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Engine Operating Instructions

VM32

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

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Engine Operating Instructions
VM32

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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

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Total Index
Book A, B and C
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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

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Total Index
Book A, B and C
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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

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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

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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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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.

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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.

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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.

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04 1. 2. Check lube oil pressure switch.3 Check if emergency stop safety device is operational. en / 20.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. lube oil temperature) Emergency stop due to lack of lube oil Checks: • • • • • Visual inspection of engine.2 Contact the Caterpillar/ MaK-Service. 2.2008 AA033984 2/5 .Check gears for damage or loss. Contact your Caterpillar/ MaK Service. Check oil sump and piping for leaks and cracks.1 1. Check lube oil filter for metal chips. Verification of possible out of calibration of actuator (if fitted).02. Lube oil pump drive: . 1.1 Lube oil (lube oil pressure. Checking governor drive.2 How high was the maximum rpm before emergency stop was triggered? Why did engine go into an overspeed condition? Check: • • • • • 1. Overspeed condition Emergency stop due to excessive rpm.

of combustion chamber.11. Visual inspection of engine and gear train. Cooling water (fresh water . Check cooling water circuit.11. nn.2008 AA033984 3/5 .nn).04 2. Check oil cooler. of cam shaft trough. of turbo charger. Pressurize each cylinder through opened indexing valves with shop air.01.18. 3.05.02. Engine room monitoring Emergency Stop due to excessive oil mist concentration (refer to A3.HT. 3. pressure and temperature) Emergency stop due to excessively high cooling water temperature Checks: • • Visual inspection of engine Check temperature sensors en / 20.1 Contact your Caterpillar/ MaK Service.4 Contact the Caterpillar/ MaK Service.Emergency Stop Safety System M20/M25/M32/M43 A0. refer to C5.03. 4. If there is a rapid pressure drop or if no pressure builds up the cause must be investigated.02.3 Emergency stop due to high lube oil temperature Checks: • • • • Check temperature sensor. 2. Checks: • • • • • Check engine room monitoring device (operational test).

Exhaust gas Emergency stop due to excessively high exhaust temperature Checks: • • • • • Check exhaust gas temperature sensors.05. Aftercooler (differential pressure) (refer to A5. Injection valves (refer to A5.02. Check pneumatic emergency stop system on engine after every emergency stop Attention: In order for emergency stop safety device to operate properly.04.1 Check fresh water cooler Operational test of LT . 5. en / 20.Emergency Stop Safety System M20/M25/M32/M43 A0.nn).nn).nn).02.1 Contact your Caterpillar/ MaK Service.07.01.11.05. Checks: • • Check emergency stop pneumatic system on the engine for leaks. 6. Stop valve to main start line upstream from start valve must constantly be open during operation. Turbocharger 5.(Refer to A3.5 bar pneumatic supply has to be available continuously. 7.06.Cooling water circuit with cooling water pump.05.04 • • 4. Contact your Caterpillar/ MaK Service. Fuel pumps and fill level scale on each fuel pump.2008 AA033984 4/5 .08.

en / 20.RPM switch unit failure (overspeed) 7.05. the engine plant may only be operated for a short time and under permanent observation. If such a fault message appears on the monitoring display of the alarm system. 7.Safety system failure .01.2 Plant-specific fault messages: .02. 7.04 7.nn. the cause of the fault message must be remedied immediately.3 Please contact the Caterpillar/ MaK Customer Service.Emergency Stop Safety System M20/M25/M32/M43 A0. but they considerably affect reliable engine operation.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. Fault messages and measuring points Attention: The fault messages listed below do not directly lead to an emergency stop.nn.02. At any rate.2008 AA033984 5/5 .

the crankshaft rotates in the following direction: Counter-Clock Wise or Anti-Clock Wise or Left-Hand Rotation Firing Order (Injection Sequence) see A1. Note: See also A5. Bank A side and Bank B side of the engine are determined from the flywheel end.05.1 mm + 0.4 mm + 0.01.2003 AA025775 1/2 . Bank B is on the right. Viewing from the flywheel end at the flywheel.1 mm –0.500 hours and adjusted.10 Engine Valve Clearance (Lash) Inspection: The valve clearance is to be checked every 1.Specification Engine Design VM32 A0.0 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. Cylinder Number B1 is the flywheel end cylinder on Bank B (on the right as viewing the flywheel from the flywheel end).nn The engine valve clearance should only be measured with warm engine. 15 minutes after shutting down the engine. 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.01. if required. the sides of the engine are referred to as Bank A or Bank B sides.05 Engine Design – M 32 VEE When the crankshaft is viewed from the flywheel end at the flywheel. In CM and MaK Product Literature by Caterpillar Motoren.e. Cylinder number A1 is the flywheel end cylinder on Bank A (on the left as viewing the flywheel from the flywheel end). en / 11. Engine valve clearance Inlet Engine valve clearance Outlet or Exhaust 0.0 mm 1.02. Bank A is on the left.01.1 mm –0. i.

Specification Engine Design VM32 A0.05 Cyl. 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.2003 AA025775 Inlet Valve 2/2 .02. 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.

2008 AA000103 1/1 .04.Technical Engine Data M20-M601C A1 Technical Engine Data en / 24.

Governor Data - A1.02.04 Governor Data en / 20.2008 AA000097 1/1 .

66 en / 21.Governor-data VM32 A1.2008 AA041603 1/1 .26 .04.04.

326 x Motordrehzahl x engine speed Digitaler Drehzahlregler / Digital Speed Governor Reglertype: Governor type: 723+ Reglerdesignation: Governor designation: 9906-619 Abb. If the climatic conditions are considerably changed in the main district of operation (e. 1. und nicht nur vorübergehend.: Record No.: Serial No. 1 Hebel am Regler Lever on governor Serien-Nr..1) ist in diesem Fall zu vermerken. Stellgerät / Actuator Type: Type: UG40-ACT Designation: Designation: A 8251-772 beidseitig-kerbverzahnt serrated both sides kerbverzahnt serrated Serien-Nr.: 14959735 2.1 Bau-Beschreibung / Specification Ausgangswelle: Terminal shaft: Antriebswelle: Drive shaft: Basis: Base: 3/4" . von Eismeerfahrt in Tropenfahrt.1) bzw.: 3. After oil change or repair of the governor the adjustment data must set again.2 Ölfüllung des Stellgerätes: Oil filling of the actuator: Siehe Abschnitt "Betriebsstoffe" See section "Operating Media" Ändert sich das Klimaniveau des Hauptfahrgebietes wesentlich.02.: Motor-Nr. g.m Motor-Type: Engine type: Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Kostenträger-Nr. B.48 1 1/8" . change from polar sea navigation to tropical regions) eventually causing failures.48 UG 40 2.: Engine No.2008 6200 750 kW Regelbereich: Control range: 450-750 1/min 1/min Gesamt-Massenträgheitsmoment: Total moment of inertia: 5533 kg m² 2. 1 (entspricht einer Stellgeräthubausnutzung von: Link between governor terminal shaft and injection pump control shaft see Fig.2 Hinweise / Notes Nach Ölwechsel oder Reparatur des Reglers müssen diese Einstelldaten wieder angestrebt werden.1) or adjustment (3. Caterpillar Motoren GmbH & Co. / Fig. so ist bei evtl. Hebel an der Regulierwelle Lever on injection pump control shaft Anlenkung zwischen Reglerausgangswelle und Regulierwelle siehe Abb. Motordaten / Engine Data Leistung: Power: Vollastdrehzahl: Full load speed: CA31 Name: Steiner Datum: 27. KG Auskunft einzuholen. KG should be asked with respect to change of the grade of oil 2. z.1) must be recorded on this sheet.: 16 CM32 Aussteller: Abteilung: 262134-1 34184 * Ortsleistung / Site output 1. Jede Änderung der Reglerausrüstung (2.1 Reglereinstellung / Adjustment of governor siehe Programmierliste: see program list: . Caterpillar: Confidential Green . der Reglereinstellung (3.. Every change of the governor equipment (2. 1 (corresponds to a governor stroke utilization of: 75 (%) 3.3 Stellgerätdrehzahl: Actuator speed: 3.: Serial No. auftretenden Reglerschwierigkeiten wegen eines Wechsels der Ölsorte bei der Caterpillar Motoren GmbH & Co.

2008 6200 750 kW Regelbereich: Control range: 450-750 1/min 1/min Gesamt-Massenträgheitsmoment: Total moment of inertia: 5533 kg m² 2.m Motor-Type: Engine type: Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Kostenträger-Nr. auftretenden Reglerschwierigkeiten wegen eines Wechsels der Ölsorte bei der Caterpillar Motoren GmbH & Co. KG Auskunft einzuholen.: Record No.: Engine No.: 3. change from polar sea navigation to tropical regions) eventually causing failures.1) bzw. g. der Reglereinstellung (3. von Eismeerfahrt in Tropenfahrt.: Serial No. Caterpillar: Confidential Green .: 14891626 2. so ist bei evtl. Hebel an der Regulierwelle Lever on injection pump control shaft Anlenkung zwischen Reglerausgangswelle und Regulierwelle siehe Abb.1) must be recorded on this sheet. KG should be asked with respect to change of the grade of oil 2. Stellgerät / Actuator Type: Type: UG40-ACT Designation: Designation: A 8251-772 beidseitig-kerbverzahnt serrated both sides kerbverzahnt serrated Serien-Nr.326 x Motordrehzahl x engine speed Digitaler Drehzahlregler / Digital Speed Governor Reglertype: Governor type: 723+ Reglerdesignation: Governor designation: 9906-619 Abb. After oil change or repair of the governor the adjustment data must set again..: Serial No. B.: Motor-Nr. z. und nicht nur vorübergehend.48 1 1/8" .2 Hinweise / Notes Nach Ölwechsel oder Reparatur des Reglers müssen diese Einstelldaten wieder angestrebt werden. Every change of the governor equipment (2.1) or adjustment (3. 1.02. If the climatic conditions are considerably changed in the main district of operation (e.: 16 CM32 Aussteller: Abteilung: 262134-2 34185 * Ortsleistung / Site output 1. 1 Hebel am Regler Lever on governor Serien-Nr.1 Reglereinstellung / Adjustment of governor siehe Programmierliste: see program list: . 1 (entspricht einer Stellgeräthubausnutzung von: Link between governor terminal shaft and injection pump control shaft see Fig.3 Stellgerätdrehzahl: Actuator speed: 3..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. Motordaten / Engine Data Leistung: Power: Vollastdrehzahl: Full load speed: CA31 Name: Steiner Datum: 27. / Fig. 1 (corresponds to a governor stroke utilization of: 75 (%) 3.1 Bau-Beschreibung / Specification Ausgangswelle: Terminal shaft: Antriebswelle: Drive shaft: Basis: Base: 3/4" . Jede Änderung der Reglerausrüstung (2. Caterpillar Motoren GmbH & Co.48 UG 40 2.

1) ist in diesem Fall zu vermerken.: Serial No.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. auftretenden Reglerschwierigkeiten wegen eines Wechsels der Ölsorte bei der Caterpillar Motoren GmbH & Co. Motordaten / Engine Data Leistung: Power: Vollastdrehzahl: Full load speed: CA31 Name: Steiner Datum: 05. 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.m Motor-Type: Engine type: Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Kostenträger-Nr.2 Hinweise / Notes Nach Ölwechsel oder Reparatur des Reglers müssen diese Einstelldaten wieder angestrebt werden.. so ist bei evtl. 1. Caterpillar Motoren GmbH & Co.: Engine No. 1 (corresponds to a governor stroke utilization of: 75 (%) 3.: Record No.: Motor-Nr. KG should be asked with respect to change of the grade of oil 2.1 Bau-Beschreibung / Specification Ausgangswelle: Terminal shaft: Antriebswelle: Drive shaft: Basis: Base: 3/4" .1) must be recorded on this sheet. Caterpillar: Confidential Green .1 Reglereinstellung / Adjustment of governor siehe Programmierliste: see program list: .326 x Motordrehzahl x engine speed Digitaler Drehzahlregler / Digital Speed Governor Reglertype: Governor type: 723+ Reglerdesignation: Governor designation: 9906-619 Abb.. Stellgerät / Actuator Type: Type: UG40-ACT Designation: Designation: A 8251-772 beidseitig-kerbverzahnt serrated both sides kerbverzahnt serrated Serien-Nr. z.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) or adjustment (3. Jede Änderung der Reglerausrüstung (2.48 UG 40 2. B. und nicht nur vorübergehend. von Eismeerfahrt in Tropenfahrt. der Reglereinstellung (3.: 16 CM32 Aussteller: Abteilung: 262134-3 34186 * Ortsleistung / Site output 1. g.03. 1 (entspricht einer Stellgeräthubausnutzung von: Link between governor terminal shaft and injection pump control shaft see Fig.: 15092904 2.3 Stellgerätdrehzahl: Actuator speed: 3. Every change of the governor equipment (2. If the climatic conditions are considerably changed in the main district of operation (e. / Fig. change from polar sea navigation to tropical regions) eventually causing failures.48 1 1/8" .: 3.: Serial No. After oil change or repair of the governor the adjustment data must set again.

