first cylinder onwards Check the running surface of all the camshaft bearings and the corresponding bearing journals from the first cylinder onwards 15. B1.02.05.9. 1.51 30000.01.nn. 1/2) before disassembly of the camshaft bearing for the last cylinder! 1.Camshaft Bearing Maintenance / Disassembly and reassembly VM32 A5. Check the running surface of one camshaft bearing and the corresponding bearing journal from the first cylinder onward Attention: Secure the vibration damper (fig.04. 04.05.9. 15000 02.04.03.2001 IB022830 1/4 . Refer to 04.nn B1.3122.04.3123 1 Pers.04.03.01.nn Note: The camshaft bearings are only subject to stress in the lower contact area where the stress is relatively high.02.05.1 Dismantle the camshaft section of the respective cylinder.01. 04.nn.000 h - 30.000 h Tools: refer to 04. en / 06./ 0.

3 Lubricate the outside of the bearing journal. Pull out the bearing journal (3) without tilting it! Check the running service of the bearing journal and replace the journal if there is any scoring. 2.6.Camshaft Bearing Maintenance / Disassembly and reassembly VM32 A5.5 Fit the bearing journals of cylinder row A and B with straight pins (fig.5 1.02.6 04 To do so: 1.2001 IB022830 2/4 .01.01. 1/7) according to the pin code (fig.02. 2.2 Reassembly Insert the camshaft bearing and align it with the locating screwing (4).nn.1 2. 04.4 2. 2 /fig. 3) and insert them in the camshaft bearing correct left to right. Also check the back of the bearing.1 Loosen the locating screwing (4) and remove the camshaft bearing. Check the camshaft bearing (1) and dismantle it in the event of: a poor contact pattern pressure on the edges scoring. 2. Remove the hexagon bolts (fig.4 1. 1.51 30000. 15000 Mount the mounting / extraction device for camshaft sections on the corresponding left hand / right hand camshaft section and bring it into position.04. 2. 1/5) from the bearing journal which is to be checked.05. Note: The bearing journals are equipped differently with straight pins according to the firing order and the cylinder to which they belong.3 1. en / 06. Tighten the locating screwing (4) at a torque of M = 60 Nm. Further assembly: refer 04.2 1.

2001 IB022830 3/4 . 15000 Cylinder row A Bearing journal number Pin in bore coupling side X 2 3 4 5 6 7 8 1 Bearing journal A1 coupling side X opposite side of coupling Y opposite side of coupling Y 1 1 1 1 1 1 1 - 04 A1 A2 A3 A4 A5 A6 A7 A8 en / 06.51 30000.02. 04.01.Camshaft Bearing Maintenance / Disassembly and reassembly VM32 A5.02.05.

51 30000.05.Camshaft Bearing Maintenance / Disassembly and reassembly VM32 A5. 04. 15000 Cylinder row B Bearing journal number Pin in bore coupling side X 1 1 1 1 1 1 1 1 Bearing journal B1 opposite side of coupling Y coupling side X opposite side of coupling Y 2 3 4 5 6 7 8 - 04 B1 B2 B3 B4 B5 B6 B7 B8 en / 06.01.02.02.2001 IB022830 4/4 .

10.4 Disassembly Remove respective camshaft cover.9104 A Also needed: “G-Rapid Plus“ ** Molykote Paste Vaseline ** * not shown ** or comparable product Sequence: 1.Bottom part for Valve Mechanism Maintenance / Disassembly and reassembly VM32 A5.02.0.2004 IB023923 1/5 . move up). Take off cylinder head cover.01 See also: Spare parts list: Time requirement: B1.50 h 04 Personnel qualification: skilled engine hand / Assistant engine hand Operating medium: Every fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench (100-400 Nm) Mounting bolts (2x) W1* W2 1. Turn inlet and outlet radial cam to the base circle position (unload rocker arm.9454-400 9.05.01./ 0.05.02. en / 15.1 1.00.0.) Take off rocker arm bracket (01.0.3 1.9. 1.nn) (if necessary. 04.2 1.0.04.3502 2 Pers.

05. Insert both oil tubes (5) a short distance into the rocker shaft bore and remove by tilting slightly.2/2) and their positions to prevent them from being switched up during assembly.6 1.0.02. and spring guide (18).) Remove respective injection pump (Abb.Bottom part for Valve Mechanism Maintenance / Disassembly and reassembly VM32 A5.nn).01 1. 1.01.1 1.00.1/1) (07.7 Turn injection cam to base circle position (unload rocker arm.5 1. spring collar (17). 04 Note Mark pushrods (Fig.2 1. en / 15. Take out plunger rod (15). Remove one retainer clip (4) each for oil tubes (5) on either side of the cam follower bracket to be removed.10.0.3 Remove pushrods (2). spring (16).02.0. 04.2004 IB023923 2/5 .

tigthten by hand. 04.00. cam followers (9) should be supported using timbers.4 Remove the two upper mounting bolts (7) with washer (8) of cam follower bracket (3) and replace 04 withmounting bolts (W2) .01 1.10. Attention: Inorder to prevent damage to cam followers (9) and their rollers (10) during disassembly. en / 15.Bottom part for Valve Mechanism Maintenance / Disassembly and reassembly VM32 A5.02.2004 IB023923 3/5 .05.

02. Attach cam follower bracket (3) to the crane using a sling and remove mounting bolt (W1).2004 IB023923 4/5 . Assembly: Note When assembling can follower bracket (3).7 1.10. Check all contact areas and points for cleanliness and damage. During this process. Insert lower mounting bolts (7a) with washers (8a) and tighten slightly. the cam followers (9) must be lifted so that rollers (10) come to rest on cams (12).01 1.00.5 1.6 Insert mounting bolts (W2) into the upper two mounting bores and tighten by hand.1 2. 04 2.6 1. Note Treat all threads lightly with Molykote before assembly. Set cam follower bracket (3) down on appropriate surface.9 Remove the two bottom mounting bolts (7a) and washers (8a). 04.5 2. Carefully pull cam follower bracket (3) up to the stop (bolt head). en / 15.8 1. Take sling off and place cam follower bracket (3) into position with cam followers (9) (wooden support). Remove plates (11).4 2.05. Remove mounting bolts (W2) and replace with upper mounting bolts (7) with washers (8). Insert plates (11) according to the illustration.3 2.Bottom part for Valve Mechanism Maintenance / Disassembly and reassembly VM32 A5. 2. 2. always make sure rollers (10) are not damaged.2 Attach cam follower bracket (3) to the crane using a sling and move into place carefully.

spring (16).1/15).9 2.01.13 2. and spring guide (18) lightly with Molykote and position parts appropriately.00. Install cam shaft cover.02. 04.01.nn).05. Install injection pump (1) (07.) Treat plunger rod (Fig.11 2.01.Bottom part for Valve Mechanism Maintenance / Disassembly and reassembly VM32 A5.02.nn) .02. Insert oil pipes (5) into rocker arm shaft (6) and secure with retainer clip (4). Install rocker shaft bracket (01.nn).8 2. Check valve clearance (01. Insert pushrods (2) according to their markings (note: page 1/5.10.15 2. en / 15.16 Treat new O-rings (13) slightly with vaseline and insert the rings into the oil pipe grooves without twisting them. Start pre-lube pump and check oil pipes for leaks.2004 IB023923 5/5 .12 2. spring collar (17).14 2.01.01 2.10 2.7 Tighten mounting bolts (7/ 7a) incrementally ”working crosswise “ until a torque of M = 300 Nm has been reached. 04 2.

4 W4 * W5 * W6 W 6.3122.3 W1.52 See also: Spare parts list: Time requirement: 01.00 h 04 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Mounting / extraction device for camshaft section consisting of: Grip Adjustment bar Fine adjusting devices Locking lever 100 .Camshaft Repair / Disassembly and reassembly VM32 A5.400 Nm torque wrench 1/2“ changeover ratchet Tool holder Attachment screw W1 W1.05.3123 1 Pers.nn B1.2 W1.01. 01.01.04.01.9.01.9459-033 9. 04./ 3.1 W1.04.02.nn.1 9.03.nn. B1.9. 04.020" sealing compound ** ** or a product of equal standard Sequence of operations: Attention: The camshaft is not allowed to be turned after a camshaft section has been removed! The section which has been removed must always be refitted before dismantling a further section! en / 05.08.05.2103 A * not illustrated Auxiliary material: Molykote paste "G rapid plus" ** "Dirco 610.05.2006 IB023956 1/6 .01.9454-400 1.04.9230 B 1.

04.3 1.5 Dismantle the injection pump (07. The gear casing cover must also be removed when disassembling the camshaft section of cylinder 1. lift the cam follower of the inlet and exhaust valves off the cam and secure them with wire. in case of reIB023956 2/6 en / 05. furthermore.02. Open the indicator valves and dismantle the respective camshaft covers. the camshaft sections of cylinder bank A must only be displaced towards the free end of the engine.Camshaft Repair / Disassembly and reassembly VM32 A5. 1.2 1. Dismantle all rocker arms to relieve the corresponding camshaft (cylinder bank A or B) (01.01.1 when working on the camshaft of cylinder bank B. the camshaft sections remaining in the engine must be displaced accordingly towards the free end / driving end of the engine. When dismantling a camshaft section of cylinder bank B.05.2.01.52 1.1 1. Dismantle the pushrods of the corresponding camshaft section.02. 1.nn).01.01.2. 1/2) at the free end of the engine and remove all sealing compound from the cover and the engine block.1 Disassembly Dismantle all valve covers on the respective side of the engine. 04 Note: To be dismantled.2006 .nn) of the respective cylinder.04.4 Only carry out operating sequence 1. 1. Remove the cover (fig.

05.01.04. Cylinder bank B Dismantle the injection pumps of all cylinders of side B.6 Loosen all hexagon bolts (fig. 1. 04. Note: Secure the vibration damper (20) when dismantling the camshaft section of the last cylinder! Attention: en / 05.52 pair on Cylinder bank A Dismantle the injection pumps of all cylinders arranged in way of the free end of the engine.01.2006 IB023956 3/6 . making sure that the inlet and exhaust cams are more or less in a horizontal position before loosening the last hexagon bolts.Camshaft Repair / Disassembly and reassembly VM32 A5.7 Turn the camshaft to make hidden hexagon bolts accessible. 2/18) on the camshaft section which is to be replaced and remove them. 04 1.

04. axially up to 10 mm to the left / right. 2/15). 3/15). 1.9 1.10 1. The camshaft section which is to be replaced must lie between the straight pins (fig. including the bearing journal. Cylinder bank A camshaft Push the remaining part of the camshaft at free end including the bearing journal.52 The engine must no longer be turned! 04 1.01.8 Fit tool holder (fig.2) into the tool hoder (W6) and tighten well using attachment screws (W6.1) to press it down until the fine adjusting devices (W1.3) lie firmly (without pressure) on the camshaft section (4).01. Pull the locking lever (W1.1). Displace the camshaft section which is to be replaced in such a way that it lies between the straight pins (fig. 3 /W2) as shown in the figure onto the stud bolts of the camshaft cover retainers and tighten with hexagon nuts (5).Camshaft Repair / Disassembly and reassembly VM32 A5.2006 IB023956 4/6 .04. adjust the fine adjusting devices and bring the locking lever (W1.05. If necessary. Insert the mounting/extraction device (W1) with adjustment bar (W1.11 Attention: Do not use any force when displacing the camshaft.4) into the locking position and lock it. Cylinder bank B camshaft Push the remaining left-hand and righthand camshaft components.4) and use the grip (W1. axially up to 20 mm to the left (free end of the engine). Check the clearance of the cam followers if there is a restriction! en / 05.