1 (corresponds to a governor stroke utilization of: 75 (%) 3. B. z.03.2008 6200 750 kW Regelbereich: Control range: 450-750 1/min 1/min Gesamt-Massenträgheitsmoment: Total moment of inertia: 5533 kg m² 2. change from polar sea navigation to tropical regions) eventually causing failures.48 1 1/8" .1) ist in diesem Fall zu vermerken. Motordaten / Engine Data Leistung: Power: Vollastdrehzahl: Full load speed: CA31 Name: Steiner Datum: 05.: Serial No. 1... Caterpillar: Confidential Green .3 Stellgerätdrehzahl: Actuator speed: 3. 1 Hebel am Regler Lever on governor Serien-Nr.326 x Motordrehzahl x engine speed Digitaler Drehzahlregler / Digital Speed Governor Reglertype: Governor type: 723+ Reglerdesignation: Governor designation: 9906-619 Abb.2 Ölfüllung des Stellgerätes: Oil filling of the actuator: Siehe Abschnitt "Betriebsstoffe" See section "Operating Media" Ändert sich das Klimaniveau des Hauptfahrgebietes wesentlich.1) must be recorded on this sheet. KG Auskunft einzuholen.1 Bau-Beschreibung / Specification Ausgangswelle: Terminal shaft: Antriebswelle: Drive shaft: Basis: Base: 3/4" . Stellgerät / Actuator Type: Type: UG40-ACT Designation: Designation: A 8251-772 beidseitig-kerbverzahnt serrated both sides kerbverzahnt serrated Serien-Nr. / Fig.1 Reglereinstellung / Adjustment of governor siehe Programmierliste: see program list: .1) bzw. so ist bei evtl. Caterpillar Motoren GmbH & Co.1) or adjustment (3.: Serial No. und nicht nur vorübergehend. Jede Änderung der Reglerausrüstung (2. KG should be asked with respect to change of the grade of oil 2.48 UG 40 2. After oil change or repair of the governor the adjustment data must set again. Every change of the governor equipment (2.2 Hinweise / Notes Nach Ölwechsel oder Reparatur des Reglers müssen diese Einstelldaten wieder angestrebt werden.: Engine No. g.: 16 CM32 Aussteller: Abteilung: 262134-4 34187 * Ortsleistung / Site output 1. 1 (entspricht einer Stellgeräthubausnutzung von: Link between governor terminal shaft and injection pump control shaft see Fig.: 14487726 2. If the climatic conditions are considerably changed in the main district of operation (e. der Reglereinstellung (3. von Eismeerfahrt in Tropenfahrt.: Motor-Nr. Hebel an der Regulierwelle Lever on injection pump control shaft Anlenkung zwischen Reglerausgangswelle und Regulierwelle siehe Abb. auftretenden Reglerschwierigkeiten wegen eines Wechsels der Ölsorte bei der Caterpillar Motoren GmbH & Co.: 3.: Record No.m Motor-Type: Engine type: Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Kostenträger-Nr.

3 Stellgerätdrehzahl: Actuator speed: 3. Caterpillar Motoren GmbH & Co. KG should be asked with respect to change of the grade of oil 2. Stellgerät / Actuator Type: Type: UG40-ACT Designation: Designation: A 8251-772 beidseitig-kerbverzahnt serrated both sides kerbverzahnt serrated Serien-Nr.. Jede Änderung der Reglerausrüstung (2.48 1 1/8" .1) bzw. KG Auskunft einzuholen.: 14487727 2. Hebel an der Regulierwelle Lever on injection pump control shaft Anlenkung zwischen Reglerausgangswelle und Regulierwelle siehe Abb. von Eismeerfahrt in Tropenfahrt.2 Ölfüllung des Stellgerätes: Oil filling of the actuator: Siehe Abschnitt "Betriebsstoffe" See section "Operating Media" Ändert sich das Klimaniveau des Hauptfahrgebietes wesentlich.: Serial No.1 Bau-Beschreibung / Specification Ausgangswelle: Terminal shaft: Antriebswelle: Drive shaft: Basis: Base: 3/4" ..48 UG 40 2.: Serial No. z. g.04.1 Reglereinstellung / Adjustment of governor siehe Programmierliste: see program list: .: Motor-Nr.1) ist in diesem Fall zu vermerken. 1 (entspricht einer Stellgeräthubausnutzung von: Link between governor terminal shaft and injection pump control shaft see Fig. After oil change or repair of the governor the adjustment data must set again.ã Motor-Type: Engine type: Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Kostenträger-Nr. so ist bei evtl. und nicht nur vorübergehend.: Engine No. 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. 1.326 x Motordrehzahl x engine speed Digitaler Drehzahlregler / Digital Speed Governor Reglertype: Governor type: 723+ Reglerdesignation: Governor designation: 9906-619 Abb. der Reglereinstellung (3. 1 Hebel am Regler Lever on governor Serien-Nr. change from polar sea navigation to tropical regions) eventually causing failures.: 3.: 16 CM32 Aussteller: Abteilung: 262134-5 34188 * Ortsleistung / Site output 1. Motordaten / Engine Data Leistung: Power: Vollastdrehzahl: Full load speed: CA31 Name: Steiner Datum: 24.1) must be recorded on this sheet.1) or adjustment (3.2 Hinweise / Notes Nach Ölwechsel oder Reparatur des Reglers müssen diese Einstelldaten wieder angestrebt werden.2008 6200 750 kW Regelbereich: Control range: 450-750 1/min 1/min Gesamt-Massenträgheitsmoment: Total moment of inertia: 5533 kg m² 2.: Record No. Every change of the governor equipment (2. / Fig. 1 (corresponds to a governor stroke utilization of: 75 (%) 3. B. Caterpillar: Confidential Green .

04. 1.m Motor-Type: Engine type: Reglerdatenblatt / Governor Data (Woodward-Regler / Woodward Governor) Kostenträger-Nr. If the climatic conditions are considerably changed in the main district of operation (e. Every change of the governor equipment (2. so ist bei evtl.1) or adjustment (3. auftretenden Reglerschwierigkeiten wegen eines Wechsels der Ölsorte bei der Caterpillar Motoren GmbH & Co. von Eismeerfahrt in Tropenfahrt.. 1 (corresponds to a governor stroke utilization of: 75 (%) 3.1 Reglereinstellung / Adjustment of governor siehe Programmierliste: see program list: . Motordaten / Engine Data Leistung: Power: Vollastdrehzahl: Full load speed: CA31 Name: Steiner Datum: 24.48 1 1/8" . / Fig. KG Auskunft einzuholen. und nicht nur vorübergehend. z. der Reglereinstellung (3. KG should be asked with respect to change of the grade of oil 2.: Serial No.: Record No. Caterpillar Motoren GmbH & Co. g. change from polar sea navigation to tropical regions) eventually causing failures.2 Ölfüllung des Stellgerätes: Oil filling of the actuator: Siehe Abschnitt "Betriebsstoffe" See section "Operating Media" Ändert sich das Klimaniveau des Hauptfahrgebietes wesentlich.: 3.: Serial No. After oil change or repair of the governor the adjustment data must set again. Hebel an der Regulierwelle Lever on injection pump control shaft Anlenkung zwischen Reglerausgangswelle und Regulierwelle siehe Abb.: Motor-Nr.3 Stellgerätdrehzahl: Actuator speed: 3.326 x Motordrehzahl x engine speed Digitaler Drehzahlregler / Digital Speed Governor Reglertype: Governor type: 723+ Reglerdesignation: Governor designation: 9906-619 Abb.: 14487725 2.1 Bau-Beschreibung / Specification Ausgangswelle: Terminal shaft: Antriebswelle: Drive shaft: Basis: Base: 3/4" .1) must be recorded on this sheet..: 16 CM32 Aussteller: Abteilung: 262134-6 34189 * Ortsleistung / Site output 1. B. Stellgerät / Actuator Type: Type: UG40-ACT Designation: Designation: A 8251-772 beidseitig-kerbverzahnt serrated both sides kerbverzahnt serrated Serien-Nr. Jede Änderung der Reglerausrüstung (2.48 UG 40 2.1) bzw.1) ist in diesem Fall zu vermerken.2008 6200 750 kW Regelbereich: Control range: 450-750 1/min 1/min Gesamt-Massenträgheitsmoment: Total moment of inertia: 5533 kg m² 2.: Engine No.2 Hinweise / Notes Nach Ölwechsel oder Reparatur des Reglers müssen diese Einstelldaten wieder angestrebt werden. Caterpillar: Confidential Green . 1 Hebel am Regler Lever on governor Serien-Nr. 1 (entspricht einer Stellgeräthubausnutzung von: Link between governor terminal shaft and injection pump control shaft see Fig.

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

3 13 1738 14 21.0000 09 Triebwerke Zyl.02.00 1.50 1.4/1299 0.00 1.00 1.9 10 11 69.00015 12 673.00 1.00 1.5 κ/ω= .00 1.00 1.40 22.70 11.0000 13 Lüfter fan 113.00 1. Bezeichnungen Designations I[kgm2] L[rad/GNm] D[cm] i[-] --------------------------------------------------------------------------------------------01 AT-Schwingungsdämpfer op-vibration damper 30.00 28.53 2 121.7 7 Elastisches System Mass Elastic System Bericht-Nr.0000 08 Triebwerke Zyl.50 28.0000 04 Triebwerke Zyl.00015 11.0000 10 Triebwerke Zyl.51 7.70 11.7 9 123.63 Nr.70 11.70 11.00015 11.4 / 1299 22.0000 12 ST elastische Kupplung sp flexible coupling 69.1 15 625 κ/ω= .c 30.50 28. A7/B7 121.0000 11 Schwungrad + PT. A8/B8 running gears Cyl.50 28.50 28.0000 14 Generatorpolrad generator rotor 1738.50 28.4 12 113. A6/B6 121. A4/B4 running gears Cyl.30 625. A4/B4 121.5 κ/ω= .0000 de/eng/20.7 5 121.90 673.00015 11.00 1.53 11. A2/B2 121.9 / .89 30.0000 07 Triebwerke Zyl.00 7. Kupplung flywheel + pp coupling 496.00 0.50 28.00 1.5 κ/ω= . A5/B5 running gears Cyl.5 κ/ω= .2008 Blatt/Sheet: 4 von/of: 9 . A3/B3 121.10 0.5 κ/ω= .5 κ/ω= .00156 11.0000 06 Triebwerke Zyl.3 1 2.00015 11.70 12.50 28.89 ψ= . A8/B8 121.7 3 121.50 28.00 1.70 11.0000 02 IT-Schwingungsdämpfer ip-vibration damper 2.00015 11.0000 03 Triebwerke Zyl.00 1.5 11. A1/B1 123./ Report No.7 6 121.70 11.79 22. A6/B6 running gears Cyl.0000 15 Erregermaschine exicter 21. A3/B3 running gears Cyl.00 1. A5/B5 121.0000 05 Triebwerke Zyl.00015 11. A1/B1 running gears Cyl.00 1.7 4 121.00 0.5 κ/ω= . A7/B7 running gears Cyl.7 496. 08032019 121.7 8 121.51 36.30 6.79 6.70 11. A2/B2 running gears Cyl.

6 .. 50 45 40 35 30 25 20 15 10 5 0 Elast.13 Spannung/Stress [N/mm2] 5 4.0) Ordnungen: 0....5 . de/eng/20.c 2 1..0) Ordnungen: 4.6 1.0 ..4....8 1.8 . Coupling Location.0) Ordnungen: 0..4 .3.14 Alternating Stress Location 13. Motordrehzahl/engine speed [1/min] (i=1./ Report No.5 ...5 ...8 .5 _____ 1...13 Alternating Stress Location 12.5 .. Coupling Location.5 .0 .3 Total .0) Ordnungen: 0..4 1. 11.12 Flex.3 Spannung/Stress [N/mm2] Wechselspannung Systemstelle 4.5 _____ 9. 11.7...... 10 9 8 7 6 5 4 3 2 1 0 Wechselspannung Systemstelle 12..5 ..2008 Blatt/Sheet: 5 von/of: 9 .5 Total 3 2..2 0 Drehzahldiagramme Speed Diagrams Bericht-Nr.9 ....1 0 Elast.2 1 .4 .0 . Kupplung Systemstelle 11..7 ... Motordrehzahl/engine speed [1/min] (i=1.5 _____ 1.0) Ordnungen: 1.12 Moment/Torque [kNm] 1 .4. Motordrehzahl/engine speed [1/min] (i=1..6 ....12 Flex.0 _____ 2..0 . 08032019 Generatorcharakteristik (P=const) / Alternator Characteristic Wechselspannung Systemstelle 2..5 4 3.5 1 .5 _____ 9.3 Alternating Stress Location 2..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..0 .8.5 ..0 _____ 0...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..5 0 Wechselspannung Systemstelle 13..5 Alternating Stress Location 4. Kupplung Systemstelle 11.5 .8.5 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..2 .0) Ordnungen: 0.5 2 1...02.

.0 _____ 0.0) Ordnungen: 3. Motordrehzahl/engine speed [1/min] (i=1.12 (Aussetzer Zyl... 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=1.5 .2.5 3 2.. A 8) Spannung/Stress [N/mm2] Wechselsp. 50 45 40 35 30 25 20 15 10 5 0 Elast...8 1..9 .12 (Aussetzer Zyl.. A 8) Alternating Stress Location 13. Kupplung Systemstelle 11.2008 Blatt/Sheet: 6 von/of: 9 .13 (Misfiring Cyl.2. Coupling Location...1. A 8) Alternating Stress Location 12.8 ..9 (Aussetzer Zyl.12 (Misfiring Cyl.5 0 Drehzahldiagramme Speed Diagrams Bericht-Nr..0 . Systemstelle 8.0 .4...2 1 .0 .12 (Misfiring Cyl..0 _____ 2. Systemstelle 2.6 Wechselsp..0 . A 8) Flex.... 08032019 Generatorcharakteristik (P=const) / Alternator Characteristic Wechselsp.13 (Aussetzer Zyl..5 4 3.5 1 ....0) Ordnungen: 0.8 ..3 (Aussetzer Zyl. Systemstelle 12..5 .5 _____ 9.02.0) Ordnungen: 0..0) Ordnungen: 0..2.0) Ordnungen: 0.7 .c 5 4... Systemstelle 13. A 8) Moment/Torque [kNm] 1 ..14 (Misfiring Cyl.4 .5 . A 8) Alternating Stress Location 2.0 .5 _____ 1.2 . Motordrehzahl/engine speed [1/min] (i=1.5 _____ 1. Kupplung Systemstelle 11.0 ...5 . de/eng/20.. 11. A 8) Spannung/Stress [N/mm2] 2 1..4 1. 10 9 8 7 6 5 4 3 2 1 0 Wechselsp. Coupling Location..8.. Motordrehzahl/engine speed [1/min] (i=1...5 2 1.5 _____ 9..4 ..14 (Aussetzer Zyl.6 .3 (Misfiring Cyl.6 1. 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. A 8) Flex. A 8) Spannung/Stress [N/mm2] Total Total ..3 ./ Report No.0) Ordnungen: 1..1 0 Elast.. A 8) Alternating Stress Location 8.. 11..5 ..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...9 (Misfiring Cyl.5 .

1427 0.2015 0.0 8.3255 0.0110 2.0 2.7225 0.4667 1.0125 0.0 3.0 3. 08032019 8 9 10 11 12 13 14 15 2.5 3.0 0.8894 0.1897 0.0 7.5 9.5 4.5 6.5 6.0 1.1399 0.2259 0.0515 0.0035 11.2585 2.0 10.0199 0.0 5.0755 12.5 2.5 0.0 5.5 7.2049 0.0 9.0061 10.8109 4.5 8.Grad / Node 2.0 0.0 4.Grad / Node 0.0 1.0214 0.3472 0.0115 0.6836 3.3445 0.5 4.4262 0.0 8.1202 0.6166 2.1904 0.2344 0.5 0.2180 0.0 6.5 4.0145 10.Grad / Node 387 1/min 1 2 3 4 5 6 7 Eigenfrequenzen Natural Frequencies Bericht-Nr.5 12.0 5.3217 0.2530 5./ Report No.0402 9.2858 3.7753 0.2451 0.0 9.7901 0.0 0.0715 0.3787 6.0984 0.0 0.6415 8.0380 0.5 5.0050 11.0337 0.2443 1.5 8.3462 0.5 0.0 0.0155 6.0 1.3043 6.5 0.0 14.5 6.9063 1.5 3.0326 0.0 11.0 4.2008 Blatt/Sheet: 7 von/of: 9 .6238 de/eng/20.5 7.0 3.0 2.02.2463 1.5 5.0258 7.1388 0.2489 8.7214 0.0 5.0961 0.0 0.5 5.5 2.5 11.3367 5.Grad / Node 1989 1/min 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 3.0963 6.2688 0.1096 1.5 0.0 11.2117 9.5 9.0 4.0 0.2766 0.5 3.5 10.0 7.Grad / Node 3.5 12.0 10.5 2.5 1.0331 1.0566 7.5 10.1193 0.4161 0.0570 0.5 11.5 0.5 1.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 1.7055 0.5515 6.0 7.c 1.0147 0.0 2.5 1.

0 5.1742 3.6599 3.8175 2.5 11.8992 1.7649 1.5 5.2008 Blatt/Sheet: 8 von/of: 9 .5 9.0777 0.9270 1.5 11.0 1.6650 6.4134 1.5 6.1990 0.1632 0.0875 4.3204 2.5 7.5353 0.5 9.2494 0.5448 0.2374 2.0 10.5 7.9895 4.5 4.5 1.4936 0.0 2.6812 4.7745 6.Grad / Node 4804 1/min 1 2 3 4 5 6 7 Eigenfrequenzen Natural Frequencies Bericht-Nr.5 4.4539 8.0 11.9020 0.1603 0.2094 0.2148 3.0 4.9799 7.3108 1.Grad / Node 0.5 2.2677 0.0 3.0 2.0 1.4688 0.0 4.8545 1.0 9.0 3.c 4.1849 5.4173 1.3409 0.5 11.0 7. 08032019 8 9 10 11 12 13 14 15 5.5 7.3632 1.5014 6.5 6.0 2.0 1.0 11.0 7.6403 0.0 5.6945 0.6316 6.0 10.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 3.5 12.5853 0.5 8.6827 1.5 2.0 1.0 5.Grad / Node 5.9991 1.0 3.0 8.3869 0.5668 1.0 11.0 5./ Report No.2559 0.5 12.0 4.0767 1.02.5 3.0 10.0825 3.1962 2.0 9.5 12.5 8.1000 1.1904 de/eng/20.7714 6.5 3.5 1.2627 0.5 10.0 7.7380 7.2397 0.5885 2.0 2.0 9.5 3.0 8.8447 1.1239 0.7039 2.0 8.5 5.Grad / Node 6716 1/min 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 6.5 9.7594 0.1240 0.5 4.9739 0.2423 0.0 1.5 8.3477 2.0 1.5 10.6596 0.5 6.8191 0.3968 5.7253 0.9050 0.Grad / Node 6.5 2.1707 4.5 10.5 5.7472 0.2519 0.4820 6.5 1.

9 Units of measurement used: All figures mentioned in this report correspond with the International System of Units (SI Units). die schneller drehen als der Motor haben ein Übersetzungsverhältnis größer als eins. which.c Erläuterungen Explanations Bericht-Nr. das abwechselnd aus Massen und Federn besteht. Drehschwingungsersatzsystem: Die Antriebsanlage ist auf ein berechnungsfähiges Ersatzsystem.2008 Blatt/Sheet: 9 von/of: 9 . 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. can only be influenced by us within our scope of supply. Equivalent torsional system: The propulsion plant is substituted by a computable equivalent system. sind auf die Motordrehzahl reduziert. Alle Anlagenteile. Die Ergebnisse und Schlussfolgerungen sind nur gültig. dass der Auftraggeber allen Bauteillieferanten die Drehschwingungsberechnung zur Verfügung stellt. 2 The unit of all moments of inertia is [kgm ]. which alternately consists of moments of inertia and springs. Es wird empfohlen.02. however. G = 10 . Sämtliche Massenträgheitsmomente sind in der Einheit 2 [kgm ] angegeben. um diesen eine Nachprüfung auf Richtigkeit der Daten und Zulässigkeit der auftretenden Beanspruchungen zu ermöglichen. Berechnungsfehlers auf Nachbesserung oder Ersatz des schadhaften Teiles an unserem Liefergegenstands beschränkt. die nicht mit Motordrehzahl umlaufen. 08032019 Verwendete Maßeinheiten: Alle in diesem Bericht genannten Zahlenwerte entsprechen dem internationalen Maßsystem (SI-System). 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. G = 10 .ausgeschlossen. Components running faster than the engine have a gear ratio greater than unity. Unsere Gewährleistung wird neben der Beseitigung eines evtl./ Report No. worauf wir jedoch nur bezüglich unseres eigenen Lieferanteils Einfluß haben. 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. Wichtige Anmerkung: Vorliegende Drehschwingungsberechnung wurde . Instead of the usual torsional rigidity c [kNm/rad] we indicate the reciprocal value L [rad/GNm]. soweit die Eingabedaten korrekt sind.entsprechend den Regeln der Schwingungstechnik nach bestem Wissen und unter Zuhilfenahme modernster Rechenhilfsmittel durchgeführt. Weitergehende Ansprüche sind . The results and conclusions are only valid as far as the data given are correct. All components not running at engine speed are referred to engine speed. de/eng/20.gleich aus welchem Rechtsgrund . Any other claims are excluded irrespective of their basis in law. Anlagenteile. zurückgeführt. Anstelle der üblichen Drehsteifigkeit c [kNm/rad] wird der Reziprokwert L [rad/GNm] angegeben.

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

25 en / 21.04.10.28.20.2008 AA041605 1/13 .Technical Data Acceptance test records VM32 A1.

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2008 AA000108 1/1 .04.Operating Instructions M20-M601C A3 Operating Instructions en / 24.

00 A3.01 A3.02 en / 24.07.Table of Contents - A3.00 A3.04.00 A3.04.06.04 A3.00 A3.07.07.02 A3.01 A3.05.2008 AA020023 1/3 .05.08.05.11.05.00 A3.10.00 A3.18.06.08.04.01 A3.05.00 A3.01 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 A3.05.09.03 A3.00 A3.15.06.18.01 A3.04.00 A3.08.00 A3.06.04 A3.05.06.02 A3.05.00 A3.05.05.06.04.

01.09.06.00 A3.Table of Contents - A3.01.00 A3.01.18.00 A3.00 A3.00 A3.00.06.2008 AA020023 2/3 .06.08.06.07.09.09.11.07.11.00 A3.18.18.08.00 A3.06.03.00 A3.00 A3.01 A3.00 A3.10.02.10.00 A3.01 A3.00 A3.07.00 A3.18.10.00 A3.06.01.01 A3.06.01 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 A3.09.08.11.07.01 en / 24.00 A3.09.00 A3.04.09.

18.01.12.01 en / 24.12.00 A3.11.2008 AA020023 3/3 .Table of Contents - A3.00 A3.04.01 A3.12.02 A3.02.01 Fault tracing Remedial measures Emergency Operation Engine Emergency operation With a defective turbocharger Emergency operation Operational misfire Emergency operation Operational misfire A3.12.02.

Introduction M20-M601C A3. 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. • Rated power this is indicated on the acceptance test records for your engine. to meet special requirements. • Full stop power this is the power output limited by a restrictor on the injection pump racks. the limiting position must also be accordingly lower.02 Contained herein are certain points regarding the initial operation. 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. As such. Attention: When using heavier fuel grades independent on the density of the fuel. Thereby in compliance with DIN ISO 3046 we differentiate between: • Maximum continuous power this is the maximum permissible output for this type of engine. please bear the following in mind: It is possible for the engine power to be limited before reaching its full performance capacity.2006 AA000295 1/5 .10). For any working data mentioned in this book. Any other arrangements can be seen from the acceptance test records (A1. our information always refers to the maximum continuous power and if this is unknown to the operator he should make inquiries to the manufacturer. 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. Unless otherwise indicated.01. 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. the rated power will be reached at a fuel rack position that is accordingly lower.

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. The existing protection and safety devices must not be removed nor changed. After commissioning the engine.01. The preparations for the first startup are made by the MaK service engineer. and any damage detected must be immediately reported.Introduction M20-M601C A3. Please observe the data and recommendations in your operating instructions together with the maintenance and servicing measures recommended by us.2006 AA000295 2/5 . Detail questions are to be settled on site from the operating instructions and explanations should be noted down in the instructions. who will explain the plant to the engine room staff in detail. 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.02 The operators have to work with the necessary care and to keep to the safety notes. They are the basis for a long useful life with a constant degree of economy for your engine installation.

strong acids will be formed from constituents of the fuel (e. CIMAC). although they do meet the generally applicable requirements (ISO.Introduction M20-M601C A3. therefore.g. Past experience has shown that this may already be caused by one charge. and liner are the operating conditions of the engine. thus considerably decreasing the expected or scheduled TBO. This may result in fuels that tend to have poor ignition qualities and a slow rate of combustion and are inclined to form hard. can be influenced to a very large extent by the operator of the plant. piston. however. In the worst case vanadium may act as a catalyst to the formation of acid. 1. 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. 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. Suppliers of fuels are currently working to define properties and limits more accurately. en / 17. These.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.e. 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. We are. these standards do not provide any information about the combustion properties of fuels. abrasive constituents. sulphur) beyond the normal extent.01. i. In extreme cases this may even result in valve burnout and piston burn. Therefore. 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. At the moment. it is becoming increasingly difficult for operators and manufacturers of heavy-fuel compatible large engines to assess the combustion properties of the fuel.2006 AA000295 3/5 . 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.

which in turn leads to piston burn. 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. Important characteristics of the lubricating oil are: • • • • Viscosity: For the formation of a corresponding lubricating wedge a correct viscosity is of vital importance. 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. in bearings). the viscosity must range within the specified limits.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. A high percentage of heavy fuel in the engine lubricating oil may particularly affect piston cooling. This will be done until there is no more discrepancy between the current and the preset viscosity value. The connection between the viscosity of the fuel and its temperature is used for controlling the injection viscosity. the viscosimeter is continually capturing the current viscosity.Introduction M20-M601C A3. To this end.01.2006 AA000295 4/5 . These forming acids must be neutralized in order to protect the engine components against corrosive attack. Low temperatures of the fuel always lead to higher viscosity and vice versa. Percentages of individual chemical elements: Especially important is the vanadium content. Depending on the measuring method the vanadium content can indicate a rising percentage of heavy fuel in the lubricating oil. 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. steam bubbles may form under certain pressure and temperature conditions (e. 2. interrupt the lubricating film and thus cause damages. In order to avoid damages to the engine.g. Through the combustion air and the fuel acid formers are introduced into the engine. Furthermore. To this end. we recommend to have the lubricating oil analyzed at regular intervals by a laboratory. Water content: A high percentage of water in the oil has a corrosive effect. en / 17.

It is absolutely required to make sure that all available engine room ventilators are running and all air ducts are fully open. Especially during the hot summer months or in warm regions of the world particular attention should be given to this aspect.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). Formation of steam bubbles due to excessive temperature and resulting excess consumption. injection pump.01. 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. en / 17. 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.2006 AA000295 5/5 . Turbocharging The turbocharger is one of the most sensitive components of the engine. fuel injector. An indicator of sufficient ventilation by a given engine room ventilation system is a slight overpressure in the engine room. piston crown. which determines whether the individual cylinders are supplied with a sufficient amount of air. The efficiency of the turbocharger depends on its degree of contamination.Introduction M20-M601C A3. High viscosity: • Poor atomization of the fuel which may lead to severe formation of soot due to poor combustion. which may significantly reduce service life particularly of the combustion chamber components. cam follower. Furthermore. high mechanical load on the entire injection system and combustion chamber components: Roller. Engine room ventilation Prerequisite for a properly working turbocharger and thus for proper air supply to the engine is a good engine room ventilation.

heat insulation. 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. 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. The service personnel must possess the corresponding qualification and authorization (qualification certificate) for the engine system in operation.g. are to be observed. 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.Safety Instructions M20-M601C A3. e.02. requirements/characteristics can be carried out in the training center of Caterpillar / MaK. 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). 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. An introduction to the system specifications. the service personnel must be fully aquainted with the characteristic features therein.2008 AA000338 1/2 .03 Safety Instructions The Caterpillar / MaK engine has been built in accordance with state-of-the-art standards and the recognized safety regulations. Nevertheless. detachable protection facilities. For the operators of the system this is a necessary requirement to the order. linings. Before the initial operation of special systems.

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. California / USA Proposition 65 Warning • Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer. operating controls. 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.Safety Instructions M20-M601C A3. ensure that there is no danger to persons by the starting engine/plant! Move operational controls to neutral position and/or minimum position (r. birth defects.p. 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.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. and other reproductive harm.m.02.2008 AA000338 2/2 . en / 20. check lamps! • • • • defective instruments.

requires perfect fuel and depends upon optimal concentrations and monitoring supervision.08.04 The instructions stated below are to be stringently observed.07.04.Instructions for Heavy Fuel Operation M20-M601C A3.04.nn en / 10.12.nn • Lubricating oil system A3.1997 AA000291 1/1 . as the readiness for service and operational reliability of the engine system during high extremes of use. • Fuel system A3.

For information about heavy fuel quality and for instructions and maintenace see section A4. sodium and cat fines etc.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”. increased.07.12. 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.04. however. vanadium.1997 BA000004 1/1 .07.05. en / 10.00 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.nn.