Attach the camshaft section (4) to a crane by means of a sling.Camshaft Repair / Disassembly and reassembly VM32 A5. without pressure.3 Reassembly Place the camshaft section (4) on the grip (W1.1 2. 2. en / 05. 04 1. pull the locking lever (W1. 2.2) in this position.5 Apply Molykote to the thread and contact surfaces of the hexagon bolts (fig. press over the casting projections on one side and lift out.13 1. Set down onto a suitable surface.52 Note: The camshaft section which has been removed is held in the engine by the mounting/extracting device. if applicable.1) to a horizontal position. The straight pins in the bearing journals and the recesses must hold the camshaft section securely. If necessary. Remove the sling.1) by means of the crane and roll it into the engine block as far as possible.2006 IB023956 5/6 .14 2. axially. Roll the camshaft section (4) up to the opening of the casing.01.04. Raise / lower the camshaft section towards the center of the camshaft axis by means of the fine adjusting devices and align the bore (fig. 04.05. 1/5) with the bearing journal (22) and.2 2. Insert the hexagon bolts (18) as far as possible and tighten them finger-tight. to the right (driving end). 2/18). 1.4 Cylinder bank A camshaft Push the camshaft section without pressure flush against the bearing journal on the driving end. It must lie flush on the camshaft section. Push the rest of the camshaft including the bearing journal. Lock the locking lever in the bearing block.12 Pull the locking lever (fig. Note: No pressure is allowed to be applied when pushing together the camshaft sections.01.4) and lift the grip (W1. Cylinder bank B camshaft Push the camshaft gearwheel (fig.4). the camshaft sections from the driving end and the remaining camshaft from the free end against the camshaft section which has been fitted. 2/23) in the flange with the straight pin (15) of the bearing journal on the free end. optimize the height of the camshaft section. 3/W1. 2. Lock the locking lever in the adjustment bar (W1. lower it by means of the grip and raise the camshaft section (center of camshaft axis).

1/2) and mount it. at a torque of M = 210 Nm Make the hidden hexagon bolts accessible by turning the camshaft.9 2.04.2006 IB023956 6/6 . valve covers as well as the gear casing cover if it has been removed. 2/18) and tighten them finger-tight.Camshaft Repair / Disassembly and reassembly VM32 A5.02. 04. Turn the engine if necessary.01.52 2.11 2. 3/W1). Close the indicator valves and check the lubricating oil passage.nn). Mount the rocker arms (01.05.01. All injection cam followers must be raised! Mount all injection pumps (07.13 Apply a thin film of sealing compound to the contact surface of the cover (fig. en / 05. 2.nn).01. 04 Note: The engine can now be turned again! 2. Check the axial play of the camshaft gear wheel (04. crosswise.6 Dismantle the mounting / extraction device (fig.08.01.03. Check the gaskets and mount the camshaft covers.7 Fit the remaining hexagon bolts (fig.12 2.8 2.nn) and check the valve clearance.10 2.02. Tighten the hexagon bolts (18) by progressive stages.

03. Check the tooth faces of both camshaft gear gear wheels (Fig.04.08.01.0.9.400 Nm Changeover ratchet 1/2" Dial gauge with holder * no illustration W1 * W2 * W3 * 1.08.2000 IB021951 1/2 .05.05.4 Check function and tight fit of oil nozzles (2).01.nn B1.06./ 0.3 1 1.31 .2 Inspection of tooth faces and oil nozzles Dismantle the gear casing covers on both sides of the engine.1112.9454-400 1. B1.38 z = 0.05.0.Timing Gear Train Inspection / Checking VM32 A5.43 1 X 2 5 Z 2 X 4 1.05.000 h Tools: Torque wrench 100 . 04. 3750 02. Measure the tooth clearance between intermediate wheel and camshaft gear wheels (x) and between intermediate wheel and crankshaft gear wheel (z). B1.4 1. en / 05. 4). Set-points 1.50 h See also: Spare parts list: Time requirement: 04 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: of tooth faces and oil nozzles firm seating of locking ring on intermediate wheel axle axial clearance of intermediate wheel every 3.5140.19 .9459-033 Auxiliary material: Molykote-paste „G-Rapid“ ** ** or a product of equal standard A 2 3 2 B Sequence of operations: 1.1 1.750 h every 15.01. 1.9.8450 1 Pers. 1. 1/1.51 15000.5 Check the gaskets and mount the gear casing cover.5 x = 0.the intermediate wheel (3) and the crankshaft gear wheel (5).9.

2.3 .7 Mount the protective hood on the flywheel and . 2. Push the intermediate wheel toward the opposite side of the coupling and determine the axial clearance „s“. 2/3).51 15000. Set-point s = 0.08.6 mm 2.5 04 Inform the MaK after-sales service in case the tooth faces are damaged or the allowable set-points(tooth clearance.1 2.0. axial clearance) are not observed. 2.06.2 2. Pull the intermediate wheel (3) against the cylinder crankcase towards the coupling side.6 2. 04.05. Check the axial clearance „s“ of the intermediate wheel (Fig. If necessary. if necessary. Place the dial gauge on the intermediate wheel (3) and set to „O“. loosen the drainage pipe (15) and the bearing blocks (12) for the control rod (13).6 Check the gasket on the cover (10) and replace it.01.mount the drainage pipe (15) and the bearing blocks (12) for the control rod (13).if removed at all .Timing Gear Train Inspection / Checking VM32 A5. Dismantle the protective hood for the flywheel and the cover (10) with the gasket.4 2. 3750 6.7 2.2000 IB021951 2/2 . A-A 3 12 13 15 10 W A A W s 2 en / 05. Mount the cover together with the gasket.3 2. Mount the dial gauge together with the holder.

10. 1.9.1. 04. bolt (6) and washer (2).000 h Tools: Torque wrench 40 . Remove hexagon head screws (11) and lift up the governor (10).03.2 en / 18.3 1.020” ** ** or a product of equal standard Sequence of operations: 1. 1/1).9. Put aside the spring element (7).00 h See also: Spare parts list: Time requirement: 04 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: Contact pattern on helical gear wheel every Contact pattern on intermediate gear wheel Serration of governor drive shaft End float of camshaft gear wheel 15.05.51 15000 04.180 Nm Shift ratchet 1/2" * not illustrated W1 * W2 * 1.05.05./ 2.04.1 1.1. Remove the prevailing torque type nut (1) with spacer sleeve (4). B1. to this end: Arrest the stop lever in stop position.1110.2 Disassembly Loosen the governor linkage from the governor (fig.nn B1.Governor Drive Inspection / Disassembly and reassembly VM32 A5.9454-040 1.03.2001 IB020902 1/4 . 1.08.04.4111 1 Pers.1.1 1.01.9459-033 Auxiliary material: Molykote paste “G-Rapid Plus” ** Sealing compound “Dirco 610.

3/30) and O-rings (31).3 04 1. Mind the cylindrical pins (32).4 Attach the governor drive housing (23) to a crane by means of a sling and carefully lift up from the engine block Attention: Danger of damage to lubricating oil passage sleeve fig.5 1.10.2001 IB020902 2/4 .05.08.6 Put the governor drive housing (fig.Governor Drive Inspection / Disassembly and reassembly VM32 A5. en / 18.51 15000 Remove hexagon head screws (fig. Remove gasket (24) and clean the contact face on the engine block.03. 2/20) with spacers (21) and hexagon head screws (22). 1. 1. 2/23) onto a suitable base. 04.

41) for pittings. 1.10. 4/40.9 Check the serration of governor drive shaft (43) and governor (fig. Check the intermediate gear wheel (42).Governor Drive Inspection / Disassembly and reassembly VM32 A5. if necessary clean it. 04. skewing or break off.8 1.05.08. 1/10) for wear.03. Check all oil lubrication bores for lubrication of the governor drive shaft and the helical gear wheels for free passage.2001 IB020902 3/4 . en / 18.51 15000 Check the gear flanks of the helical gear wheels (fig.7 04 1.

8 Insert and firmly tighten screws (fig.2 04 Attention: It is absolutely necessary to reuse the old gasket or use a gasket of same material thickness! 2.51 15000 Reassembly Provide the lubricating oil passage sleeve (fig.03.05.3 Carefully put the governor drive housing (fig. 2/23) onto the engine block by means of a crane. 2.020". 1/11). 2/23).Governor Drive Inspection / Disassembly and reassembly VM32 A5.5 2.7 2. Insert screws (fig.4 2. Firmly tighten screws (20) and (22) crosswise. Daub the contact face for the governor with "Dirko 610. Put gasket (24) onto the engine block. en / 18. 2. 1/10) onto the contact face of the governor drive (fig. 3/30) with new O-rings (31). gasket (24) and cylindrical pins (32). In doing so absolutely mind the lubricating oil passage sleeve (fig. If required readjust the governor (see also Governor adjustment. 2/20) with spacers (21) and screws (22). 2.1 2. Mount the governor linkage in reversed disassembly sequence. 2.08. 3/30). Book C). 4/43). 04. Put the governor (fig.10.6 Note: The serration of the governor shaft must smoothly slide into the serration of the governor drive shaft (fig.2001 IB020902 4/4 .

00 h 04 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: 40-180 Nm torque wrench * not illustrated W1* 1.9.05. Support the vibration damper (1). Reassembly Clean the support surface of the vibration damper (1) and the intermediate piece (4).3140 1 Pers. (Free from grease). B1./ 1. 2. Apply Molykote paste to the contact surface and thread of the hexagon bolts (3).03.1 2.2 Safety note! Attention.52 15000 See also: Spare parts list: Time requirement: B1. Pull it off the intermediate piece (4) and remove it.1112.Vibration Damper on Camshaft Repair / Disassembly and reassembly VM32 A5. 04. en / 30.9.01. Sequence of operations: Disassembly Completely remove the camshaft cover of the last three cylinders.2006 IB024242 1/2 .9454-040 Auxiliary material: Molykote paste "G-Rapid Plus" ** ** or a product of equal standard Note: The vibration damper must be replaced by a new one after 15.000 operating hours! ~ 1.05. Remove the hexagon bolts (3) and resilient sleeves (2). there is a risk of injury! Never open a vibration damper.04.09.2 1.1 1.3 2.05. 1.11.

3 2.09.01.Vibration Damper on Camshaft Repair / Disassembly and reassembly VM32 A5.5 Apply Molykote paste to the contact surface and thread of the loosened hexagon bolts (5) and tighten at a torque of M = 210 Nm. Mount the hexagon bolts (3) together with the resilient sleeves (2).11. 04.4 04 2. Mount the complete camshaft cover for the last three cylinders together with the gasket. en / 30. 2. 2.52 15000 Push the new vibration damper (1) onto the intermediate piece (4).05. Tighten the hexagon bolts (3) at a torque of M = 50 Nm.2006 IB024242 2/2 .6 Check the gasket on the camshaft cover and replace if it necessary.

2000 IB021386 1/1 . 5.9.20 h See also: Spare parts list: Time requirement: 05 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Oil control shaft after 1. 2.4523 1 Pers.02.9.05. Note: At V-engines the swivel heads of the intermediate shaft of both control shafts are to be greased.08.05.05. Care has to be taken that all cleaned bearings are thoroughly greased.05.05.04.swivel head of spring link between control shaft and regulator Remove excessive gease. Check control shaft and spindle to emergency-off lever and oil bearing areas slightly with lubricating oil. Remove control shaft/injection pumps and control station covers.9. B1. 05./ 0.4110.01.swivel heads of the intermediate shaft between shaft and control station and control shaft .Control shaft bedding Maintenance / Checking M32 A5. B1. Assemble covers.05. en / 30.nn Sequence of operations: 1.4210.500 h Auxiliary material: Multi-purpose grease or lubricating oil according to A4. Oil all moving bearings of the swivel arm between control shaft and injection pump slightly.00 1500 B1. Grease the following bearings with multi-purpose grease: . all bright-metallic components are to be oiled slightly.05. Attention: After cleaning with fat dissolving agents. 3.05. 4.