07. 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 / 10.1997 BA021421 1/4 .Instruction for heavy fuel operation Care and supervision / Engine fuel M32 A3.04.03. a careful ascertation of the quality must take place.01 Care and supervision If you are uncertain of the bunker quality.

04.06. During operation. Separator HS1. thoroughly remove any water and sludge.03. and a part of the water and heavy contaminations are separated from the heavy fuel as sludge. The operational capacity is designed according to the rules and regulations of the individual manufacturer. whose authorised department has coordinated the design with MaK-Kiel. HS2 The separators have the most important task in the heavy fuel treatment.90 °C 3.07.01 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. 2.07. HT6 Emulsions are normally broken up under temperature influence in a settling tank. 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. The longer the fuel remains in the settling tank. They lower the content of solids and water of the heavy fuel to the minimum that can technically be reached. en / 10. 1. 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. only empty storage tanks are to be used. Storage tank When fueling with heavy fuel. Separation temperature 98 °C.Instruction for heavy fuel operation Care and supervision / Engine fuel M32 A3. • • Both separators are always to be operated parallel independently of the manufacturer/system. • • Connect the two tanks alternaly irrespective of the fuel consumed so as to obtain the best settling effect possible. the more contaminants and water will be deposited.nn. This is to avoid segregation or the consequences of any incompatibilty that may occur when taking on different types of fuel. Before cutting a tank in.1997 BA021421 2/4 . please refer to diagram A3. If a plant has no storage tank heating. the set temperature of the tank should be between 80 . Settling tank HT5.

book C).01 4.1997 BA021421 3/4 . This prevents the formation of water condensation.95 °C should be maintained. 5. 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. Test procedure: The system pressure must not rise when increasing the valve spring load. it will always be filled to the overflow level. Self cleaning fuel filter HF4 For fuel (heavy fuel and destilled fuel). the operation of the separators must be checked and the filter cleaned (for servicing instructions see the document of the manufacturer. HP2 The fuel pump pressurizes the mixing tank. 8. Fuel pressure pump HP1. 7. In the event of alarm and/or when filling the tank. filter elements with a mesh size of 10 µm are required. In the event of filter alarm. A temperature level between 80 . for a minimum of 4 hours of full load operation. which is activated between the flushing intevals if the differential pressure is accessive. en / 10.05).04. If the treatment plant is in order.03. Mixing tank HT2 This mixing tank is equipped with a level monitor.Instruction for heavy fuel operation Care and supervision / Engine fuel M32 A3. Day tank HT1 The day tank is designed to collect the treated fuel.07. 6. The pump relief valve has to be closed in operation. • • Daily de-sludging is important. open the vent valve several times for a short time by hand.

07. (1.Instruction for heavy fuel operation Care and supervision / Engine fuel M32 A3. 10 .1997 BA021421 4/4 .8 . in order to reach a good atomisation and fuel-air mixture. The pump relief valve has to be closed in operation. 12.05. en / 10.04.06) and ajust the viscometer if necessary. ensure the temperature switch may be set to at max. 180 °C • If the preheater is of steam type. 11. see A5.12 mm2/s cSt. Circulating pump HP3. 10.03. • If the preheater is of electrical type.2 °E). Attention: Fuel temperature before engine intake ≈ 150 °C. check the temperature and viscosity against the viscosity-temperature sheet (see A4.07.07.01 9.nn. Final preheater HH1 The preheater is to lower the fuel viscosity to a level that is optimal for injection. Viscosity measurement and control equipment HR2 (Viscometer) Check whether the indicated viscosity is actually run: whenever taking on fuel. 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. For service measurements.01.12. a condensation trap should be installed at the steam outlet to ensure sufficient heating if possible. Fine filter HF1 The fine filter prtects the fuel injection system and removes solids not previously separated. HP4 This pump is designed like a force pump.

g.1997 BA020008 1/1 .nn.08.04. Note: Sulphurous residues and combustion products of the fuel form sulphuric acid with the water vapor which results from combustion and which afterwards condenses. • • • • Dissipate frictional heat. Improve the seal between piston. combustion residues and products of deterioration. Lubricating oil The selection of the suitable lube oil and the limit values are observed according to the operating media A4.12. piston rings and cylinder liner.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. valves and cylinder liners. Protect engine parts from corrosive combustion gases.08.05. This produces corrosive wear on bearings. en / 11. For this reason. to limit gas blow-by. The lube oil has important functions in engine operation as e. pistons. 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. Act as a coolant (pistons).: • • Replace metallic friction with the much lower fluid friction of the oil film.Instructions for heavy fuel operation Lubricating oil system M20-M601C A3. Suspend abraded particles.

nn.08.Instructions for heavy fuel operation Care and supervision / Lubricating Oil M32 A3. see A4.02.03. 1. lube oil purification by separators is indispensible for a proper treatment.95 °C. see A3.nn. 3. it is distributed among the engine lubricating points. and after longer periods of shutdown an analysis circulatory lubricating oil. There are no other means to eliminate from the oil. • The separation temperature must be between 90 . 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. This will replace parts of the additives consumed. if 20% of the specified quantum has been consumed.01 Care and supervision In heavy fuel operation. Top up with fresh oil. 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. Oil level control • • • • Check the oil level daily. Lubrication oil filtering Oil cleaning in separators is specified for heavy oil operation.05. en / 01. the products resulting from cleaning and neutralisation (carbon and asphalt compounds) including water.05.08.2005 BA020010 1/4 . After this.08. 2. Perform during operation regularily. (For restrictions of guarantee see A4.04.

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 / 01.03.08.2005 BA020010 2/4 .04.Instructions for heavy fuel operation Care and supervision / Lubricating Oil M32 A3.

03.04.2. 3. • • Check the pressure build-up at the last main bearing (if there is no automatic engine locking). the cause of the oil contamination must be detected: check the separator function charge air is too cold (soot formation) en / 01. The automatic filter is the main filter and as such it has the finest filtration. 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. Prelubrication LP2 (standby or prelubrication pump) Only a sufficient prelubrication will produce the necessary oil filn on all bearings for engine starting. Attention: The functioning of the entire series of filters is indispensible for the proper filtration of the lube oil.01 3.3. It must therefore only be bypassed in extreme emergencies.1.1. If there are more than 100 flushing per day. • Monitor the flushing intervals of the filter (the flushing cycle counter indicates the contamination level). 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). if the pressure is too low.08.3. Check the operation of the engine-driven force pump LP1 • Check the oil pressure (at rated speed and working temperature). 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. 3.2005 BA020010 3/4 . Prime the circuit until the pump pressure is steady.Instructions for heavy fuel operation Care and supervision / Lubricating Oil M32 A3.

12.Instructions for heavy fuel operation Care and supervision / Lubricating Oil M32 A3.05. • • 3. the filter cartridges being installed at working temperature. See servicing instructions in the documents of the manufacturer. • 3. 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. 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 the back-flushing filter is equipped with flushing oil preparation.2005 BA020010 4/4 . see A1.04.08. Carefully check the filter elements for damage.01. carefully clean the isolated filter chamber.05. See servicing instructions in the documents form the manufacturer. If required (differential pressure indicator shows 50% of the red area or filter alarm). Renew damaged cartridges. If the filter has various cartridges. one damaged cartridge means a malfunction of the entire filter.01 • Check and clean the filter elements. the inserts of this must be cleaned or exchanged in he event of a filter alarm.07. • • 3.03.2.5. book C. Renew damaged filter cartridges For servicing instructions see A5. 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). en / 01.3.Remove the cartridges during every third cleaning. book C. If the back-flushing filter flushes with oil. set the flushing flow (valve in the flushing line) so that there will be no drop in the working pressure.nn.4.

Initial Operation Engine - A3.00 Initial Operation en / 20.2008 BA000022 1/1 .02.05.

flange connections and threaded pipe unions for leaks. Vent the fuel system.12. Switch the fuel circulation pump on.07. en / 11. In case the day tank is at a higher level and the pump has a bypass line: open the stop valve at the pump. it will not be necessary to fit uncooled nozzles.Initial operation Fuel system M20-M601C A3. The rule is: heavy fuel . Use auxilary fuel pump.nn.07. Check the nozzles and opening pressure according to A5.07.06). Ensure that all cocks and valves are in the correct position.07.07. Clean the fuel filter according to A5.nn. • Check for smooth operation of the control rack linkages: Each individual control rack has movement in both directions so as to give perfect operation.05.07.01.00 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. is to be only temporarily run on distillate fuel. Additional preparation work for heavy fuel operation (see A3.1997 BA000018 1/1 .05.05. The fuel temperature before the injection pumps is to be checked according to its viscosity (see A1.04.cooled nozzles distillate fuel . • • Set all equipment parts of the fuel and nozzle cooling systems into the operating position.01.08.12.05. Switch the fuel circulating pump on and check the vent screws.uncooled nozzles If an engine equipped for heavy fuel. remove the sludge and refill. • • • • Drain the day fuel tank.01.nn.nn) • • Switch on all necessary preheaters for the correct time.

nn.Initial operation Lubricating oil system M20-M601C A3.08. en / 28.08.08. • • • Plants with lubricating oil separator: • Start the separator and preheat the oil in this manner in due time before starting the engine. Check lubricating oil pressure.08. these both being situated in front of the lube oil force pump and the standby pump (see A5.01. • Clean the lubricating oil duplex filter and the suction strainer. The working pressure has to be reached with switched-on standy or pre-lubricating pump. Turbocharger with independent lubricating oil supply: • Check the oil levels at the turbine and compressor ends (sight glass).1997 BA000026 1/1 .Check the oil level Wet sump . see A1.Drain off the water from the oil tank .nn.01. see A4.04.02.05. 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. A5. Switch on the standby or pre-lubricating pump and Vent the entire lubricating oil system.05.Check the oil level in the sump by means of a dip stick.nn) Dry sump .00 Lubricating oil system The lubricating oil should be analyzed regularily during operation and after a longer period of engine downtime.05. Check all flanges and threaded connections in the system for tight connection.05.02.

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.18. cylinder head. for draining individual cooling water spaces for repair (e. For pressures and temperatures see A1.g.05 an A1. It is required that the cooling water has a level of corrosion protection (see A4. Water condensation is avoided and the time needed until the engine has been warmed up to normal working temperature is considerably shorter. Set the correct position of the isolating and changeover cocks and/or valves on the cooling water system. For preheating temperature see A3.12. see book C. If there are cocks or valves in the cooling water piping on the engine.06. check whether these cocks or valves are open. turbocharger etc.05. The vent pipe from the engine to the header tank generally has a stop valve to throttle the water flow. a sufficient permanent venting must be ensured.09.00 Cooling water system • Fill the cooling water system via the expansion tank. Unless connected to a permanent venting arrangement.Initial operation Cooling water system M20-M601C A3.). all components and pipes belonging to the system must be consecutively vented.09.nn. Switch on the fresh water standby pump and check the system for leaks. The starting performance is better with distillate fuel. While the engine is running. preheating is absolutely necessary.nn). so that there will be no heat accumulation in the parts to be cooled.05. • • • • • en / 16.1997 BA000030 1/1 . If an engine is running on heavy fuel from pier to pier.05.

05.05.02.01.01.05.11.05.nn A5.nn)! en / 01.Initial operation Starting air system M32 A3.05.02.05. • • • • Drain the starting air equipment.05.05.05. the engine will have a fuel limiter depending on charge air pressure. Check: A5.10.05.01.05.05.03.1997 BA000405 1/1 .nn. In no case the starting air shut-off valve must be closed during engine operation (A3. Open the main valve on the air bottles.04.01.10.02.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.nn).10. and this also limits the starting fuel.00 Compressed air system • Check the following components for ease of movement and leaks: Starting air distributor Master starting and vent valve • A5.nn) If there are special requirements to be met. Check emergency stop unit (A5.07. For bottle pressure see A1.

the engine air system also supplies the emergency stop devices and the crankcase oil mist detector.11.Initial operation Starting air system M20/M25/M32/M43/M282/M332C/M452/M453C/M551/M552C/M601/ M601C A3. the air supply of the emergency stop cylinders at the injection pumps and at the crankcase oil mist detector are shut off.00 Do not close starting air shut-off valve during operation! • Apart from the starting system.1997 BA000719 1/1 . in addition to the starting air. to ensure the operational reliability of the engine. • When the shut-off valve is closed.07.05. • In no case the starting air shut-off valve must be closed during engine operation! en / 01. • • 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 General performance testing • • • Ensure that the air admission into the engine room is in order. engine is ready for commissioning. Drain the water from the exhaust piping after the turbocharger and check pipe for free passage. Close indicator or decompression valves. Check the permanent water drain at the charge air manifold for free passage.05. Note: If the amount of water is large. Do not start the engine to avoid the danger of water shocks.Initial operation General performance testing M20/M25/M32/M43 A3. Turn the engine by baring gear or rod. en / 11.2000 BA000034 1/1 . • • Open the indicator or decompression valves.05. until no water is blown out. the cause must be traced. a small amount of water may come out as a result of condensation.15. for this If the engine has a clutch: • • Declutch the engine Carry out starting attemps. When the engine is cold.

Starting (operating panel in the gauge board) • • • Switch position selector in the board on “2 = OFF”. 5 min. then a functional scheme and description of the functional scheme applying especially to this particular system will be prepared and coordinated (see book C). see A1.18. Manually start the engine at the starter solenoid or master starting valve.nn)! • en / 05.08. safety systems and also revolution counters are switched off normally all functions are automatically monitored.Initial operation Putting into service/starting M20/M25/M32 A3. In order to ensure the functioning.1996 BA000042 1/1 . 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. Put emergency operating lever into the operation position at the operating stand or at the control linkage. apart from the basic equipment for the local control of the engine (emergency control) further special fittings and facilities to operate these are provided. In the event of a direct engine start with electronic governors the stop must be reset parallel to actuating the starting solenoid valve. These are not dealt with in this section. For operating pressure. When alarm.05. Keep the starting attempt as short as possible.05. prior to start. In no case the starting air shut-off valve must be closed during engine operation (A3.02 According to the application of the engine and the degree of automation. it is important to know the automation degree of the system.11. manually checked or executed. • • • 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.05. Unless these facilities are included in the contractual supply scope of Caterpillar / MaK. Engine prelubrication: Switch on the engine prelubrication pump or auxilary pump approx.

with heavy oil).: 20 °C 5 °C approx. Severe working conditions If for example. The engine is started at a nominal speed. at maximum intervals of 1/2 h. Extreme loading should be avoided when simulating an emergency.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. When working temperature has been reached. the water jacket has to be kept at working temperature and the engine lube oil circuit automatically primed for 2 min.93 BA000050 1/3 . For routine testing of. loading of the engine is possible after a correspondingly shorter period. See A1. the engine is equipped with automatic starting/stopping or is used as a standby generating set.g. en / 01. 20 min approx. 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. as this would not provide any additional findings about engine availability in the case of need.Initial operation Putting into service/loading M20-M601C A3. for instance.06.06. generating sets.18. proceed as follows: Prime the engine lube oil circuit (if there is no continual prelubrication) and start operation as described under “Normal working conditions”. load may be added as described in operating media increasing the load of a warmed-up engine. 40 min If the engine has been preheated to a higher temperature (e.05.

06.Initial operation Putting into service/loading M20-M601C A3. 4. load stage from max.93 BA000050 2/3 . load stage from max. 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. The graph below shows the possible load stages at which the frequency settling time stipulated by DIN/ISO is possible. load stage from 0 % to 37 % to 61 % to 37 % Pnom 61 % Pnom 83 % Pnom 83 % to 100 % Pnom en / 01. on the example of a 6 M20-engine with a full load pme = 21.9 bar.05. 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. max. 3. 2.18.04 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.

The local control station should only be left when the readings have approximately reached a steady-state condition in the desired power range.Initial operation Putting into service/loading M20-M601C A3. the indicators. en / 01. If higher load increases are required than previously recommended.18. The engine should always reach working temperature after every start. If there is a bad speed range owing to torsional vibration. See the plate on the engine and/or A1. such as pressure gauges. then in every instance these must be discussed with Caterpillar / MaK. running gear and engine housing must be reduced according to the duty required and its frequency.04 Accelerated load increase Loading within the shortest period possible. With local control or manual monitoring of the engine.06. depends on various factors.09. The maintenance intervals for cylinder heads. this should be passed as rapidly as possible.93 BA000050 3/3 . thermometers and tachometers must be continually watched. 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). particularly in short test runs. will produce sulphurous acid which will damage the valves and exhaust ducts in conjunction with other corrosive combustion residues.05.

02.00 Operational Supervision en / 20.06.Operational Supervision Engine - A3.2008 BA000058 1/1 .

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.05. 90 % power if the air intake temperatures are below +10 °C as otherwise the permissible nominal ignition pressure is exceeded.Monitoring Intake air temperature M20-M601C A3. en / 28.00 Operation in the case of low intake air temperatures The engine is only allowed to be operated at max.06.05. 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.1998 BA000595 1/1 . In the case of compressor inlet temperatures below +10 °C.

05. The maximum firing pressure is set at the camshaft drive gear which has a hydraulic detachable shrink brace for this pupose.06.Monitoring of operation Exhaust system/Firing pressure M20/M25/M32/M43 A3. To prevent the existing firing pressure differences from being balanced by adjusting the filling at the injection pump. the engine does not have this adjustment possibility. An adjustment of the filling would result in the cylinders having different performances and torques. 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. 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. firmly mounted plates. The individual erection heights of the injection pumps of the individual cylinders are secured by ground. Owing to this measure. cylinder-tied. 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.06.2000 BA000498 1/1 . all tolerances are eliminated between the base circle of the cam up to the upper edge of the push rod. en / 11.

nozzle. The cause must be determined if there are any deviations (e.nn. exhaust valve). injection. The temperatures after the cylinder.2008 BA000658 1/4 .g. the fuel injection of the injection pumps alone is decisive for balancing the cylinder power values. The influence of the prevailing air intake conditions on the engine data must be seen and taken into account.10.06. Check the temperature after the cylinders regularly. for instance. injection pump. 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. Injection pump or nozzle wear. 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. however.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. refer to A3. en / 04.11.Operational supervision Exhaust system/supercharging M20/M25/M32/M552C/M601C A3. should not deviate more then ± 30 K from the respective cylinder value given in the acceptance test certificate A1.06. Such as measurement therefore only has a limited informative value which could be misleading. combustion). will have a direct effect on the thermal engine performance.18. 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.04.

400 °C ttexh. then determine the cause of the temperature rise (different ambient conditions. Assessment of the exhaust colour: refer to A3. exhaust turbine and intake condition. after turb.18.nn. max. en / 04.Operational supervision Exhaust system/supercharging M20/M25/M32/M552C/M601C A3.12.nn.11. Refer to A3. Also refer to A3. fouled charger etc. The temperatures after the turbocharger should not exceed the full load value in the acceptance test certificate A1. ∆ttexh. ≈ 30 K • Compare the exhaust temperature after the turbocharger during full load operation with the specification in the acceptance test certificate A1.nn.10. after turb.18. type of fuel.). the exhaust will be invisible or a light grey.06. Total misfiring can cause damage to the flexible coupling! It should be noted that partial misfiring already subjects the flexible coupling to impermissible loads.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. after turb. max.10 by more than 30 K.11. If ∆ t > 30 K.2008 BA000658 2/4 . If combustion is good. 420 °C • Make an additional check of the combustion by assessing the exhaust opacity. 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).02.06.04. Reduce the engine power if the maximum permissible temperature after the turbine is exceeded during operation with Heavy fuel Distillate fuel ttexh. Note for exhaust temperature monitors: Contrary to the monitor for the average exhaust temperature.

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

06.00.04. en / 04. 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.nn.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.2008 BA000658 4/4 .06.05. Refer to Exhaust temperatures after the turbine. refer to the operating instructions for the turbocharger in manual C. For cleaning the compressor. • • Electronic thermostat: Raise the temperature by adjusting the thermostat. raise the air charge temperature until condensation stops. If the volume of discharged water is not reduced despite the temperature increase. • • Observe the maximum permissible exhaust temperatures after the turbine. • • Daily cleaning of the compressor Periodic washing of the turbocharger during heavy fuel operation: refer to A5. 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.Operational supervision Exhaust system/supercharging M20/M25/M32/M552C/M601C A3.05.06. Attention: This increases thermal engine stress. check the air charge cooler for leakage.

04.07. see changing the type of fuel A3.06. (See A3. If the engine is running on heavy fuel. For operating with heavy oil see diagram in A3.03. Changing over to distillate fuel may be necessary: after lengthy service at partial load operation.00 Fuel system • • • Drain the water from the day fuel tank and check it at regular intervals. change over to distillate fuel in time. or before scheduled maintenance work on the fuel system. Note: The following fuel diagram is only valid for a permanent operation of the engine with distillate fuel.1997 BA021416 1/4 .nn.18.nn).06. Inspect the fuel treatment plant.07.Operational supervision Fuel system M25/M32 A3. en / 12.06.nn.07.

It shall lower the content of solids and water to the minimum that can technically be reached. 2.07.03. Storage tank DT4 When fueling.1997 .06. Separator DS1 The separator is only switched on. This is to avoid segregation or the consequences of any incompatibility that may occur when taking on different types of fuel. if distillate or mixed fuel is used instead of distillate fuel with 7 cSt/ 40 °C.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. only empty storage tanks are to be used.Operational supervision Fuel system M25/M32 A3. 3. Day tank DT1 BA021416 2/4 en / 12.

06.03. This avoids the formation of water compensation.07. • If the preheater is of electrical type.distillate fuel with 7 cSt/40 °C o . of 50 °C • If the preheater is of steam type. Upon alarm and/or when filling the tank. If the treatment plant is in order. 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. in order to reach a good atomization and fuel-air mixture. Diesel oil preheater DH1 Note: The diesel oil preheater DH1 does not apply upon employment of: .Operational supervision Fuel system M25/M32 A3. Fuel fine filter DF1(duplex filter) en / 12. diesel oil standby feed pump DP2 These pumps are designed as force pumps. 8.1997 BA021416 3/4 . 7.distillate fuel with 7 cSt/40 °C o . Intermediate tank DT2 Note: The intermediate tank DT2 does not apply upon employment of: . 6. It has to be ensured. Diesel oil feed pump DP1. it will always be filled to the overflow level. 5. 4.heated day tank DT1. ensure that the temperature switch is set to a min. open the vent valve several times for a short time by hand.00 The day tank is designed to collect the treated fuel for a minimum of 4 h load operation. a condensation trap should be installed at the steam outlet to ensure sufficient heating as possible.heated day tank DT1. The preheater is to lower the fuel viscosity to a level that is optimal for injection. The intermediate tank is equipped with a level monitoring device. that the relief valves of the pumps are closed during operation.

01.07.12.Operational supervision Fuel system M25/M32 A3.05). 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. en / 12. 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 A1.05.06.00 The fine filter protects the fuel injection system and removes solids not previously separated.03.1997 BA021416 4/4 .nn. 9. For service and maintenance instructions see A5.

05.04. At the earliest. A differe nt procedure may lead to sticking (scuffing) of the injection pump plungers. to empty heavy fuel filled system more rapidly. Changing over from distillate fuel to heavy fuel Prepare the system according to A3.01 Changing the type of fuel 1. 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.07. The change-over has to be exclusively made by the three-way selector cock for heavy fuel/distillate fuel. before the mixing tank.06. 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.07.06.Operational supervision Changing the type of fuel M20-M601C A3. en / 27.1996 BA000074 1/1 . Changing over from heavy fuel to distillate fuel while the engine is running see diagram in A3. 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.nn. Note: A change-over of the flow towards the heavy fuel day tank (emergency) and flushing with distillate fuel.07. 2. the circulating pump/final preheater should be switched off 1 h after change-over. If the engine is to continue with distillate fuel operation.

temperature For Pressure-.1997 BA000078 1/1 .10. Temperature indications see A1.12.06 and also Acceptance Test Records page A1. . en / 16.05 and A1.06.00 Lubricating oil system • Check daily the levels in the: • Lube oil sump tank Base frame Oil sump Monitor the lubricating oil pressure.Operational supervision Lubricating oil system M20-M601C A3.08.

If for any reason whatsoever temperatures are too high.10.10.05. lower them gradually to the normal values. it will create thermal stresses and possible damage.nn en / 17.2007 BA000082 1/1 . see A1.Operational supervision Cooling water system M20-M601C A3.00 Cooling water system • • Check the level in the fresh-water expansion tank.06 as well as Acceptance Test Records A1.05 of the operation media. For specifications and care of the engine cooling water see Operating Media A4. Attention: If the cooling is too rapid.09.06.09. for Temperatures of the Operating Media A1. Check the water pressure. For pressure-temperature indications. temperatures and temperature rise.

outlet temperature of 90 °C. 1. *These values do not take into account the static pressure of the gravity tank.3 bar 2.Operational supervision Adjustment Instructions M20/M25/M32/M43 A3.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. If the cooling water pressure drops by another 0.2008 BA021432 1/4 . 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. Example: Static pressure at engine control stand is (both electric pumps switched off) 1 bar This results in a minimum operating pressure of 3. This static pressure is to be added to the operating pressure.06. If the pressure in the cooling water system continues to drop down to 1.5 bar at the engine in order to safely dissipate from the engine the amount of heat generated under full load operation.1 bar 1. 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 2.9 bar.01 Adjustment Instructions for Cooling Water Pressure (Start of Standby Pump. a standby pump will be started. The following values are to be adjusted and checked: en / 10.09.2 bar below the minimum cooling water pressure.04. an emergency stop will be triggered. Example . and Emergency Stop) There must be a minimum cooling water pressure of 2.9 bar If the cooling water pressure in the cooling water system is 0. an alarm will be triggered.5 bar 2.5 bar.2 bar. In the following examples static pressure is also considered. The pressure indicator for HT freshwater on the engine control stand displays the static pressure for HT freshwater. If these temperature values are not reached. 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. Alarm.

This static pressure is to be added to the operating pressure. the electric standby pump and the engine are switched off. outlet temperature of 90 °C.Operational supervision Adjustment Instructions M20/M25/M32/M43 A3.3 bar 3. 4. Under full load operation the cooling water will be heated up by 7 to 10 K to a max. 2.09.06. Example .9 bar For sensor equipment adjustment and test instructions please refer to the manual.5 bar 3.01 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 3.3 bar 3. The pressure indicator for HT freshwater on the engine control stand displays an operating pressure of min.1 bar 2.5 bar .5 bar. 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 3.2008 BA021432 2/4 . en / 10. The pressure indicator for HT freshwater on the engine control stand displays the static pressure. Example: Static pressure at engine control stand is (electric standby pump switched off) 2 bar This results in an operating pressure of 4.Controllable pitch propeller plant and generator plants with attached and electric cooling water pump The HT freshwater pressure tank is full of cooling water.5 bar 3.04. At nominal speed the attached cooling water pump must generate an operating differential pressure of 2.9 bar Adjustment at nominal speed: The engine is running at nominal speed and the electric standby pump is switched off.1 bar 2.5 bar at nominal speed.

5 bar This results in an operating pressure of 3 bar at nominal speed.04. Cooling water temperature monitoring must not be disabled. For sensor equipment adjustment and test instructions please refer to the manual. 3. Below 70 % nominal speed the complete cooling water pressure monitoring system is to be switched off. outlet temperature of 90 °C.Alarm 2106 2. 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.Operational supervision Adjustment Instructions M20/M25/M32/M43 A3.09.6 bar 1. At 70 % nominal speed the attached cooling water pump must generate an operating differential pressure of 1. (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.4 bar 0.5 bar.0 bar 1.01 Adjustment at 70 % nominal speed The engine is running at 70 % nominal speed and the electric standby pump is switched off. Under full load operation the cooling water will be heated up by 7 to 10 K to a max. 3. The pressure indicator for HT freshwater on the engine control stand displays the static pressure. This static pressure is to be added to the operating pressure. the electric standby pump and the engine are switched off.Fixed pitch propeller plant with attached and electric standby pump The HT freshwater pressure tank is full of cooling water.2008 BA021432 3/4 . Example .8 bar en / 10. speed below 70 % .8 bar 1. The pressure indicator for HT freshwater on the engine control stand displays an operating pressure of min.5 bar. Example: Static pressure at engine control stand is (electric standby pump switched off) 0.06.