05.500 h Tools: Fork wrench * not available as figure W1* 0.nn.05. In the event of a repair only this grease may be used. 2/17) is under spring tension.05.02 7500 A3. 05.01.9105 A Auxiliary material: Molykote paste “ G-Rapid “ ** ** or a product of equal standard ~ Note: Safety note: Danger of accident! Be careful during disassembly! Position (Fig.08.1.2000 IB021402 1/4 . en / 30./ 1.05.02.nn B1. All pneumatic elements are lubricated with a special grease (see A4.20 h See also: Spare parts list: Time requirement: 05 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: of the starting valve every 7. If other lubricants are used.4906 1 Pers.05.Starting Valve Maintenance / Disassembly and reassembly M32 A5. multi-purpose grease) which ensures sufficient lubrication for several years.05. the function of the components cannot be guaranteed.

2 Close the main shut-off valve on the air receiver. en / 30.Starting Valve Maintenance / Disassembly and reassembly M32 A5. Unscrew the screws (Fig.02 7500 Sequence of operations: 1.05. 1/1) and disassemble the starting valve from the engine. Vent the air pipes on the engine.2000 IB021402 2/4 . 05. 1.05.01.02. Disassemble all pipework and cable connections from the starting valve.1 1. 05 Disassembly: 2.

if necessary carefully rework with polishing cloth.1 3. Pay attention to the spring (10). Disassemble the silencer (3) and remove the solenoid (4).02.4 3.05. Disassemble screw connection (11) and nut (12). Unscrew the hexagon socket screws (16) and disassemble flange (17).7 4.2 3. Clean the casing by means of gas oil. Pay attention to the spring (18). To this end put a wrench through the air duct (15) on the key face of the spindle (14) and counterhold it. Disassemble piston (13) by means of the fork wrench (W1). 3. Pay attention to the spring (7). 3. 3.01. Disassemble the armature (5) by slackening the screw connection (6).2000 IB021402 3/4 .5 05 Note: When disassembling nut (12) and piston (13) secure the spindle (14) against being dragged along. Slacken the screw connection (8) and pull out the emergency actuation knob (9). 2/2). Remove the spindle (14) completely from the casing. 05.02 7500 Disassemble the protective cover (Fig. en / 30.Starting Valve Maintenance / Disassembly and reassembly M32 A5.6 3.3 3.05. Check the sliding surfaces for rust formation.

1 5. piston guide ring (19) and other sealing rings. Mount all pipe and cable connections. 2/2). Carry out a functional and leakage test with starting air. 7.4 5. Insert a new. Mount the protective cover (Fig.2 5.05. Assemble all valve parts in inverse disassembly order. Grease the sliding surfaces slightly.02.Starting Valve Maintenance / Disassembly and reassembly M32 A5. 1/1). Put the finish assembled valve onto the engine. Open the main shut-off valve on the air receiver.6 6.5 5. Firmly tighten the screws (Fig.02 7500 Reassembly: 5. Assemble the emergency actuation knob (9) with a new spring (10) and a new O-ring (20). 5.01. completely assembled spindle (14). en / 30.05.. 05 Note: Daub the threads of all fixing screws slightly with Molykote paste "G-Rapid". 05.3 Renew all O-rings. 5.2000 IB021402 4/4 .

Control shaft Maintenance / Disassembly and reassembly M32 A5.1 2. Insert new bushes (1) in bracket (6). 1/7) and hinged lever (8) of control shaft.03.9.00 7500 See also: Spare parts list: Time requirement: B1. 1.500 h Sequence of operations: 6 1.2000 IB021423 1/2 . When you tighten the nut make sure the bushes (1) are not twisted. 2/1) from bracket (6).05.3 2.50 h 05 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Replacement of bushes every 7. washers (4 and 5) and nut (2) to connect the bracket (6) to the hinged lever. Mount bolt (3).2 1.08. 05. 7 8 Dismount linkage between injection pump control shaft (Fig. X 1 en / 30. Remove bracket (6) from hinged lever.01./ 0.2 Attention: Tighten the nut (2) until the connection between bracket (6) and hinged lever is smooth.05. 1.05. 2. Mounting of bushes (1).1710 1 Pers. Remove bushes (Fig.1 Dismount the bushes (1).

When you tighten the nut make sure the bushes (1) are not twisted.08.00 7500 Mount bolt (3).05. en / 30. 05.3 05 X 2 4 8 1 6 5 3 2 Attention: Tighten the nut (2) until the connection between bracket (6) and injection pump control shaft is smooth. 2.Control shaft Maintenance / Disassembly and reassembly M32 A5.01.05. washers (4 and 5) and nut (2) to connect the bracket (6) to the injection pump control shaft.2000 IB021423 2/2 .

05.05. temperature and operating site. Fit the bent pipes carefully and free them from any scale or other impurities before mounting them on the engine. The drain cocks are fitted at lowest points on the inclined side of the pipes. The interval for draining results from the water quantity stated that depends on air consumption.Compressed Air System Inspection / Checking M32/M282/M332C/M452/M453C/M551/M552C/M601/M601C A5. Sequence of operations: Drain pipes and air vessel.01.n. All pipes are to be bent in a cold condition. Water pockets which cannot be avoided must have a draining socket with plug at the lowest point. normally an air detector will be required to find the leakages.2000 IB022014 1/2 . 05. Notes: When fitting new pipes. en / 05.50 h 05 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: Check control air lines and fittings for tightness and proper function. lnspect the piping visually and check for tight fit of the fittings and tightness of the screwed connections. the following must be observed: Use either seamless steel pipes or copper pipes (against corrosion) for the control piping. Note: During the checks air must be admitted to the piping.09./ 0.10. The radius of pipe bends must be as large as possible. Never fill the pipes with sand or similar material for bending. All pipes have to be laid as straightlined as possible without water pockets.00 750 See also: Spare parts list: Time requirement: B1.861n 1 Pers. Steel pipes must not be corroded nor have any other fault impairing their good operation. In rather rare cases leakages can be stated by noise.06. Only copper pipes are permitted for the pneumatic remote control.

00 750 05 Keep the number of pipe connections and the resulting sealing points as low as possible. Even the slightest dirt particles in the lines could entail failure of the control units. The use of red lead.Compressed Air System Inspection / Checking M32/M282/M332C/M452/M453C/M551/M552C/M601/M601C A5. Attention: Assembly work must be done with extreme care and cleanliness.05. en / 05. varnish or white lead is not permitted because this would make a later undoing of the connections more difficult and disintegrated particles might enter the air ducts and cause damage.09. 05. Blow through them with compressed air after bending. If any pipes do not properly fit together they must be rebent so that they can be laid without tension.2000 IB022014 2/2 .06.01.

Do not dismantle control fittings at random since the built-in springs are sometimes prestressed. 05.05. 15000 See also: Spare parts list: Time requirement: B1.Control Valves Inspection / Checking M32/M282/M332C/M452/M453C/M551/M552C/M601/M601C A5.05. en / 05. In case of deficiencies reconditon all control valves.05. Regulating units (pressure reducers) must be checked in their circuit after maintenance work for their setting values and must be reset if required. slacken these completely.08. e.g. The use of other lubricants may be in detriment of the function of the fittings. There will result a certain cycle for control or inspection depending on kind and function of the individual control units.09. General instructions for maintenance see “Description to Functional Diagram” in book C.00 30000. after four years of the low pressure valves.06. See to it that no air is available at the components to be disassembled or that no air can be admitted to these.. actuators. During assembly slightly grease rubber rings and their sliding surfaces with the grease prescribed.2000 IB022029 1/1 . lengths of levers and lever travels of. limitations by set screws. Thoroughly clean the individual parts and exchange wear parts. section 1./ 2.nn. In case there is available a screw or nut for adjustment of the prestress.05.861n 1 Pers.10.00 h 05 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: After two years carry out a random test of the high pressure valves. Note: Low pressure valves: High pressure valves: < 10 bar > 10 bar Special grease for all control units see MaK Lubricant Recommendations A4.n. and so on. Prior to disassembly operations and where required measure and mark the position of valves.

1.4900 1 Pers./ 0.00 24.20 h 05 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance/cleaning: Drain compressed-air filter: Disassemble and clean compressed-air filter: Disassemble and clean compressed-air filter: every initially every 24 h 150 h 7. 05.05.Compressed-Air Filter Maintenance / Cleaning M20/M25/M32/M43/M453C/M552C/M601C A5.06.05.05.2000 IB021438 1/2 .05. 7500 See also: Spare parts list: Time requirement: B1.09.500 h Auxiliary material: Nitro-Solvents * * or a product of equal standard ~ Note: Safety note: Close feed air lines and depressurize air system before every disassembly! It is to be checked to what extent following units/systems (emergency stop) in the circuit are affected in their functioning by the execution of the disassembly and cleaning measures! en / 30.

Remove locking ring (8). unscrew drain plug and check O-ring (6). Disassemble compressed-air filter and clean Loosen drain plug (7) and drain filter completely. 8 7 6 2 05 1 3 4 5 2.2 2.05. Clean all disassembled parts and check for reuse.2000 IB021438 2/2 .05.09. 05.Compressed-Air Filter Maintenance / Cleaning M20/M25/M32/M43/M453C/M552C/M601C A5.00 24. Loosen Phillips screw (4). Assemble compressed-air filter in reverse sequence. 7500 Sequence of operations: 1. Loosen housing cap (5) and remove. 2.1 1. check O-ring (1) and replace if necessary. replace if necessary. Close compressed-air feed line and secure. Relieve compressed-air filter via drain plug.4 2.9 en / 30.1 2.7 2.3 2. 1.06. remove with guide (3) and filter element (2). Close drain plug. Close drain plug after a short while.6 Drain compressed-air filte Loosen drain plug (7) and empty filter completely.8 2.5 2.2 2. Open shut-off valve in the compressed-air supply line.

/ 3. they must not be subjected to bending or radial forces during disassembly and reassembly. To prevent any damages to the expansion joints.2001 IB022965 1/3 . Safety note! Beware.05. danger of getting burnt! Check the temperatures and let the exhaust piping cool off sufficiently before working on the exhaust manifold! Check all screwed connections for firm seating. Accumulation of soot on flanges and expansion joints is in an indication of leakages. 3.Exhaust Manifold Inspection / Checking VM32 A5. "Dag S 5080" high-temperature thread paste must be used on all bolts to avoid sticking due to heat. In case of severe exhaust gas turbine vibrations or noise the flange connection of the exhaust piping after the turbine must be slackened and the tension of the piping has to be checked.01.9.00 h 06 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: Check the exhaust manifold for leakage every 7.06. ~ 2.52 7500 See also: Spare parts list: Time requirement: B1. 3-5 mm) in an axial direction is attained during installation by tightening the expansion joints. 06.01. en / 26.05.7260 2 Pers. Remove the covering from the exhaust manifold. A slight pretension (expansion approx.01.500 h Auxiliary material: "Dag S 5080" high-temperature thread paste * * or a product of equal standard Note: Also check the exhaust piping after the exhaust gas turbine within the scope of this inspection. Sequence of operation: 1.