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

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.02.nn).06. en / 24.01.nn and/ or A3.01.09. Exact instructions for the use.nn. it will be necessary to protect the system by the use of an antifreeze solution with protection against corrosion (see A4.Danger of frost Antifreeze protection M20-M601C A3. For a lengthy down-time period with a danger of frost the engine is to be preserved.1996 BA000110 1/1 . see A3. during times when the temperature can fall under freezing point.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).08.05. can generally be mixed with commercial antifreeze. the chemical corrosion inhibitors used in the coolant water.09. must be enquired from the manufacturer of the anti-corrosive agent.09.

01. 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.09.12. It is also suitable for a possibly necessary road transport within Central Europe.Preservation Engine M20-M601C A3.09.00. A long term preservation (A3. 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 / 16.02. if the engine is shut down for longer than 2 months.1997 BA000114 1/2 . but not longer than 1 year and stored within national or Central European areas.nn) is to be carried out.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.09.00 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. 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.

nn and/or A3. Secure tarpaulin/foil against mechanical damages.03.nn and A4.05. If there is a danger of frost.09. Remove already existing corrosion and renew preservation.nn.02. Ensure sufficient ventilation below the covering.09. 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.08. In Central Europe.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. sufficient protection must be provided.1997 BA000114 2/2 . Depreservation: The measures for depreservation (A3.09.nn) are to be carried out and the engine and the fittings/tools are to be checked below the tarpaulin every 2 weeks. check tarpaulin and preservation regulary every 4 weeks.09. the measures of a long term preservation (A3.02.09. In case of bad climate conditions.Preservation Engine M20-M601C A3.12. see A3. 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. Found damages are to be immediately corrected.00.00 Package/Storage: The measures for storage and package depend on period of storage and storage location.01.

01.2 1.01. Mix destilled fuel and corrosion inhibiting oil in a ratio of 1 : 1.nn.00 Light preservation (short term preservation) 1. 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. switch over to destilled fuel.nn.05. Aral Konit SAE 30) a viscous.20 min.g. cleaning and auxiliary means 1. The required quantity of fuel “B” (liters) for 15 . see 1.06.09.g. sticking and drying preservative (e.6 spray gun. Note: If the engine is seperated from the plant. brush preserving oil that can be sprayed and does not dry (e. Valvoline Tectyl 506) corrosion-inhibiting oil (e. preservation. ensuring that the fuel system (piping and equipment) remain full. see A5. see A3.1 Fuel system • • • In case of heavy fuel driven engine.Preservation Short term preservation M20-M601C A3.1996 BA000118 1/3 .5 1. Clean fuel duplex filter. Monitor the level in the day tank and stop the engine. Operate warmed up with the fuel/corrosion inhibiting oil at 75 % of the nominal revolution speed at a low load.07.1 1. Preservation measures engine The preservation measures for the individual engine components are to be carried out according to the following sequence of operations. injection pipe. 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.06. Required tools.4 1.3 1. Then firmly seal the connection points with plastic plugs! en / 24.g. 2.g.07. Rust Ban 310) ethylene glycol inhibitor (e. run the engine until the fuel system is empty.4. safety and sanitation instructions of the manufacturer! 2.

01.nn). see 1.02. 2. charge air manifold • • Spray the parts with preserving oil (see 1.nn. Open the charge air manifold and spray the interior with preservation oil (see 1.00 2. Note: If the engine is separated from the plant.2).04. Fit and tighten the rocker gear cover. cam shaft.08.2) and make sure that all areas of the crankshaft. 2.5 Upper valve rockers • • • • Slacken and remove rocker gear cover.5. • Engines with caged exhaust valves: fill the water spaces of the cages with glycol if there is a danger of frost. see A5. 2.01. until clean oil drips out of the last small end bearing. roller tappets for valves.2 Lubricating oil system • Cleaning the lubricating oil duplex filters.05. Note: The cooling water tracts are protected by the corrosion inhibiter in the cooling water.05.06. injection pumps.2) and reclose. The lubricating oil remains in the circuit if the values required for engine operation are in order (see A4. cam shaft. Spray the parts fitted in the cylinder heads with preservation oil (see 1.1996 BA000118 2/3 . Clean the seating of the rocker gear cover.09. running gear. en / 24.05.08.Preservation Short term preservation M20-M601C A3. Then firmly seal each connection with blind flange or stop plug.09. see A4.4 Crancase. Recommendation: • Pump fresh lubricating oil through the engine circuit. connecting rods and gears are coated. remove lubricating oil.3 Cooling water system • Cool the engine down to 30 °C and drain the cooling water.

6 External preservation • Clean or wash all unpainted bright parts of the engine.Preservation Short term preservation M20-M601C A3. safety and sanitation instructions of the manufacturer! • Dry the cleaned parts and coat them with a drying preservative (see 1.3).09. Preservation measures fittings and tools Preservation measures for 6 and 12 months see heavy preservation. 3. Attention: The engine finish may not be etched by cleaning and/or washing agent! Use only suitable washing agents! Keep to the operation. en / 24.1996 BA000118 3/3 .00 2.06.01.

g.02.3 1. rotate to the engine in nominal direction of rotation to TDC and spray the inlet valves as well with preservation oil (see 1. Spray preserving oil (see 1.09.g. Required tools. Then.4 1. Turn the piston of one cylinder in the normal direction of rotation to BDC with opened exhaust valve.1 Combustion chambers and cylinder liners • • • • • • Open indicator valves.nn.g.g.6 1. preservation. Close the indicator valves.1 1.2000 BA000122 1/3 . brush.10.nn) slovent-free cleaning and/or washing agent plastic plugs (e.2) through the indicator passage into the combustion chamber by means of spray gun and injection pipe.8 spray gun.2 1. Valvoline Tectyl 506) non-drying corrosion-inhibiting grease (e. Hydrol DO 46) clean turbine or hydraulic oil (A4.Preservation Long term preservation M20-M601C A3. following work is to be carried out beside the measures stated under A3. sticking and drying preservative (e. cloth preserving oil that can be sprayed and does not dry (e. 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. cleaning and auxiliary means 1. 2.08. Repeat this operation for the other cylinders.05. Aral Konit SAE 30) a viscous.09. en / 30. injection pipe.5 1. safety and sanitation instructions of the manufacturer! 2.2).01.g. Shell ALVANIA 3) governor oil (e.7 1. Preservation measures engine In case shut down of the engine for longer than 2 months.00 Heavy preservation (long term preservation) 1.

2.00 2. In case the engine is taken out of the plant: .10. Preservation oil must emerge at the control apertures.2) through the distributor lines.Preservation Long term preservation M20-M601C A3.6). level with clean turbine or hydraulic oil (see 1. carry out further preservation measures according to instructions of manufacturer. drain plug and flange. .5).2) and refit banjo plug. with a batten wall). Spray preservation oil (see 1.09. Fill governor according to manufacturer document (book C) up to the rim with governor oil (see 1.2000 BA000122 2/3 . . Refit the banjo plugs. en / 30. 2.3 Mechanic-hydraulic governor • • • Change the oil in case of due interval. 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. open the starting valves several times by means of a drift inserted through the air control bores. Spray in preservation oil (see 1. While spraying. Note: • Keep to the instructions of the manufacturer.wrap air filter with PET-foil and lute air-tight. if necessary. see book C.seal exhaust flange with cover and seal.4) to the gear wheel behind the governor dial.02.2 Starting system and starting air distributor • • • • • • • Remove the sealing flange from the starting air distributor.protect foil against shocks (if necessary.4 Turbocharger • Change oil and fill turbocharger up to max. Apply non-drying preservating grease (see 1. Slacken and take out banjo plug of the starting air distributor.

grooves and similar parts with self-adhesive aluminium foil. Make sure.8). cover threads.3). apply a second coat of drying preservative for securing a sufficient thickness. Attention: The engine finish may not be etched by cleaning and/or washing agent! Use only suitable washing agents! Keep to the operation. all not immersed fittings are to be welded. safety and sanitation instructions of the manufacturer! • • Dry the cleaned parts and coat them with a drying preservative (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. If necessary. Then seal small parts immersed with thermoplastic. en / 30. 3.3) at the bright parts and packed in oil paper! Store fittings and tools in wooden box lined with bituminous felt. Clean or wash all unpainted bright parts of the engine.5 External preservation • • Close the crancase ventilation with protective plug so that it is air tight (see 1. Seal opening of the box with plastic foil prior to putting on the cover. all part are secured within the box.00 2. bores.02.09. • • 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).2000 BA000122 3/3 .10.Preservation Long term preservation M20-M601C A3. When this has dried.

02.05.08.Preservation Depreservation M20-M601C A3. see A4. refill with the specified grade.3 Lubricating oil system • • No depreservation measures are required.1997 BA000416 1/2 .09. • 2.05. en / 15.2 Clean turbine or hydraulic oil (A4. Reconnect the engine to the plant if it has been necessary to seperate it. even if the piping is still filled with the mixture used for the preservation run.2 Fuel system • • Depreservation is not required. blanking flanges or other sealant parts and any locking devices.1 General work • Establish the condition the engine was in before the preservation and disassembly measures were taken: remove the protective plugs.12.4 Cooling water system • • Check the condition of the cooling water system and flush with fresh water if necessary.1 1. Required cleaning and auxiliary means 1. the entire system must be flushed with an alkaline solution. 2.03. Restart the engine with this possibly in the system remaining mixture. 2.09.00 Depreservation 1.08.nn. If chemical corrosion inhibitors are to be used and corrosion inhibiting oil has been previously used. 2. safety and sanitation instructions of the manufacturer! 2. covers.05. see A4. If the lubricating oil was drained.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. Depreservation measures The following measures are to be implemented after a light or heavy preservation.

2. 2. bright engine parts.Preservation Depreservation M20-M601C A3.12. Attention: The engine finish may not be etched by the cleaning and/or washing agent! Use only correspondingly suitable washing agents! Keep to operation.09.00 2.6 Turbocharger (with independent lubrication) • • • If necessary. Drain protective oil.5 Governor (mechanical-hydraulic regulator) • • Re-establish the correct oil level in the governor. Dial governors: remove any excess preserving grease from the gear wheels behind the governor dial. wash. safety and sanitation instructions of the manufacturer! en / 15.1997 BA000416 2/2 . if necessary. clean the preserved parts according to instructions of the manufacturer. Assemble new bearings and fill up oil.03.7 External depreservation • Remove corrosion inhibiting coating completely from all coated.

10.Running-in Engine - A3.02.00 Running-in en / 16.2001 BA000242 1/1 .

nn) and cylinder liners (A5.10 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.2001 BA000126 1/1 . No running-in instructions need to be followed when repairs have been carried out on the main and big end bearings.18. thus no further running in instructions are required.nn). such as reconditioning work on pistons (A5.01.02.02.01.01.nn).10. as is pointed out on the job card in question. While increasing the power. piston rings (A5.Running-in Engine M20-M601C A3.04. M 601. M 32. en / 26.05.nn). M 601 C M 43 6h 8h 8 .05.10. the following instructions must be observed: • When the engine has been preheated.03. start at 20 % rated power and then go to full power within the time provided for each type of engine: M 20. the fuel should be of the distillate variety because of the higher production of combustion residues at part load (A3. In the case of certain repairs however.06.05.00 Running-in All engines leaving our works have been fully run in. M 453 C M 552 C.10 to assess the engine working conditions.07. M 332 C M 25. compare the pressures and temperatures with the figures on the exceptance test records A1.03. M 282.02.

11.2008 BA000130 1/1 .00 Fault Tracing en / 20.02.Fault Tracing Engine - A3.

18.Fault tracing Introduction M20-M601C A3. This is especially so if an alarm or safety device is concerned.06. They have to be repaired as soon as possible. if such a degree of automation has been provided.nn and/or A3. Any essential fault deviations will be signalled by the alarm and safety system. depending on the foreseeable date of reconditioning.01.09. en / 24. In the event of trouble in the remote control or certain components such as governor. it has to be preserved as in section A3.00 Fault tracing In the event of any irregularity in the machinery the characteristic of the trouble should be ascertained. run the engine with particular care. turbocharger etc. whose cause is not obvious or whose influence on operation seems to be less important for the present. Attention: In case of discernible faults stop the motor timely to avoid the risk of greater damages. the fault traced and the cause found. must never be ignored.1996 BA000134 1/1 . If a defective engine cannot be quickly repaired. will be the determining factor as to whether the power or speed have to be reduced for the duration it lasts. Remedial actions must be initiated immediately. Minor troubles.02.11.09.. see the respective sections in book C. The nature of the trouble.nn. that cannot be repaired immediately. If there is a failure in the measuring instruments or monitors.

When an alarm is triggered. Note: Besides carrying out a normal functional check of the oil mist detector the measuring chamber should be examined for traces of water. Check of the oil mist detector: Check the oil mist detector for correct function according to the documentation of the manufacturer (siehe C5. If.11.01 Introduction: The crankcase monitoring device (oil mist detector) monitors the oil mist concentration in the crankcase. During engine operation there is always a slight oil mist concentration. In case of doubt stop the engine immediately by hand. in case of a further increase in concentration. wait 10 to 15 minutes before opening the crankcase doors in order to prevent a possible explosion by air supply from outside.01. 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. Water vapour may trigger a false alarm. piston seizure or blowby from the combustion chamber being the most frequent causes.Fault tracing Oil mist detector M25-M601C A3. Attention: With increased oil mist concentration there is a risk of crankcase explosion. This may lead to severe personal injuries and engine damages.2006 BA021345 1/3 .02. timing gear train damages. nn). contact the Caterpillar/ MaK-Customer Service! Checks after an engine stop due to oil mist alarm: 1.05. the measuring chamber and the sensors must be cleaned. fixed value first an alarm and then. If necessary. however.11.02. en / 21. the actual oil mist concentration exceeds a preset.18. an automatic engine stop will be triggered! An increased oil mist concentration in the crankcase may be indicative of operational disturbances. If there should be any traces of water.03. the cause of it must be identified as quickly as possible. with bearing damages.