To this end: Slacken and remove adjacent expansion joints (4. but can be easily displaced! Displace the clamp top parts.05. 06.1 06 4.3 Slacken hexagon bolt (1) to such an extent that both clamp top parts (3) are still connected.01. Unhook the chain links (2) on both sides from the clamp bottom parts.2 4.52 7500 Exchange damaged exhaust pippe. Do not subject the expansion joints to any stress caused by bending or radial forces! 4. en / 26. 4.Exhaust Manifold Inspection / Checking VM32 A5.01.01. 5).2001 IB022965 2/3 .

en / 26.Exhaust Manifold Inspection / Checking VM32 A5.01. 5) pay attention to the marked flow direction. Mount the lagging. Exchange the damaged exhaust pipe.5 06 4. 4.05.52 7500 Lift off both clamp top parts together.7 4.When mounting the expansion joint/s (4. .10 Expansion joints with cracks in the bellows must be replaced.2001 IB022965 3/3 . Length of the fitting piece x = 263 mm y = 267 mm 4. Remove fitting piece/s.01. see New gaskets (7) at the marked positions only.4 4. mount expansion joint/s and screw down. 06.8 Screw the fitting piece/s to the new exhaust pipe. Manufacture fitting pieces (x or y) for mounting the new exhaust pipe.01.6 4.8. arrow on the flanges! Do not subject expansion joints to any stress caused by bending or radial forces! Put all bolts (6) through from expansion joint side and tighten with a torque of M = 85 Nm. see 4. All other flange connections without gasket. Mount exhaust pipe and clamp top parts.9 4.

20 h 06 Personnel qualification: skilled engine hand Operating medium: Every fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: for proper function of the filter elements every every 24 h 750 h Tools: Ring wrench (SW 36) * no picture W1 * Hilfsmittel: Molykote paste "G-Rapid Plus" ** ** or equivalent product Note: The water traps (Fig. en / 24.09./ 0. 750 See also: Spare parts list: Time requirement: B1.06.05.Charge air drain Inspection / Cleaning VM32/GCM34 A5.9.05.1/ 1) are located at the free end of the engine.05.8392 1 Pers.04 24.00. Another water trap of different construction which is located at flywheel end is described in the documentation as from Book C. 06.2006 IB025326 1/2 .

Slightly coat thread of the hexagon plug (3) with Molykote paste.1 2. In case of a malfunction the filter has to be cleaned. 06 Attention: The following maintenance work may only be carried out when the engine has come to a standstill! 2.05. 2 en / 24. parallel to this the instructions of the manufacturer as from Book C. 750 1. water (water steam) must continually emerge out of the drain hole (2) during engine operation. Carefully take out the filter element (4) and clean it. Insert cleaned or new filter element. mount.5 Check the filter receptacle in the water trap (1) for dirt and clean it if necessary.2006 IB025326 2/2 . 06.04 24. and tighten it.1 Functional check (every 24 h): When the water trap (1) is working properly.3 2.06.05.2 Inspection of filter elements (every 750 h): Disassemble the hexagon plug (Fig.4 2. Note: Damaged or severely oxidized components may not be used any more and are to be replaced. 2. 1. 2.Charge air drain Inspection / Cleaning VM32/GCM34 A5.00.2/ 3).

/ 1. Turn the engine so that the rocker (Fig.05. 1.8510.9459-033 1.15.01.11.2 1.9.nn B1.nn).01.1 1.3 Disassembly Open indicator valves. 07.6 en / 26.04.03. 07. 1.9.01.15.2004 IB024739 1/3 .9454-400 1.01.3580.9497-030 Auxiliary material: Molykote paste "G-Rapid" ** ** or a product of equal standard Sequence of operations: 1.4 1.07.Injection Pump Repair / Disassembly and reassembly M32 A5.00 h 07 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench 100 . B1.9.05. 3/ 20) of the injection pump drive is on the base circle of the injection cam. B1.07.05.400 Nm Switch-over ratchet 1/2" Claw foot wrench * not available as figure W1* W2* W3* 1.nn. Disassemble the fuel overflow line on the injection pump.5 1. Remove corresponding camshaft cover on the control side.8525 1 Pers.02 See also: Spare parts list: Time requirement: 07.02. Remove the fuel distributor/collecting pipe (07.05. 1/4) in the nozzle leakage pipe at the side of the injection pump for cylinder 1). Close the shut-off cocks and drain the fuel distributor pipe (drain cock (Fig.

dismount the extention sleeve (17) and lift the injection pump from the cylinder crankcase.Injection Pump Repair / Disassembly and reassembly M32 A5.02. slightly lift forced fuel pipe (5).8 1.05.02 1. Secure fuel bores (injection pump. glue if necessary! 07 1. Loosen the pipe clamp (12). Loosen bracket (9) for stop cylinder (10) on the injection pump. forced fuel pipe) with suitable caps. turn 90° to the right and lift out of the cylinder head.01. Loosen nuts (11) evenly. Loosen hexagon cap screw (14) and remove with leak fuel drain (13). Push the control rod (15) right into the injection pump.12 ~ 1.11. 07. Completely loosen pressure screw (6) and union nut (8). 3/23) are secured with grooved drive studs and must not be removed.13 Safety note: Careful! Spring tension of the injection pump drive works against the injection pump. 2/16) and disconnect the connection of the injection pump control rod to the regulating shaft.2004 IB024739 2/3 .9 1.10 1.11 1. en / 26. Attention: The spacer plates belonging to the cylinders (Fig.7 Loosen screwed connection (Fig. Push union nut upwards.

Check O-ring (7) and replace if necessary. 1/3) in front of the injection pump. Check emergency-stop facility (operation of the stop cylinder). Clean the contact surfaces on the injection pump. Mount the control air line (Fig. See sequence of operations 2.01. forced fuel pipe). en / 26.9 2.11 2. turn engine if necessary. the spacer plates and the spring plate (21). turn. Tighten the nuts (11) with a torque of M = 260 Nm.3 2. lift slightly and place union nut (8) on injection pump.8 2. fill up fuel system with reserve pump and vent.14 Then tighten union nut (8) and pressure screw (6) with a torque of: M = 160 Nm + 10 Nm = angle of rotation of 25 deg + 5 deg 2.02).10 2.2004 IB024739 3/3 . Remove seals from the fuel bores (injection pump.05.17 Check compressed-air lines for stop cylinder for leakage using compressed air.6 2.4 ~ 2. Before tightening the screwed connection (Fig. 3/20) of the injection pump drive must lie on the base circle of the injection cam. Replace O-rings (22). Coat the threads and contact surfaces of the nuts (11) with Molykote paste and pull the injection pump onto its seat by tightening the nuts evenly. Assembly For assembling.07.15 2. 2/16) check the linkage for ease of movement.11. place the injection pump over the retaining screws.02 2. Insert forced fuel pipe with pressure screw (6) into the cylinder head. Tighten fuel injector nuts in two steps. Screw regulating shaft to control rod (15) of the injection pump. Tighten union nut (8) and pressure screw (6) evenly with a torque of M = 80 Nm 2.5 2.01. pipe clamp (Fig. Open shut-off cocks. Tighten union nut (8) and pressure screw (6) evenly by hand. 07.Injection Pump Repair / Disassembly and reassembly M32 A5.02. Close indicator valves and mount camshaft cover on the control side.12 2. 07 Note: 2.7 Safety note: Careful! Spring tension of the injection pump drive works against the injection pump.2 2. the rocker (Fig.16 2. Mount the extention sleeve (17).13 2. 2/12) and bracket for stop cylinder (9).9 (07.1 2.

This is the only guarantee for proper function.01.Injection Pump Inspection / Disassembly and reassembly M32 A5.02.9470-051 1.000 h Tools: Pressure pipe Nozzle testing device Torque wrench 40 . Piston and guide must only be replaced as a unit.9454-040 Auxiliary material: Molykote paste "G-Rapid Plus" ** ** or a product of equal standard Note: All parts of the injection pump are manufactured with atmost precision in special workshops.00 h See also: Spare parts list: Time requirement: 07 Personnel qualification: skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: a) of one injection pump after b) of all injection pumps after 7. control sleeve. any parts to be reconditioned should be shipped only complete and the possibility of a mix-up must be excluded. e.9.3597 2 Pers.9470 F 1. remain allocated to the respective housing. control rod.500 h 15.g. pointer etc.2000 IB021555 1/4 . Lapped surfaces must be preserved and not touched with the fingers. The pump must therefore be reset on a test rig.03 15000. In order to keep repair costs low.05.180 Nm 1/2" * not available as figure W1 * W2 * W3 * 1./ 2.01. 7500 07. When repairing a pump.05. make sure that the various parts of one pump.05. If there is a noticeable drop in the cylinder performance.nn B1.03.07. 07. check the pressure keeping valve and replace it if necessary! The admissible lube oil leak rate of the fuel injection pump is 1l / 24 hours en / 30. A renewal or exchange of the parts will considerably influence the fuel delivery.

05. 2. Remove the baffle screws (Fig. 17 27 30 28 29 1 en / 30. The fillister head screws (2) are tightened securely! Pump with tester and increase the pressure gradually up to the opening pressure pÖ and check whether the pressure keeping valve holds the pressure level set. 1/7).01. Screw the pressure pipe (W1) onto the connecting piece (Fig.2 Checking the pressure keeping valve (Fig. Loosen fillister head screws (18) and remove plate (17) with flange (15).1 1. check (see assembly) and replace if necessary. 2. remove the retainer ring (14) and slowly open the spindle device.03. 1. 07. do not remove! 15 16 18 X ~ 2.3 10 11 20 19 12 2.2 Disassembly Clean the outside of the injection pump. 1/6) Place the injection pump next to the nozzle tester (W2).3 2.5 Safety note: Careful! The spring tension of the tappet spring (11) works against the retainer ring (14)! Load the tappet axially in a vice.1 2. Clamp the pump with the mounting flange (13) upwards.2000 IB021555 2/4 . 7500 Sequence of operations: 1.05. the tappet spring is relieved.4 13 X 14 Note: The tappet (16) is held by the retainer ring (19). 07 3 2 4 5 6 1 7 25 24 23 22 21 8 9 1. pÖ = 130 +10 -20 bar Replace the pressure keeping valve if the valve ejects before the lower opening pressure.03 15000. 1/4) and connect to the test device (W2).Injection Pump Inspection / Disassembly and reassembly M32 A5.

pull out retaining pin (9) and control rod (8) and check toothing. Clean all parts with gas oil and a hard brush and blow out with compressed air.01. worn contact face of pump.10 2.13 2.Injection Pump Inspection / Disassembly and reassembly M32 A5. Worn tappet guide. en / 30. Loosen fillister head screws (2) alternately and carefully lift off connecting piece (4). Check tappet spring for possible corrosion. special attention is to be paid to the following wear phenomena: Plunger Scores in the running surface.05. After replacement of O-ring (29) and rotary shaft seal (28). Remove locking ring (10).14 2. Force pump element (25) out of housing (1) with round block of wood. Caviation in the inner bore. do not pull over sharp component edges. Scores in the running surface. Remove fillister head screws (3).05.8 2.12 2. 07. Barrel Buffer screws Tappet Delivery valve Pressure keeping valve Plunger foot plate Scores on the running surface. Pay attention to delivery valve spring (5) and valve spring (6).16 07 Note: Place O-rings untwisted with vaseline in the grooves. mainly in the inlet bush. damage to the sealing surface of the pump element. insert plate (27) and tighten hexagon sockt head cap screws (30) at a torque of M = 5 Nm 2.03. worn contact face of stud. A black plunger or black spots on it indicate water in the fuel. Unscrew hexagon socket head cap screws (30) and dismount plate (27) to replace rotary shaft seal (28) and O-ring (29).11 2. check the toothing of the control sleeve.6 2. During visual check. worn seat. tappet spring (11) and pump plunger (12).7 2.9 2. Clamp injection pump housing (1) with connecting piece (4) facing upwards. Replace all O-rings and gaskets. Remove control sleeve (22) with spring plate (21). control helix worn (by cavitation or erosion).03 15000. worn pressure valve spring (5) and valve spring (6). Damaged sealing surfaces.2000 IB021555 3/4 .15 2. 7500 Remove plunger foot plate (20) with tappet (16).

Apply engine oil to the thread and contact surface of the following screws and tighten them cross-wise at the respective tightening torque: Fillister head screw (Fig. as is the case with all injection parts. 2/23. 3. it is marked with a tooth and the control rod is marked with two teeth.4 Check free movement of the control rod.03 15000. 24) with the lips and the metal spiral facing upwards. is not possible on board and is therefore not permissible! When assembling.2 Insert the rotary shaft seals (Fig.2000 IB021555 4/4 . 3. en / 30. 7500 Assembly Assembling is carried out in reverse sequence of disassembly. 07.05.3 25 24 23 2 3. 3. The tooth marked on the control sleeve must be positioned between the two teeth of the control rod.Injection Pump Inspection / Disassembly and reassembly M32 A5.1 07 Attention: A refinishing of sealing surfaces. make sure that the marks on the control rod and control sleeve correspond with each other and likewise the marks on the control sleeve and plunger! In order to position the control sleeve to the control rod.05. 1/2) Fillister head screw (3) Fillister head screw (18) Buffer screws (7) M = 70 Nm M = 140 Nm M = 30 Nm M = 150 Nm 1 3. see Fig. 2.03.01.

00 h 07 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: fuel injector extractor Cleaning tool for valve seat * not illustrated W1 W2 * 9.04. B1.2 1.2107.nn.2005 IB023912 1/3 .5 h before working on the injection system so that the fuel injector is thoroughly flushed. Loosen hexagon nuts (Fig.1 Disassembly Remove the valve cover. Sequence of operations: 1. To this end: en / 07. 1/8) of the injector valve (4). 1.9222 D Auxiliary material: Molykote paste "G-Rapid"** "Dag S 5080" high-temperature thread paste ** or a product of equal standard Note: When running the engine on heavy oil. Reassemble extension sleeves (10).3 1.05.01.07.01.01. remove extension sleeves (10) and flange (3).9.02. Bolt the injector valve pulling unit (Fig.2144 A 9.2260 2 Pers. ~ 1. the system must be switched over to distillate fuel for at least 0.01. 07.03 See also: Spare parts list: Time requirement: 07. 07.nn B1.05.07. 1/1). 2/W1) securely to the adjuasting screw (Fig.05.4 Disassemble the high-pressure injection pipe only after complete mounting of pulling unit (W1).9.08.Fuel Injector Maintenance / Disassembly and reassembly M32 A5./ 1.

nn).12 2. Remove extension sleeves (Fig. Firmly screw the threaded rod (22) onto the adjusting screw (Fig.5 1. 2. Place the torsional lock (Fig.5 1. 2/23) on the hexagon of the threaded rod (22).9 1.7 1. 1/10).1 20 21 23 en / 07. mark it with the cylinder number and carry out a functional check of the injector (07.4.01. Remove the pulling unit completely and reassemble it.Fuel Injector Maintenance / Disassembly and reassembly M32 A5. 2/20) Pull out injector valve with pulling unit.02.4 1. 07.04.10 1. Remove hexagon head bolts (Fig.1 1.07.8 1. 2/20) a bit and firmly screw the threaded pieces (21) onto the extension sleeves (2) up to stop.08. 25 24 20 07 1. Clean the inside of the sleeve.2005 IB023912 2/3 .4.2 Put in place the complete unit. 1/7) is exposed. Clean the injector seat (9) in the sleeve (6) by scraping with tool (W2).4.01. 1/8).3 1.4. Loosen the hexagon head bolts (Fig.4.6 21 22 10 2 23 1. Clean the injector valve externally. Loosen the injector valve by turning the threaded sleeve (24) by means of wrench (25) and screw out until the bottom O-ring (Fig.05. 25 Assembly Replace O-rings (7).11 22 24 20 1.03 1.nn). Disassemble high-pressure injection pipe (07. Firmly tighten the hexagon head bolts (20).01.

1/3) with the dowel pin (fig.8 Mount the fuel delivery pipe (07. 2.02.2005 IB023912 3/3 . 1/X). Make sure flange (3) is level with injection valve (4). 07.01. Check the lubricating oil and fuel circulations for leakage. en / 07. nozzle element (fig.nn) and the cylinder head cover.2 2. Mount extension sleeves (10) and tighten nuts (1) by hand uniformly. contact surface of the nuts (1) and Orings (7). 1).03 Attention: use original MaK spare parts only! 07 2.05. Pay attention to the position of the positioning pin (fig.4 Insert the fuel injector in the sleeve. Apply a thin film of Molykote paste to the stud threads (2).01. Mount the flange (fig. 1/5) and valve stem.3 Apply a thin film of high-temperature thread paste to the valve seat. 5/11) facing the exhaust side and the neck facing downwards (fig.6 2.7 2. Excessive paste must be removed! Excessive paste could squash the O-rings in the retention groove in the cylinder head! Attention: No gasket between the fuel injector and sleeve in this area (fig.Fuel Injector Maintenance / Disassembly and reassembly M32 A5. Tighten nuts (1) in two steps with a torque of M = 60 Nm 2.07. 5/12).04.5 2.

9470 F 9.09. The fuel injector should only be checked in case of a clear deviation of the exhaust gas temperature from the mean temperature.07.01.9. The poor opening of heavy fuel nozzles in the nozzle tester is often caused by an insufficient flushing of the fuel injector with diesel oil before the test.07.9. the charge air temperature may also be too low or water in the charge air. 07.2260. the smoking behaviour.01. en / 18.9208 B 1.50 h 07 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Nozzle tester Adapter/nozzle support nozzle tester Injector delivery pipe W1 W2 W3 1. 20 bar is normal after a short period of operating (set of nozzle spring and needle).9470-051 ~ Note: Safety note: When checking the opening pressure: Danger! Keep your hands off the fuel jet! Carbon trumpets at the nozzle are mostly caused by unsufficient cooling. B1.04./ 0.07.nn. this should be cleaned again thoroughly.05. A drop in the opening pressure of approx. The proper function of the fuel injectors can exclusively be assessed from the behaviour of the exhaust gas temperatures resp.08.2002 IB002481 1/2 . Corrosive attack and erosion.05.00 See also: Spare parts list: Time requirement: 07.2267 1 Pers. Previous to replacing the fuel injector.nn B1. are the consequence.01.Fuel Injector Maintenance / Adjust M32 A5. if the nozzle temperature is too low. however. 07.05.

07 Note: If a high portion of fuel is leaking. Place the injector with the adapter (W2) in the tester (W1). 5.09.Fuel Injector Maintenance / Adjust M32 A5.2002 IB002481 2/2 . 3.04. Increase the pressure gradually until the nozzle opens. 07. 5.01. 4. 2. Injector opening pressure. Tighten the lock nut (1) again. repair (07.01. ovalization. en / 18. slacken the lock nut (1) and turn the adjusting screw (2) until the pressure is correct. Check the nozzle hole for sharp edges.1 If the opening pressure is not correct.00 Sequence of operations: 1.05.08. corrosion and damage.nn) or replace the injector. Connect the injector delivery pipe (W3). see acceptance test records A1. Remove carbon deposits from the nozzle with a hard brush (no wire brush).10.

09.07. 07. All parts of the fuel injection system are manufactured with utmost precision in special workshops. 07.Fuel Injector Repair / Disassembly and reassembly M32 A5. low opening pressure etc.00 7500 07.50 h See also: Spare parts list: Time requirement: 07 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------- Maintenance: Replace all injector elements every 7. For this reason.07.). and the required maintenance work should be confined to • • • Cleaning Checking opening pressure and tightness Replacement of wearing parts using original spares and components. repair carried out by the operator is impossible.2267 1 Pers.nn./ 0.01.05.nn B1.08.08.9. To keep repair costs low.nn) reveals faults (e.2001 IB021570 1/3 .420 Nm * not available as figure W1 * 1.9454-060 Auxiliary material: Hydraulic sealing compound Loctite 566 ** ** or a product of equal standard Note: Injectors should only be dismantled.05.08.01. any parts to be reconditioned should be shipped complete. Only this guarantees a perfect function. en / 09.500 h Tools: Torque wrench 60 .g.01. and the possibility of inter-changing must be excluded.01. leakage. preserved. if the test (07.

Be aware of cylinder pin (7). Fit a nozzle needle with gasoil in the nozzle (8) and check. anti-fluff paper.01.00 7500 Sequence of operations: 1.4 4 5 6 7 8 en / 09. Reassembly Wipe all sealing surfaces dry with clean. Submit all parts particularly seat and sealing faces to a visual inspection. 2.2 2. Submit nozzle spring (4) and setbolt (5) to visual inspection. whether the needle falls on the seat by its own weight.4 1.2001 IB021570 2/3 .5 1. 1/1) and relieve nozzle spring (4) by unscrewing the adjusting screw (2). If the needle is hanging or jammed. locking screw (3) and unscrew adjusting screw (2) . 07.3 1.8 2.2 1. Apply a film of lubricating oil to the thread of the fuel injector housin To assemble. nozzle spring (4) and setbolt (5). 1. 07 2 1 11 10 9 3 1.09. remove spring guide (10).1 1.08.1 2. reverse the dismantling sequence.3 2.05. Clean the parts with gasoil. Replace defective parts. Slacken nozzle nut (6) by turning left and unscrew. Extract nozzle (8) including nozzle needle without damaging the lapped surfaces. Renew O-ring-type sealing ring (9).6 1.7 Disassembly Slacken nut (Fig. When inserting into the casing (11) align the spring guide (10) to the locking screw (3). replace it together with the nozzle.Fuel Injector Repair / Disassembly and reassembly M32 A5.

Fuel Injector Repair / Disassembly and reassembly M32 A5.00 7500 Degrease and dry locking screw (3) and bore hole.08.5 2. Tighten the nozzle nut (6) with a torque of M = 350 Nm 2.9 Remove residues of adhesive from housing (11) and locking screw (3).Screw the locking screw into the housing (11) with two turns.2001 IB021570 3/3 . 2.8 2.01. Tighten the locking screw (3) with a torque of M = 20 Nm.09. unscrew it and screw it in again.08. en / 09.01.7 07 2. Apply “ Hydraulic sealing compound Loctite 566 “ to the thread of the locking screw (3).10 Check the injector according to 07.6 2.nn and set.05. 07.

Fuel Distributor Manifold Repair / Disassembly and reassembly VM32 A5. loosen screw plug (Fig./ 0.2002 IB023870 1/3 .9.9454-020 Aids: Molykote paste “G-Rapid Plus“ ** ** or equivalent product Procedure: 1. 07. 1.8510 1 Pers.07.2 Disassembly Remove pump chamber covering.01.9454-040 1. en / 08. 3 turns to drain fuel distributor line.05.10.05.90 Nm *not shown W1* W2* 1.50 h 07 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench 40 .15.180 Nm Torque wrench 20 .1/1) by approx.1 1. Close shut-off valves.56 See also: Spare parts list: Time requirement: B1.

56 1.1.3 1. en / 08. 07 1.Fuel Distributor Manifold Repair / Disassembly and reassembly VM32 A5.2002 IB023870 2/3 .05. 2/5) can be detached from sleeves at injection pump cyl. 07. Remove fuel lines (4). 3/7).01.4 1. Release cheesehead screws (8) and screwed connection (9) so that blind flange (Fig. 2/5) at injection pump cyl.5 Loosen cheese-head srews (Fig. Shift sleeves (3) with O-rings (17.6 Remove tube (Fig. 2/2). 10) and plate (18) with guide ring (19) to the right and left respectirely. 1/6).1 dismantle jet leakage pipe (Fig.15. To remove blind flange (Fig.10.