Fault tracing Oil mist detector M25-M601C A3. 4. liners. Inspection of the combustion chamber: • Admit compressed air to each cylinder via opened indicator valves.) for discoloration and traces of seizing. piston skirts. the cause of this must be identified. traces of seizing. Check the main running gear for ease of movement by turning the crankshaft. en / 21. Check the lubrication oil filters for metallic material. and chips.01. Check of the main running gear: • • • • • • Remove all crankcase doors. and chips. Visually inspect the main running gear (bearings. etc. If the pressure drops very quickly or no pressure builds up.02.11. Check the oil pan for chips. Measure the temperatures of all camshaft bearings.18.01 Extended checks: 2. Visually inspect the drives of all attached pumps. Visually inspect the timing gear train for discoloration. 3. Check of the timing gear train: • • • Remove all inspection doors from both sides. 5. pay particular attention to major differences.2006 BA021345 2/3 . Visually inspect camshaft. wear (seizing). Inspection of the camshaft casing: • • • Remove all camshaft casing covers. cam followers and rollers of all valve and injection pump drives for discoloration. Measure all bearing temperatures.

The engine must not be restarted until the disturbance or damage has been eliminated. fuel or water. en / 21. check the indicator valves for emerging oil. The engine may then only be started with fully functional oil mist detector. they cannot cover the full range of all possible causes.Fault tracing Oil mist detector M25-M601C A3. 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. However. Check the turbine shaft for ease of movement.01 6.11. Check of the turbocharger: Note: An incipient turbine bearing damage will also be indicated via the oil mist detector.18.01. • • • Remove intake air filter. If an emergency stop should occur again after a short time. Attention: Only after having completed all the above checks and if no failure causes have been identified the engine may be restarted.02. the root cause must absolutely be found out. Check the operating parameters. 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.2006 BA021345 3/3 .

18.nn Repair or replace pump.07.nn • Clean filters.05.07. 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.12.01. see A3.18.02 Engine starts poorly or does not start at all Possible cause: Remedy: See A1. see A3.11.13.01.07.nn ____________________________________________________________________________________ en / 10.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. see A5.05.2007 BA000727 1/4 .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.Fault tracing Remedial measures M20-M601C A3.05. see A5.12.

see A5.12.01.05. A5.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.13.08.11.06. nozzle needle is seized Repair or replace pump.07.03.12.02 Filter differential pressure is too high during starting/pre-lubrication Possible cause: Remedy: Fuel filter is dirty Clean filter.12.Fault tracing Remedial measures M20-M601C A3.01.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 / 10.18.07.nn For servicing the injection pump.05.07.01. see A5.2007 BA000727 2/4 .05.07.05.01.01. see A5.04.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 A5.02.07.05.nn Clean filter.05.nn. see A5.

07.05.01.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 • Poor combustion due to very low load.08.Fault tracing Remedial measures M20-M601C A3.12. A5.nn For increasing the load or change over to gas oil operation see A3.2007 BA000727 3/4 . 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. 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.01.06. especially at heavy fuel operation ____________________________________________________________________________________ en / 10.18. 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 .02 Engine speed is not steady Possible cause: Remedy: • • • • • • • see manufacturer’s instructions in book C.

12.05.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.nn „Charge air cooler“ For replacement of cooled valve seat inserts see A5. ovality • For checking the valve guide clearance see A5.07.01.01.18.Fault tracing Remedial measures M20-M601C A3.03.05.03.nn For checking the cylinder liners see A5.05.08.18.nn • Cylinder head is cracked ____________________________________________________________________________________ en / 10.nn Severe wear and tear of cylinder liner: scoring.01. A5.11.nn see A3.01.06.05.02.02 Exhaust gases are blue Possible cause: Oil in the combustion chamber Remedy: • • Piston rings are sticking For servicing the pistons and rings see.03.05.01.2007 BA000727 4/4 .06.05.

02.12.2008 BA000142 1/1 .Emergency Operation Engine - A3.00 Emergency Operation en / 20.

en / 26.01 Emergency operation of the generator engine Plant service permitting.1997 BA000737 1/1 . = abt. the set with a defective turbocharger should be shut down and separated from the mains. • Interrupt the oil supply to the turbocharger.disassemble the rotor. 25 %. so that the motor can operate with a Pme ≤ 4. If an engine shut-down is not possible. especially if exhaustgas alarms have been cut out. 500 °C Carefully monitor the exhaust gas temperatures during emergency operation. which would endanger the engine. 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.11. Note: The cooling water supply is to be interrupted only in case there is a considerable leakage at the turbine housing on gas side. we recommend the change to distillate fuel in emergency operation.unscrew the connection of the pipe at the engine and close the connector with a plug an union nut.01. If the installation is for heavy fuel.Close the air outlet casing of the turbocharger taken out of service with a blanking cover. Finishing with emergency operation After an emergency operation with heavy fuel. ^ Note: If blocking is not possible: .Plug and fasten the free end of the pipe. disconnect all consumption as far as is possible.Emergency operation With a defective turbocharger M25/M32 A3. If there are two turbochargers feeding into one charge air manifold: . .12. for this: . at least one cylinder head must be removed for reasons of safety and to ascertain whether a general overhaul of the valves is necessary. . see manufacturer´s instructions book C.5 bar at nominal power • • • Stop the engine Remove the air filter silencer Shut down the turbocharger (block the rotor.obturate the exhaust gas side against bearing housing and air side by means of a blind flange. Note: • Start the engine and reduce the output. Special tools are not included in the scope of supply).

09. and touch the coupling with your hand to check it for heating. Notes will be given to this effect on the engine control console or in the torsional vibration calculation. en / 24.02. If misfiring operation cannot be avoided. For results of this calculation.00 Operational misfire . this will always increase the stresses in the flexible coupling.06. Attention: If one cylinder fails partially or completely. 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. it may be necessary to limit the power output of the whole plant in conformity with its type. The additional loads will be the heavier.12. If the gear becomes noisy and/or the speed hunts. vary the speed until the operation is acceptable.protection of the flexible coupling The following instructions and restrictions refer only to engines with flexible couplings. A cylinder head. No changes reducing the output to any one cylinder on the engine should therefore be made. compression should remain. valve or piston and connecting rod should only be removed if unavoidable. if one cylinder completely misfires. If you have any doubt.1996 BA000154 1/2 . the smaller that the output of a defective cylinder is. see A1. Stop the engine not later than 30 min.Emergency operation Operational misfire M20-M601C A3. For this reason.

Emergency operation Operational misfire M20-M601C A3. If this is impossible.1996 BA000154 2/2 .06. If heating is only moderate. The defect should be repaired immediately. en / 24. 60 °C.12. the flexible coupling should be checked for damage by a specialist of the maker. Defective engines of generating sets should also be shut down. Before returning to normal operation again. Twin engine installations: Shut the defective engine down and run the plant with the other engine alone. which should not be exceeded for thermal reasons. 80 % of the rated power. occasionally check the flexible coupling visually and its temperature.00 The permissible surface temperature in misfiring operation is approx. the power output can be increased in steps up to max.02. the emergency operating mode can be started analoguously with single-engine installations with fixed CP propeller. • • At this speed stage.

however. we differentiate between the following extreme conditions. • • • • Required output and speed restrictions are indicated in the torsional vibration calculation (A1. Even if there are not restrictions regarding the position of the torsional vibration. It has to be avoided that with permanently existing engine load variations a „surging“ of the turbocharger occurs in any operating point. „operational misfire“ means that the engine is operated with non-uniformly loaded cylinders. 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.e. Misfire Misfire means engine operation with interrupted injection at any cylinder.01 Operational misfire In general.02. Connect the drain pipe to the indicator valve with the means available on board so that there is no risk of accident.12. en / 26. 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. it is recommended to check a flexible coupling for excessive heating. is applied.2006 BA000753 1/2 .10. depending on the severity of the troubles: 1.09). The compression pressure of the troubled cylinder. cannot be repaired by means of onboard tools. i.Emergency operation Operational misfire M20/M25/M32/M43 A3. troubles detected at individual cylinders should be remedied immediately! In case the operational misfire cannot be avoided. In case of an excessive vibration of the control rack you should relocate the operating point in order to reduce the vibrations. This will prevent the oil taken in during longer emergency operation through piston clearance / ring package from lifting the cylinder head.

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. depend on the system in question and have to be made out by touching while speed and output are slowly increased. 35 % of the rated output.12. The engine output possible under these conditions is approx. the anchor bolts of the fixing device of a flexible bearing support are to be checked permanently for tight fit.10.10). and the actual values must not fall below the limit values: • • • • • • The engine speed must not exceed 80% of the rated speed (A1. In case of doubt please contact Caterpillar / MaK .12.02.01 2. The possible outputs and speeds at which a damaged engine can be operated. This limit value applies to engines arranged rigidly as well as flexible.Emergency operation Operational misfire M20/M25/M32/M43 A3. The following limit values have to be strictly observed.02. „Surging“ of the turbocharger has to be avoided. During emergency operation.05.nn. en / 26. the engine has to be fixed in accordance with the instructions A5. 2.00.1 Twin engine systems / generator systems The damaged engine should not be restarted. The exhaust gas temperatures upstream turbocharger must not exceed the temperatures indicated in A1.2006 BA000753 2/2 .10. Total misfire In case the engine is supported by flexible bearings and a running gear has to be dismounted completely.

2008 AA020105 1/1 .04.Operating Media - A4 Operating Media en / 24.

05.09.Table of Contents - A4.07.01 A4.04 en / 24.05.05.03 A4.02 A4.05.05.07.08.2008 AA020032 1/1 .09.05.05.05.04.01 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 A4.02 A4.03 A4.09.00 A4.07.00 A4.06 A4.05.05.01 A4.05.07.09.05 A4.07.05.09.00 A4.00 A4.04 A4.02 A4.07.03.05.01 A4.

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

g rease • fu el (d istillate.Safety instructions M20-M601C A4. birth defects.1996 AA000347 1/1 . en / 13. antifreeze • d et erg ent/solven t • coo lan t ( CO 2 .02. h eavy oil) • wat er with ant icorro sive. hyd rau lic flu id . and other reproductive harm.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. 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.

2008 BA000158 1/1 .Regulations and Recommendations Engine - A4.05.00 Regulations and Recommendations en / 20.02.

07. these are: • Destillate fuel • Heavy oil en / 28.Regulations and care Engine fuel M20-M601C A4.06.1996 BA000162 1/1 .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.05.

g IF 700 with in case using the maximum limit values) RM = Residual Marine Quality classification Max.07. Depending on whether it is the highest available viscosity or a mixture with distillates to obtain the required viscosity. viscosity at 50 °C (mm2/s) (see A4. Minor quantities of additives to improve special fuel properties are permitted. ISO-Specification (ISO 8217) The ISO-Specification for Marine Fuels was issued in April 1987. A classification according to quality characteristics and viscosities was introduced.02 Heavy fuels (Viscosity in mm2/s (cSt) at 100 °C for CIMAC. General Requirements: The fuel must represent a homogenous mixture of hydro-carbon coming from the mineral oil processing. e. at 50 °C for ISO) All fuels are called heavy fuels that consits in the main of residual oils from oil refining. A revised edition was published in 2005. alcali) if not explicitely noted in the specification.01. en / 18.05. The fuel must not contain other substances (e. g.05). especially for heavy fuel oils.07.2008 BA000170 1/5 . 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. mineral acids. 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. e.05. g. and because of their activities new designations will be introduced to describe fuel properties. The classes difer from ISO-F-RM1) A2) 303) up to ISO-F-RM K 700 1) 2) 3) (before. IF 30 with satisfactory data) (before.Regulations and care Heavy fuels M20-M601C A4.

CIMAC to 100 °C The CIMAC-Specification does not fully agree with the ISO-Specifications. In accordance with ISO.01. which are decisive for a reliable engine operation. e. 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.Regulations and care Heavy fuels M20-M601C A4.07.05). g.05. identical character/figure combinations are used for the identification of quality.D15 classes. en / 18. the CIMAC Working Group “Future Fuels” has divided the fuels according to their physical and chemical data. The CIMAC-specification is the basis for the Caterpillar / MaK heavy fuel specification (A4. Since then the contents of BS MA 100 conforms with ISO 8217.2008 BA000170 2/5 . The most important differences are as follows: – – CIMAC provides fewer density limits for the A10 . BSI-Specification The BS MA 100 which came into force in 1982 was with drawn in September 1989.02 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. CIMAC-A10 corresponds to ISO-F-RMA 30.07. Introduction of minimum viscosity with CIMAC.05. ISO refers Viscosity to 50 °C.

01). according to the valid CCAI limit curves (A4.07. depending on its viscosity.05.03. not be excluded. 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” (A4.00 or A4. 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. The diagrams permit the determination of the permissible and/or maximum acceptable density of a fuel in a simple manner.07.05 shows the conversion to 50 °C. Furthermore. 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.01. Since the CCAI is no measurement for the ignition behaviour.05.07. but rather an assessment aid.05.00 an A4.85) – 81 In principle. however.07. (CCI = calculated Carbon aromaticity index). the following applies: the higher the CCI. Impairments and even damage to the engine can be expected.03.2008 BA000170 3/5 . In so doing. the poorer the expected ignition behaviour.04). I sec.07. A4. en / 18.05. the type of engine and the condition of the fittings and included in A4.03. you should ensure that restrictions with regard to the permissible densities are possible. absolute limit values cannot be specified. 80 °C and Redw.07.01. the following applies: When taking a specific CCAI value as a basis. 100 °C is to be the reference temperature for indicating the viscosity of a heavy fuel. Problematic fuels can.07. Range which should be avoided.Regulations and care Heavy fuels M20-M601C A4.02 The so-called CCAI is a useful indicator when assessing the ignition behaviour. Ignition characteristics are predominantly acceptable.05. The three sub-ranges which develop in this manner mean the following: Unrestricted permissible range. there is more risk of a poorer ignition behaviour if the viscosity is low.03.05. Impairments by insufficient ignition characteristics are not expected.

and this must be taken into account when fuelling in the Caribbean area. if the engine has no cylinder lubrication. en / 18.Regulations and care Heavy fuels M20-M601C A4. Analyses can be carried out by Caterpillar / MaK against payment of costs incurred or by the fuel supplier.05.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. The sodium and water content should be kept as low as possible after the separator (water less than 0.00). In any case a sample of the heavy fuel should be taken while bunkering. 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. Mixing of fuel components to obtain the desired viscosity should be done in suitable mixing appliances before bunkering. It is therefore preferable to bunker ready mixed fuels. Fuels to CIMAC-A10 are to be used in such cases.08. Caterpillar / MaK should be contacted if necessary. If it is intended to take such fuels for a lengthy period of time and the owners have no experience with this. A high vanadium content accelerates corrosion on the exhaust valves and turbines.2008 BA000170 4/5 .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. specially at high content of Vanadium to stop excessive high temperature corrosion. the exhaust valve seat rings have no cooling or the pistons are of the monobloc aluminium type. we recommend to contact Caterpillar / MaK first. There may be restrictions. Heavy fuel operation makes necessary the use of a medium alkaline lubricating oil in accordance with our recommendation of lubricating oil brands (A4. The flash point of the heavy fuel must be above 60 °C in accordance with the requirements of the classification societies. for instance. 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. 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.2 % weight). So preference should be given to heavy fuel with a low ash content. If there are mixing facilities on board ship the compatibility of the components must be assured by the supplier.01. The ash content determines the mechanical wear. visbreaking) with which mixing presents more of a problem than with the established heavy fuels.07.05.