2. en / 08.01.Fuel Distributor Manifold Repair / Disassembly and reassembly VM32 A5.3 Reassembly Check O-rings (Fig. 2/10.9 2.2002 IB023870 3/3 . 07 2. 1/1). When doing so check conical part (16) is in correct position. Insert fuel lines (Fig. close ball valve (Fig.1. 17) and guide rings (19) at fuel lines (4) for damages.10. Replace them if necessary.15. 2/4). Apply Molykote-Paste "G-Rapid-Plus" to cheese-head screws (2) and tighten with a torque of M = 25 Nm. Hold cone (Fig.56 2.1 2. Tighten cheese-head screws (8) with a torque of M = 65 Nm.8 Fit jet leakage pipe (Fig. 17).2 2. 2. Replace pump chamber covering.7 2. Shift sleeves (3) with O-rings (10. 3/12) with screwdriver and tighten screwed connection (9) with a torque of M = 100 Nm.05. Runddichtung (10) and plate (18) with guide ring (19) to the right and left respectirely up to limit stop. fill fuel system with spare pump and vent.5 Fit tube (7).6 2.10 Open shut-off valves.4 2. 2. Firmly tighten connectors (15). 07.1/6). Position blind flange (5) over sleeves of injection pump cyl.

Sequence of operations: 1.05. gearwheel shafts and bushes for wear and replace if necessary.6417 0 Pers. Remove suction (Fig. 1/4) and pressure line (2).08. remove the lubricating oil pump from the motor and check the gearwheels.05.90 Nm 1/2" * not available as figure W1 * 1.10. en / 08./ 0.03 See also: Spare parts list: Time requirement: B1.00 h 08 Personnel qualification: skilled engine hand Operating medium: Every fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench 20 . 08.9.2 Disassembly Drain lubricating oil system.2007 IB022585 1/3 .02. 1.03.Lubricating oil pump Maintenance / Disassembly and reassembly M32/VM32/GCM34 A5.1 1.9454-020 Auxiliary material: Molykote paste "G-Rapid Plus" ** Silicone sealing compound "Dirco Grau" ** ** or a product of equal standard Note: If necessary.

4 Loosen hexagon nuts (1) and pull lubricating oil pump (3) with gearwheel (6) out of cylinder crankcase. Loosen hexagon cap screw (8) and pull gearwheel (6) off drive gearwheel shaft (Fig.05. Disassemble driving gear wheel shaft (10) and impeller shaft (19). slanting run.02.6 1.03 1. Check the bushes (11 and 14). bearing areas of the drive and intermediate gearwheel shafts for wear and replace with original MaK spare parts if necessary.5 1.18) and remove end cover (17.3 1. Replace o-rings (12).2007 IB022585 2/3 . en / 08.21) from pump casing (20). splintering).7 1.10. Note: Cool down new bushes before installing them. 08 1. 2/10) with extractor.Lubricating oil pump Maintenance / Disassembly and reassembly M32/VM32/GCM34 A5. 08. Slacken screws (16.03.8 Check tooth profiles for wear (pitting.

05. Vent system.05. 2/10) through grinding. en / 08. 08. free from grease and dry gearwheel cone and drive gearwheel shaft cone.68 mm than in cold condition. Put gearwheel (Fig.03 2.Lubricating oil pump Maintenance / Disassembly and reassembly M32/VM32/GCM34 A5. Heat gearwheel in oil bath to approx. 1/X) and make a note of it. Tighten the hexagon cap screw (8) with a torque of M = 60 Nm. Mount suction (4) and pressure lines (2) with new seals. Fill up lubricating oil system and take lubricating oil prelubricating pump into service.58 .3 2.02. 2.nn) up to the respective level mark on the circulation tank. 110 °C to 120 °C above the temperature of the drive gearwheel shaft and shrink on firmly up to the limit of the drive gearwheel shaft cone. it must be smaller by 0. Fill in new lubricating oil (lubricating oil quality.2 Assembly Mount lubricating oil pump in reverse sequence. see A4.7 2. Check the distance S. 2/17) and the pump carrier plate (Fig. 1/5) and coat with sealing compound. Before mounting the gearwheel.1 2.11 2.0.6 2.8 2.12 2. Contact reflection must be even and the contact reflection portion > 80 %! Clean. 1/6) on drive gearwheel shaft cone. 1/6) and drive gearwheel shaft cone (Fig. check the contact reflection between gearwheel cone (Fig. Coat the thread and contact surface of the hexagon cap screw (Fig. Check oil supply of the gearwheels.03.10 2. 08 2. 1/8) and disk (7) with Molykote paste "G-Rapid Plus".9 2.2007 IB022585 3/3 .10. Carefully insert the lubricating oil pump (3) with gearwheel (6) into the cylinder crankcase (tooth profiles of the drive gearwheels must engage with each other) and mount.08.4 2. measure distance S (Fig.5 2.13 Clean the contact surfaces of the pump flange (Fig.

2001 IB022962 1/2 .04.500 h Note: The protective lube oil filter is installed between the engine and duplex filter to retain the following impurities and to protect the engine: a) Welding beads scale which have remained in the external lubricating oil lines during installation of the engine and which could come loose after the first operating hours.51 7500 See also: Spare parts list: Time requirement: B1.7650.03.9.00 h 08 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: of the protective lube oil filter every 7. The filter must be checked after 24 hours after commissioning a new plant or working on the lubricating oil pipeline system and must be cleaned if necessary.05.9./ 1.Protective Lube Oil Filter Inspection / Cleaning VM32 A5.05. B1. 08.8433 1 Pers.05.08.02. en / 07.08. b) Dirt particles freed after the possible destruction of fine filter inserts.

04.Protective Lube Oil Filter Inspection / Cleaning VM32 A5.2 1. The protective lube oil filter (1) is drained via line (2). 1. 08.2001 IB022962 2/2 .02. 1.5 1.6 en / 07.1 08 1.51 7500 Sequence of operations Unscrew the plug / thermometer or probe insert at the highest point of the pipe section to be drained. Dismantle the bracket (5) and pull out the filter insert (3). Screw in the plug / thermometer or probe insert with new gaskets.4 1.05.03. Take the standby lubricating oil pump into operation and fill the lubricating oil system.3 1. Check the filter insert and wash it out. Replace the O-rings (6 /7). Push in the filter insert and mount the bracket (5) with a new gasket (4).

Disassembly ~ 1. Remove the screw plug (26) of the pilot control unit (A-A) with the sealing ring (25).2.01.3 1. Remove and dismantle the control valve (1).06). Sequence of operations: 1.2. ~ 1.7810 1 Pers.1 1.05.05.2 Safety note: Pay attention to the tension of the pressure spring (Fig. washers (27).2. 08. en / 31.05.4 Safety note: Pay attention to the tension of the pressure spring (13) on the screwed connection (17)! Loosen the hexagon nut (18) and completely unscrew the spindle (19) by turning it counterclockwise and remove it together with the ball (16).01. 1/3) on the control valve (1)! Loosen the cheese head screws (8) evenly to relieve the pressure spring (3).10) and at the specified lubricating oil temperature (see A1.2 1.01 15000 See also: Spare parts list: Time requirement: B1.2008 IB022593 1/3 .2.08.05. The lubricating oil pressure (see A1. Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush (10).Oil pressure control valve Maintenance / Adjust M20/M25/M32/M43 A5.n.000 h Note: Disassembly of the pressure control valve during the repair interval is only necessary if the necessary lubricating oil pressure can no longer be set by adjusting the initial tension of the spring.1 1./ 1. engine data) is only allowed to be adjusted at the nominal engine speed (A1.00 h 08 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Disassembly and adjustment of the oil pressure control valve every 15. pressure spring (28) and ball (29). Remove the locking ring (9) and take out the piston (11) with washer (15) and pressure spring (13).

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.5 Clean all parts with gas oil and check them.3 1. piston seating as well as the slide faces and grind them if necessary.2008 IB022593 2/3 . en / 31.01.01 15000 08 1.05. 08.01. Check the valve seats.Oil pressure control valve Maintenance / Adjust M20/M25/M32/M43 A5.4 1.05. balls.

01. 08.2 2.05. Adjustment Pressure to be set (see engine data A1. Counter-clockwise: Clockwise: Oil pressure drops Oil pressure increases 08 3.01 15000 2.Oil pressure control valve Maintenance / Adjust M20/M25/M32/M43 A5. en / 31. Loosen the hexagon nut (18). 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 necessary. 3. 2.3 Secure the setting with the hexagon nut (18).05.2008 IB022593 3/3 .1 3. Regulate the pressure by turning the spindle (19).05).3 Reassembly Check the O-rings (2 and 7) and sealing ring (14) and replace them if necessary.1 2.2 3. Assembly is effected in the reverse sequence of disassembly.01.

Oil pressure control valve Maintenance / Adjust M32/VM32/GCM34 A5.nn B1.05. The lubricating oil pressure (see A1.2. ~ 1. washers (27).02 15000 08. Remove the screw plug (26) of the pilot control unit (A-A) with the sealing ring (25).000 h Note: Disassembly of the pressure control valve during the repair interval is only necessary if the necessary lubricating oil pressure can no longer be set by adjusting the initial tension of the spring. Sequence of operations: 1. en / 02.2007 IB022601 1/3 .2.10) and at the specified lubricating oil temperature (see A1. 1/3) on the control valve (1)! Loosen the cheese head screws (8) evenly to relieve the pressure spring (3).2 Safety note: Pay attention to the tension of the pressure spring (Fig.08. Remove and dismantle the control valve (1).6417 1 Pers.1 1. 08.04.05.00 h See also: Spare parts list: Time requirement: 08 Personnel qualification: skilled engine hand Operating medium: Every fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Disassembly and adjustment of the oil pressure control valve every 15.05.2 1. engine data) is only allowed to be adjusted at the nominal engine speed (A1.01.03.02.9.2.06)./ 1. pressure spring (28) and ball (29).05.3 1. Remove the locking ring (9) and take out the piston (11) with washer (15) and pressure spring (13).1 1.4 Safety note: Pay attention to the tension of the pressure spring (13) on the screwed connection (17)! Loosen the hexagon nut (18) and completely unscrew the spindle (19) by turning it counterclockwise and remove it together with the ball (16). Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush (10).2. Disassembly ~ 1.

02 15000 08 1.05. 08.2007 IB022601 2/3 .4 1. Check the valve seats.Oil pressure control valve Maintenance / Adjust M32/VM32/GCM34 A5.01. 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.04. piston seating as well as the slide faces and grind them if necessary.3 1.5 Clean all parts with gas oil and check them. balls. en / 02.05.

08.2 2.1 2. 2. Assembly is effected in the reverse sequence of disassembly.05. Counter-clockwise: Clockwise: Oil pressure drops Oil pressure increases 08 3.04.3 Secure the setting with the hexagon nut (18). 3. Regulate the pressure by turning the spindle (19).3 Reassembly Check the O-ring (7) and sealing ring (14) and replace them if necessary. Adjustment Pressure to be set (see engine data A1.2007 IB022601 3/3 .02 15000 2. en / 02.2 3.05.Oil pressure control valve Maintenance / Adjust M32/VM32/GCM34 A5.1 3.01. 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 necessary. Loosen the hexagon nut (18).05).

00.2 simultaneously for approx.05. since the components which run on sliding bearings. Damage caused by vibration during engine shut-down can only be avoided when the engine is lubricated and turned simultaneously. without affecting the unattended operation of the system: Sequence of operations: 1.00 150 See also: Spare parts list: Time requirement: C5.nn 08 1 Pers.1 1.1 and 1. The following method is to be applied to avoid damage caused by engine shut-down./ 0. en / 18.10.05.10. Prelubrication alone is no guarantee that damage caused by vibration is prevented.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. are not able to float in the bearing because of the prelubricating pressure. No or only a little quantity of oil is carried to the endangered contact surfaces.08. the bearings might be damaged by vibration when individual engines are shut down for more than 3 days.Prelubricating pump/Prelubrication Maintenance / Checking M20/M25/M32/M43/M453C/M552C/M601C A5. 1. Start the stand-by pump Turn the engine by means of the barring gear. 5 min.00.2 Carry out steps 1. 08.11.1999 IB004168 1/1 .

Assembly IB023242 13 12 11 Fig.000 operating hours. remove and take out control disk (2) with shaft (3). Loosen cover (4).01.4450 1 Pers. 1 1/2 en / 22.05./ 4. 4 3 2 7 1 14 8 Note: After replacing the shaft (3).9.00 h 10 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Disassemble and clean the starting air distributor every 15.Starting Air Distributor Maintenance / Disassembly and reassembly M32 A5.4 Disassembly 9 5 10 Remove air pipes from the swivelling screw fittings (Fig.3 1.10.9454-020 Auxiliary material: Molykote paste "G-Rapid" ** ** or a product of equal standard Note: Before disassembly.02.90 Nm * * not available as figure W1 1.05.2001 .2 1.05. or the carrier (7). See operation sequence 3. 10. Loosen fillister head screws (11) and pull off starting air distributor housing (10). 1. inspect and replace defective parts. Sequence of operations: 1. the setting of the starting air distributor must be checked and readjusted if necessary.00 15000 See also: Spare parts list: Time requirement: B1. Tools: Torque wrench 20 . blow out with compressed air. 1/1) and muffs (5). control disk (2). block starting valve and close air bottles. Clean all parts.1 1.! 2.

1 If necessary.1 3.5 2. (attention: lefthand thread).3 Install starting air distributor with shaft (3) and carrier (7). Clamp shaft in vice with soft blocks.05. Check function of starting air distributor and also check for leakage. 2/20) of the control disk (2) must cut the bore of the 1st cylinder (Fig. Fix compressed-air pipelines with new seals upon completion of assembly.00 15000 Reassembly is effected in reverse sequence. The housing (10) must lie flat against the cover (9) of the governor drive. Setting the starting air distributor Turn the piston of the 1st cylinder to ignition position. remove starting air distributor. coat thread of the shaft extension and contact surface of the hexagon nut with Molykote.3 Recheck the position of the disk and shaft and mount starting air distributor according to 2.2 20 a c b 2 3.2 and tighten hexagon nut by hand.02.1 2.2 10 2.4 2. Threads and contact surfaces of the loosened hexagon cap screws (8) are to be coated with Molykote and tightened. and tighten cover (4). 3. 3.2 3. torque: M = 17 Nm 2. 3. torque: M = 34 Nm 2. start engine numerous times with air. loosen hexagon nut (14) (attention: lefthand thread). Threads and contact surfaces of the hexagon cap screws (11) are to be coated with Molykote and tightened.6 Check setting according to 3.2. If necessary. Disk slot (Fig. 14 Fig.2. turn by 180° and refit.2. fix control disk and tighten nut with torque M = 35 Nm. 2 3.05.2001 IB023242 2/2 .Starting Air Distributor Maintenance / Disassembly and reassembly M32 A5. 10. 2/c) according to the engine rotating direction a = clockwise b = anti-clockwise. en / 22.01.3 Set control disk with disk slot according to 3.

Check the stop cylinder (3).01. Activate the emergency stop facility (machine control room).nn B1. Check the position of the control rods.Stop cylinder Inspection / Checking M32/VM32 A5.02.4241 1 Pers.03. 2.01.05. Note: Check all injection pumps.05.02.01. 10.20 h See also: Spare parts list: Time requirement: 10 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: Check operation of the stop cylinder every 750 h Note: Only carry out the inspection when the engine has been shut down during the scope of other work! Sequence of operations: 1. Attention: The control rods must be in the "zerofilling level" position! 2 1 3 3.2005 IB021678 1/2 ./ 0.9. en / 07. Check the control air lines for leakage/damage if all control rods can be pushed in. Press the "Reset" button on the safety system.00 750 07.12.05. 4.nn). To do so. press the control rod (2) into the injection pump by applying pressure to the saddle (1). Replace the respective stop cylinder if individual control rods/only one control rod can be pushed into the injection pump against the pressure of the stop cylinder (07. Note: The solenoid valve is reset and the emergency stop facility is vented.

2005 IB021678 2/2 .23.00 750 Attention: This document only describes the pneumatic and mechanical release of an engine stop.1 2 T3 2.10. 13 1.05.01. (Fig.05. Check the emergency stop by actuating the emergency stop lever (Fig.50. (Please refer to (C5. 10. If the shutdown air pressure is decreased below the switching value of 6 bar an alarm "Low shutdown pressure" will be released.03.Stop cylinder Inspection / Checking M32/VM32 A5. 2/T3) Measuring point 6105 (function of the safety system) in the maintenance unit (C5. In connection with this inspection work all of the emergency stop equipment on the engine is to be checked for proper function. Venting by loosening screw (13).12.05.01).05.nn) ). 3/20) on the control stand.45. 10 10 1. en / 07.05.

8 bar Sequence of operations: 1.6 bar 0 .9.11.16 bar Switching differential: Switching differential: 0.750 operating hours.05. 1 2 Fig. B1.05.11. Remove plug (2) (G1/8") (depressurizing the line. B1. 1 en / 12.11. 1.2001 IB023083 1/3 .01.00 3750 See also: Spare parts list: Time requirement: B1.4842.2 Connecting the adjusting device Turn cock (Fig.12.Pressure Switches Inspection / Adjust M25/M32/M43 A5.2 bar 0. 1/1) of the pressure line to test position (downwards). 3. 11. electric measuring instrument Inspection: Check the set operating values of the pressure switches every 3. soaking up fluid with a rag) and connect adjusting device to test connection according to Fig. Note: These testing and adjusting instructions apply to the following types: Pressure range: Pressure range: 0 .05.50 h 11 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Adjusting device.05. 2 and Fig.254842.434843 1 Pers./ 0.03.1 1.

3 Pneumatic connection (Fig. 2). 3) Connect terminals 1. 11 15 10 11 12 13 Fig.2 2. 3 in unit plug. 3 2.00 3750 1. Check the switch point with the precision pressure gauge of the adjusting device and test lamps. 11.Pressure Switches Inspection / Adjust M25/M32/M43 A5. P [–] [+] Fig.05.2001 IB023083 2/3 .4 Compressed-air flange > 16 bar Pressure reducer Shut-off valve One-way restrictor Volume 1 l Precision pressure gauge Pressure switch Electrical connection (Fig. 2. thereby observing the switch point on the precision pressure gauge of the adjusting device and test lamp(check the displayed switch difference according to the measurement points list in book C).03.1 2. 2 14 16 10 11 12 13 14 15 16 1. 2.01. Slowly vent the pressure switch.3 Inspection Vent pressure switch via adjusting device. 2 1 3 en / 12.12.

Removal of the adjusting device Loosen the cable connections and pneumatic connection of the test device.2 4. 4/20) of the pressure switch.01. 11. Seal test connection with plug and turn cock (Fig. 3.05.3 en / 12. 4. Fig.00 3750 3. Correction of the adjustment 11 Note: If there is a deviation from the set value (see measurement points list in book C). 4 20 + – 4. Loosen housing cover (Fig. The pressure switch is set when the pressure is falling.1 4. 1/1) to operating position. Screw on housing cover and seal with lead seal.2001 IB023083 3/3 . carry out correction according to operation sequence 3.1 3.12.3 Remove lead seal. Set switch point to required value according to measurement points list with a hexagon spanner (5 mm).Pressure Switches Inspection / Adjust M25/M32/M43 A5.03.2 3.

05.RPM Switch Inspection / Adjust M20/M25/M32/M43 A5. Sequence of operations: 1.70.2005 IB021724 1/2 . If the rpm switch does not work.1 and F 2.43 See also: Spare parts list: Time requirement: 11 1 Pers. Note the rpm switch point setting. 2.05.1 Voltage check at the plug-in socket contacts of the plug-in frame.05. en / 25. continue as follows: 5.1 on the plug-in card A1 in the rpm switch installation must be switched on.05.06. the output relay will switch and the diode on the dial must light up (switch hysteresis ± 25 rpm).02 7500 C5. 5. contact z20 positive). At constant speed and with the setting as under point 1. 11. The automatic cut-out F 1. Turn the pointer carefully to the left towards 0 rpm. When reaching the engine speed. Set the pointer again at the original rpm switch point and lock it. Loosen the pointer locking plate (2) and set the pointer (1) at the highest engine speed.00 h Personnel qualification: E-specialist Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: Check the function of the rpm switches every 7.01. 3. proceed as follows in order to locate the defect: 4. The output relay on the plug-in card must switch and the luminous diode (3) on the dial will go out (Fig./ 1. Note: The engine speed must be constant whilst testing. Supply (24 V DC at contact z16 and z20.05. 1).500 operating hours.

RPM Switch
Inspection / Adjust
M20/M25/M32/M43

A5.05. 11.05.01.02

7500

5.2

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.

11

Attention:
Carry out the rpm adjustment of the new plug-in card. For this see the "Plant components file (C), section 5, rpm switch".

en / 25.05.2005

IB021724

2/2

Pressure Switch
Inspection / Replace
M20/M25/M32/M43

A5.05. 11.06.05.02

22500 11.06.06.nn

See also: Spare parts list: Time requirement:

11

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:
Metric standard tools.

Set of replacement parts:
Pressure switch M2103 (emergency stop - cooling water pressure) Pressure switch M1106 (emergency stop - lubricating oil pressure) Depending on the equipment status all other pressure switches are to be replaced as well.

Attention:
- Ensure that the engine cannot be started! - When exchanging the pressure pipe or draining off the cooling water it is possible that "hot" cooling water leaks out. - There is a danger of scalding. - Avoid skin contact with cooling water emulsions, observe the safety data sheets of the manufacturers.

en / 11.04.2008

IB025581

1/3

Pressure Switch
Inspection / Replace
M20/M25/M32/M43

A5.05. 11.06.05.02

22500

Procedure:
1.

11

Put the engine and the related safety systems out of operation.
- > Notify the engine to be ’’unserviceable’’ < -.

Attention:
Prior to replacing the pressure switches the shut-off cocks of the media must be closed. Prior to installation the pressure switches are to be adjusted to the specified pressure values.

2. Note:

Replacement of the pressure switches.

The measuring point designations are always provided on the engine cable and the engine. 2.1 2.2 Remove the old pressure switch. Mount the new pressure switch. When doing so, slightly grease the O-ring (Fig. 1/1) at the foot of the new pressure switch before inserting it. Replacement of the plug.

2.3 3. 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8

Testing of the completed work:
Cooling water system Start the engine and run up to nominal speed. Simulate "Low cooling water pressure" by means of test valve (Fig. 2, 3, 4/2). The engine has to stop automatically latest after 20 seconds. Put test valve (2) into "Operation" position again. Lubricating oil system Start the engine and run up to nominal speed. Simulate "Low lubricating oil pressure" by means of test valve (2). The engine has to stop automatically without any delay. Put test valve (2) into "Operation" position again. The other pressure switches are to be tested according to the same procedure.

1

en / 11.04.2008

IB025581

2/3

Pressure Switch
Inspection / Replace
M20/M25/M32/M43

A5.05. 11.06.05.02

22500

4.

Put the engine and the safety system into normal operating condition again. -> Notify the engine to be "ready for operation" <-.

11

2

2

2

en / 11.04.2008

IB025581

3/3

Pressure Switch
Maintenance / Adjust
M20/M25/M32/M43

A5.05. 11.06.06.02

See also: Spare parts list: Time requirement:

11.06.05.nn

11

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

W1* W2*

Procedure:
1. 2. 2.1 Mount new pressure switch, see A5.05.11.06.05.nn. Close shut-off valve (Fig. 3/6) of the corresponding medium to the pressure pipe. Remove the plug from the pressure switch and connect the pressure calibrating device (W1) to the test connection. The adjustment value is to be inferred from the list of measuring points in

Book C.
2.2 2.3 2.4

In pressureless state the pressure switch contacts (Fig. 1) 1 + 2 are closed and contacts 1 + 3 are open (ohmic flow). When the pressure drops, the pressure switch should switch at the measuring point value, in this state contacts 1 + 2 are open and contacts 1 + 3 are closed. If a pressure switch is replaced, the switching value is to be inferred from the list of measuring points. (The measuring point number is indicated on the cable or the related nameplate.)

Note:
If the pressure switch responds before or after the read limit, the switching point has to be readjusted, see item 3.

en / 11.04.2008

IB025583

1/2

Pressure Switch
Maintenance / Adjust
M20/M25/M32/M43

A5.05. 11.06.06.02

3. 3.1 3.2

Adjustment of switching point Remove cover (Fig. 2/4). By turning the hexagon socket screw (5) the switching point can be adjusted correspondingly.

11

4. 4.1

Assembly: Mount cover (4).

4.2
4.3 4.4

Remove pressure calibrating device (W1).
Clip on plug to the pressure switch. Open shut-off valve (Fig. 3/6) of the corresponding medium to the pressure pipe.

Replacement of the complete switch, see A5.05.11.06.05.nn. .

en / 11.04.2008

IB025583

2/2

Crankcase Monitoring Device
Inspection / Checking
M20/M25/M32/M43/M453C/M552C/M601C

A5.05. 11.09.01.03

1500, 750, 7500

See also: Spare parts list: Time requirement: B1.05.11.nn4810 2 Pers./ 1,00 h

11

Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel

-------------------------------------------------------------------------------------------------------------------------------Maintenance:
a) Check the underpressure in the measuring chamber every b) Clean the infrared filter and replace the sintered bronze filter in the measuring attachment every c) Replace the sintered bronze filter in the pressure control every 750 h 1.500 h 7.500 h

Tools:
Test equipment and spare parts. Service box

Maintenance and trouble shooting: refer to manual C

Attention:
The engine is not monitored in the event of the device malfunctioning. his can result in engine damage!

en / 17.02.2004

IB021758

1/1

Vibration Damper
Maintenance / Disassembly and reassembly
VM32

A5.05. 12.04.01.52

30000

See also: Spare parts list: Time requirement: B1.05.12.n.6347 0 Pers./ 0,00 h

12

Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel

-------------------------------------------------------------------------------------------------------------------------------Maintenance:
Every 30,000 h check size of gap "s" between the spring ends and the flanks of the interior grooves. Renew all seals.

Auxiliaries:
Molykote "G-Rapid Plus" * Molykote lubricant "Typ 60 G" * Silicon sealant "Dirco-Grau" * Loctite 275 * or product of equivalent quality

Note:
The oscillation damper is connected to the engine lubrication system. The system must be bled before the first operation and after maintenance work (operation sequence 5.1). At every lubrication oil change, the system must be completely drained of oil (operation sequence 1.3), even in the case of self-bleeding dampers, and the oil replaced (operation sequence 5.1). If running abnormalities appear at certain speeds, the cause may be a defective damper. To avoid extensive damage, avoid critical speeds and attempt to narrow down the fault as soon as possible by measuring the torsional oscillation. In damper replacement (possible in AT procedure) or damper assembly lubricate the screw thread plate and screw head of the antifatigue screws (Fig. 1/1) with Molykote "G-Rapid Plus" paste and set with a pre-torque of M = 400 Nm and finally tighten at torque angle = 60°

The fastening screws of the pump bearing plate (4), the pump wheel carrier (15) and the pump gear wheel (14) must be tightened at the torque values given (see Assembly, Molykote Lubrication).

en / 05.02.2001

IB022862

1/4

7 1. 12.Vibration Damper Maintenance / Disassembly and reassembly VM32 A5. Remove the oscillation damper and forcing screw from the crankshaft and dismantle.02. Remove O rings (20 and 21).52 30000 Sequence of operations: 1. Dismantle the pump wheel carrier (15) and pump gear wheel (14). 1. (30).2001 IB022862 2/4 .04. 1. forcing may be carried out through tapping bore holes. Remove the antifatigue screws and fastening screws (1) (12).3 1.2 1.4 1.5 1.8 1. 1.1 Dismantling Drain the oil: 12 • Turn oil flow boring to lower position • For full drainage turn the damper through 180° m several times. Dismantle side plates (18).01. Check oil flow bores and oil feed bores are clear. Clean all parts thoroughly.6 Mark the position of the damper to the crankshaft. Remove fastening screws (13).9 en / 05.05.

04.18 0.18 1. Tighten hexagonal screw (23) until cup spring (22) lies flat.2001 IB022862 3/4 .10 12 Damper No. en / 05. 2/"s" ) between spring ends and groove flanks of the interior using a feeler gauge.. D 80/20 G1 05043 D 80/21 G1 05044 Anzugsmoment (Pos 23) 226 Nm 226 Nm Gap "s" (mm) 0.Vibration Damper Maintenance / Disassembly and reassembly VM32 A5. At least tighten with a torque to M =226 Nm Attention: In the case of one-sided positioning of groove flank: gap "s" x 2. 12.02.52 30000 Measure gap (Fig.05.01. 1/22). Maximum permitted value for gap "s" between spring ends and groove flanks: 1.11 Apply an adequate quantity of "Loctite 275" to both sides of the cup spring (Fig.

If critical values have been exceeded.1 Bleed the air from the oscillation damper: • Turn an oil flow bore hole (30) to the highest position (30).04. the damper should be replaced as soon as possible.Vibration Damper Maintenance / Disassembly and reassembly VM32 A5. Check systems for sealing and check lubricant supply to gearwheels.05. 12. Starting torque of screws: M12 = 60 Nm . • Operate reserve lubricant pump until oil flows evenly out of the oil feed bore hole. 4. Assembly of oscillation damper: 12 5. Insert new greased O rings (20 and 21). en / 05. Set the side plates so that the oil flow bore holes are positioned between the oil feed bore holes. 2. M16 = 130 Nm 5. 3.2001 IB022862 4/4 . • Observe the marking of the damper position to the crankshaft! 5.2 Further assembly procedure takes place in reverse order from dismantling procedure.02. 5. Screw the side plates tightly with the corresponding starting torque..52 30000 Note: When critical values have been reached the damper should be replaced (AT procedure). the engine should be operated only at reduced power and avoiding critical speeds. Apply Molykote "G-Rapid Plus" to the screw threads and screw head plates of the screws.3 5. Apply Molykote "Typ 60 G" across the inner side of the side plates (18). • Operate reserve lubricant pump until oil flows evenly out of the second oil feed bore hole • Wait until no more air bubbles are visible. Seal screw threads and cup springs with oil-resistant sealant. • Turn the oscillation damper through 180°.4 Assemble lubricant piping.01.

51 45000 A5.12.000 hours deadline. Please contact the Caterpillar/ Kiel Customer Service in time before reaching the 45.05.01.03. en / 04.000 h Note: We have to point out that this maintenance sheet was prepared only for the purpose of maintenance planning.nn B1.Vibration Damper Maintenance / Replace VM32 A5.05.2004 IB024251 1/1 .02.12.04./ 0. 12.00 h See also: Spare parts list: Time requirement: 12 Personnel qualification: skilled engine hand / Cat/MaK-specialist Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance/ exchange: Vibration damper: Replacement (on an exchange basis) after 45.1.05.6347 0 Pers.04.

05.7332 1 Pers.05. en / 08.03. QNB 50“ * Gear oil „Shell Omala Oil 460“ * *or a product of equal standard 1.05. so that the gearwheel of the turning device engages completely in the flywheel toothing.and maintenance instructions of the manufacturer of the turniing device have to be observed too ! Engaging the turning device Move blockinglever (1) to position “V“ and hold.10 h 12 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Oil level check Lubricating / greasing of shaft and gearwheel Oil change every every every 3.1.52 30000.1 1. The engine cannot be started during turning ! 1.7330./ 0. 3750 See also: Spare parts list: Time requirement: B1. the operating.000 h or 6 months or monthlys or 4 years Auxiliary material: Bearing grease „Klüber Altemp.12. 12.1. Move lever (2) to position“ X“.12.3 Safety note: Protect engine against unintentional start-up! Apart from these instructions. B1.750 h 750 h 30.2001 IB022985 1/3 .1 1. 750. Let off blockinglever and make sure that the blockinglever engages in position “Z“. Operating the turning device ~ 1.2 1.Turning Device Maintenance / Disassembly and reassembly VM32 A5.9.9. the position switch (11) is automatically set to position “engine OFF“ .01.1. Attention: When the turning device is engaged.08.4 Turn the engine.1.

01. 1.3 12 Attention: The engine can only be started if the turning device is disengaged ! The position switch (11) is then in position „engine-ON“) 7 10 3 4 1 X V W Z 2 Y 9 11 5 6 en / 08. Move lever (2) to position“ Y “. Let off blockinglever and make sure that the blockinglever is engaged in position “W“.2.2 1.52 30000. 12. so that the gearwheel of the turning device is disengaged from the flywheel toothing.05.Turning Device Maintenance / Disassembly and reassembly VM32 A5.2 1.03. 750.08.2.2001 IB022985 2/3 .2.1 1. 3750 Disengaging the turning device Move blockinglever (1) to position “V“ and hold.

750.3 2.2. Shell Omala Oil 460 . ca. 3750 Maintenance Oil level check 2.5 2.52 30000.1 Grease the notch on the output shaft (9) and the gearwheel (3) with bearing grease by means of the grease nipple (4).3. 2. en / 08.6 Oil change Remove screw plug (5) on the driving gear of the turning device.3.3. Fill in new oil (e.08.2. 12.1 Check oil level at the oil level glas (10) and fill in gear oil ( e.3. Remove breather (7) on the driving gear of the turning device.2 Coat toothing of gearwheel thinly with bearing grease.10 l) up to the oil level mark (10). Attention: Grease the gearwheel toothing only if the turning device is disengaged.g.4 2. only the prescribed gear oil is to be used ! 2.2001 IB022985 3/3 .3 2. 2. 2.01. 2.1.05.Turning Device Maintenance / Disassembly and reassembly VM32 A5.03. 2.2 Lubricating / greasing of shaft and gearwheel Note: Grease the notch on the output shaft and the gearwheel only if the turning device is engaged.3.1 2.2 2.1 12 Note: If a topping up should be necessary. Shell Omala Oil 460 ) up to the oil level marke. Mount the breather (7) .g. Drain the oil from the driving gear of the turning device.3. Mount the screw plug (5) with new gasket (6).

Tools - A6 Tools en / 24.2008 AA000112 1/1 .04.

01 en / 24.04.2008 AA020050 1/1 .01 Tools Table of contents A6 A6.Table of contents - A6.

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