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).2008 BA000170 5/5 .05. it must at least be ensured that they are not sensitive to water. in the fuel filters. compatible with the fuel in any case and no cause of troubles. Proven additives can be obtained from most oil or additive suppliers. classified here according to their main effects. Should they be used. en / 18.02 Fuel additives Two types of fuel additives. however.01. 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. are used in various cases as required: a) Demulsifying additives (emulsion breakers) These additives.Regulations and care Heavy fuels M20-M601C A4. for instance. put in during bunkering. Caterpillar / MaK does not require additives against high-temperature corrosion.07.

01 CCAI-limit curves Density (kg/l 15 °C) to be avoided * limited approved * permissible Viscosity (cSt 50 °C) en / 28.Regulations and care CCAI-limit curves M20-M601C A4.03.07.05.05.1998 BA000178 1/1 .

07.Regulations and care Limit specification M20/M25/M32/M43 A4.05.05.1999 BA000424 1/1 .07.nn)! en / 27.04 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 (A4.07.03.

Limit Density at 15 °C Dichte kg/m3 max Kin.5 300 80 15 15 30 0.10 0.5 600 80 15 15 30 der Kraftstoff soll frei von gebrauchtem Schmieröl sein (ulo) Eine ungefähre Zuordnung der kin.15 7) 0.15 7) 14 14 15 20 18 22 22 0.10 0. max. Viskositäten bei 50 °C sowie in Redw.10 0. A4.10 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.10 0.5 4. I sec.05 1/1 . I sec.5 4.5 0.5 4. 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. 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 : 0.20 Related to ISO8217 (05):F– Characteristic Dim.0 4.5 150 80 15 15 30 15 15 30 80 80 15 15 30 300 350 200 500 4.10 0.5 3.05. 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. viscosity at 100 °C Kin.10 0.15 0.10 0.11.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. I sec.07. Visk.15 7) 22 0. max.15 0. Fuel shall be free of used lubricating oil (ulo) 1) An indication of the approximate equivalents in kinematic viscosity at 50 °C and Redw.5 0.2006 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) 0.5 600 0.10 0.5 600 80 15 15 30 0.

1996 BA000190 1/1 .06 en / 28.05.07.06.Regulations and care Viscosity temperature sheet M20-M601C A4.

a special oiltype should be used after consultation with MaK.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. 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. 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 fuel with a very low sulphur content liner lacquering may appear. High demands must therefore be placed on the lubricants to be used in respect of suitability.2008 BA020067 1/8 .00 1. The oil to be used should be selected according to the specifications of the fuel which is used to run the engine. This is usually given as the Base Number (BN).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: 1.05. or as Alkalinity Value (AV) and recorded in mgKOH/g.08. If there is a high luboil consumption also indicated.02. 1. For Caterpillar/MaK engines operating on heavy fuel this value should be between 30 and 40 mg KOH/g for fresh oils.2. 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. 1.2 en / 29.1 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.2. 1. Regenerated oils are not permitted.Regulations and care Lubricating Oil M20-M601C A4. On engines which are equipped with special cylinder lubrication the same oil should be used in the circulation system and for the cylinder lubrication. Have an adequate alkalinity in order to be able to neutralize the sulfur acid compositions which occur during the combustion process.

08.2 Lubricating oil filtering (full flow) In order to combat the higher amount of contamination in the lubricating oil when operating on heavy fuel.1 List of brands of lubricating oil for Operation with distillate fuel The viscosity class SAE 40 is specified for all Caterpillar/MaK engines. Caterpillar/MaK has no experience with oils not mentioned here. the firm’s name is part of the brand designation of the lubricating oil and should. oil centrifuges and by-pass filters.4.00 1.05.3. 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.4 Lubricating oil brand recommendations – Limitation of warranty In most cases. Exception: automatic filters 1.nn One stipulation for good separation of the lubricating oil is a low viscosity which requires a correspondingly high temperature. Mechanical filters suitable for filtering blended oils may be used only.Regulations and care Lubricating Oil M20-M601C A4. 1.nn) For gas oil or MDO operation. when ordering.02.2008 BA020067 2/8 . Furthermore no guarantee can be given for poor quality engine and lubricating oil care nor for the use of non-approved fuels. 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 A3.04. When separating the temperature should be between 90 and 95 °C. be placed in front of the designation to avoid confusion. en / 29. 1. For gas oil or MDO operating by-pass filters can be used instead of separators. Proof that a defect has not been brought about by the lubricating oil must be provided by the user. (See the details in the Instructions for Heavy-Fuel Operation A3. Chemically active filters are not permitted.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. a double filter with manual change-over is sufficient. Caterpillar/MaK has insufficient experience with brands of lubricating oil listed in column II. the composition and manufacture cannot be influenced by Caterpillar/MaK. 1. the installation of an “Automatic back-flush filter” in conjunction with a following indicator filter as double filter is necessary.3 Care of lubricating oil The time between oil changes can be lengthened by the use of separators.08. for example.04.3.08.

For engines under SAE 40-regulation only allowed if the oil inlet temperature can be decreased by 5 . 1) See also brand list for lubricating oils for heavy fuel operation.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. en / 29.02.Regulations and care Lubricating Oil M20-M601C A4. Caterpillar/MaK must be informed because at the moment there is insufficient experience available in Caterpillar/MaK engines.10 °C.08.When these lubricating oils are used.05.2008 BA020067 3/8 . Otherwise the warranty cover is invalid. 2) Synthetic oil with a high viscosity index (SAE 15 W/40).

Caterpillar/MaK must be informed because at the moment there is insufficient experience available in Caterpillar/MaK engines.2 List of brands of lubricating oil for heavy oil operation Only the viscosity class SAE 40 is permitted.4.02.When these lubricating oils are used.05.2008 BA020067 4/8 .Regulations and care Lubricating Oil M20-M601C A4. Otherwise the warranty cover is invalid. en / 29.00 1.08. 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.

02.5 to 1.05. The optimal oil circulation quantity should 1.5 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. which in individual cases may even be significantly below this value. the engine oil consumption. An oil change must be made every 6 months at the latest. shorter oil change intervals are necessary.and main filter Additional by-passfilter or oil centrifuge Separator – every 1.2) is reached.08. The oil level must be checked daily (the level must not drop below the minimum mark). the amount circulating in the engine lubricating system.36 l/kW when fitted with: Pre.00 1. Due to the above-mentioned factors the indicated oil change intervals are guide values only. 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. If in special exceptions circulation amounts of at least 0. The amount required is approx. the operating conditions. It must be topped up at the latest when 20 % of the amount in circulation has been used. Independent of the kind of treatment it is necessary to replenish by adding new oil when the BN limit (item 1.Regulations and care Lubricating Oil M20-M601C A4. We therefore recommended checking of the lubricating oil by means of regular oil analyses. the lubricating oil care and engine maintenance.3 l/kW cannot be avoided. Note: Modern MaK engines are characterized by low lubricating oil consumption rates of < 1 g/kWh.0 l. 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.500 h – every 3. In such cases the oil change times given below must be multiplied by the quotient of the actual quantity to the normally required quantity. 0. The essential criterion for determining the time for an oil change is compliance with the limt values specified under item 1. Oil change after operating hours (h) based on 1.6. The oil for the analysis must be taken from the oil circuit before engine during operation.2008 BA020067 5/8 .6.36 l/kW.500 h en / 29.

If the engine is running on gas oil or MDO.Regulations and care Lubricating Oil M20-M601C A4. the total base number must not fall below 50 % of the value of the new oil.08. For engine with cylinder lubrication. viscosity increase at 40 °C not above 200 mm2/s (cSt). If the content increases beyond 1 % weight. The limit is 2 % by weight. 1.02.05. the total base number of the circulation oil must not fall below 18 mg KOH/g.00 1. separators are specified to keep the oil clean. Reaching the limits at least 25 % of the oil should be changed.6.4 Contamination When Caterpillar/MaK engines are running on heavy fuel.6 Limits: 1. 1. If only the base number has reached the lower limit and the other analysis values show a satisfactory oil condition.2008 BA020067 6/8 . the alkalinity should be increased by the addition of new oil.6.2 % the cause of the increase should be identified and eliminated immediately. Vanadium content not higher than 150 ppm. the oil must be separated more intensively.2 Alkalinity (TBN) For heavy fuel operation. en / 29. For gas oil operation as well the pentane or heptane insolubles must not exceed 2 % by weight.6. The oil must be separated or it must be changed. the limit value is 15 mg KOH/g.3 Water content If the water content rises above 0.1 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).6. 1. In this way the content of insolubles can usually be kept well below 1 % by weight.

00 1. Woodward etc. 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. en / 29.08. should therefore be noted. 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. RE-Governor should be fitted with a normal 15W40-multipurpose oil.T.Regulations and care Lubricating Oil M20-M601C A4.7 Lubricating oil for exhaust turbocharger.2008 BA020067 7/8 .02.

05.2008 BA020067 8/8 .08.02.8 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 / 29.00 1.Regulations and care Lubricating Oil M20-M601C A4.

fully de-ionized water.5 3 2. The checking of the recirculating cooling water level has to occur at the expansion tank.09.Natural water (deep well-. Suitable are: .8 Chemicals 0 .Hardness * ° dGH 0. soluble .alkaline earths mmol / l . clean water. well water) .8 0 . These requirements can only be met by proper prepared.5 .2 12 6. If the the preperation. 100 max. even a short period of operation may result in damages due to corrosion.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. monitoring and maintenance work are not carried out properly.condensate and . The values for the fresh water analysis must be within the following limits: corrosioninhibiting oil total . Three decisive facts are to be considerd for a proper treatment: • • Suitable fresh water effective corrosion inhibiting agent .chemical corrosion inhibiting agent (chemicals) exact dosing of the corrosion inhibiting agent • Requirements for the cooling water Always use clear.10*** pH value ** at 20 °C Chloride ion content mg / l total chloride + sulphate ions mg / l max. monitored and maintained cooling water. 200 en / 03. 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.05.corrosion inhibiting oil.Regulations and care Cooling Water M20-M601C A4. depending on the evaporation loss.03.1.2008 BA000198 1/2 .

0). en / 03. the corrosion inhibiting effect of chemicals shows the best results with low water hardness values (.03.9 USA hardness **) pH value: Concentration of hydrogen ions < 7 = acid.05.09. Magnesium sulfate ° (Mg SO4) should be used for this purpose.09.00 *) Water hardness: Water which does not fulfil the above requirements must be hardened or softened. > 7 = alkaline.79° French hardness 1° dGH = 1. what may result in precipitations and in reduction of the inhibiting effect. ***) In general.4 g Mg SO4 per ton of water are required.2008 BA000198 2/2 . At higher hardness values and with missing hardness stabilization the chemicals may react with water contents. Dosing: For 1° dPH 21. see Diagram I (A4. 7 = neutral.Regulations and care Cooling Water M20-M601C A4.25° British hardness 1° dGH = 17. if corrosion inhibiting oils are used. 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).18° mmol/l 1° dGH = 1. Condensate and fully de-ionized water should be hardened up to 3° dPH.03).05. ° German total dGH = = Permanent hardness dPH + + Carbonate hardness dKH Comparison with other values: 1° dGH = 0.

MaK/CAT has received positive test results for the agents mentioned in 1.” (Research Association for Internal Combustion Engines Inc). 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 . No liability for the anticorrosive agent used will be accepted because MaK/CAT is unable to control the recipe and treatment. This 10 % emulsion is added to the cooling circuit which is already filled with 75 % of the necessary cooling water amount. V. MaK/CAT will issue a recommendation on the basis of the results of the test. ~ 1.25 °C) and stir vigorously.2 or they have proven effective over a long period of operation.05. For the initial filling or after cleaning the coolant circuit a 1.2005 BA020912 1/3 . via the expansion tank.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.09.5 % emulsion should be used and for the subsequent filling a 1.1 and 1.01 1. The following anti-corrosion oils are known to us to be effective (alphabetical order. Topping up can be done with the engine running. For initial fillings take so much water that a 10 % emulsion can be prepared with the required amount of anti-corrosion oil.0 % emulsion should be used. 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.Regulations and care Treatment of cooling water M20-M601C A4.11. en / 23.

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 / 23.05. because this may result in crevice corrosion! As far as we know.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.09.11.Regulations and care Treatment of cooling water M20-M601C A4. no danger of sludge formation due to breaking down of the emulsion and are simplier to prepare and control. g. BA020912 2/3 . Attention: It is important to avoid too low concentration. a filling with this chemical is to be implemented prior to commisioning. A chemical anticorrosive agent is added to the delivery scope (fittings) of some stationary engines.01 1.2 Chemical corrosion inhibitors The chemical corrosion inhibitors have some advantages over the anti-corrosion oils e. taking particular care not to use any poisonous substance it fresh water plants are connected into the cooling circuit. 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 . In any case.

05. possibly incorrect measurement In case the measured values are higher than 1. 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. After a freshening up of the concentration mix well with engine running! en / 23. also possible with engine running. During prolonged operating breaks.02 Emulsion freshening required Emulsion in order Concentration too high. 2. Take the emulsion sample out of the supply line from expansion tank to pump and let it stand for 1 h.04) and refill the circuit with conditioning water.2) is to be carried out with the relevant testing equipment every 150 h in accordance with the instructions of the supplying companies.09.1 % >1% – – – – Cooling water change and cleaning necessary.05.09.05.2 Chemical corrosion inhibitors.5 %. 0% < 0.09. The maintaining of the determined concentration is of decisive importance for a proper corrosion protection.09. see A4.11.04) with conditioning water to a highly concentrated emulsion.5 . a monthly check should be made.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. Pour off oil which rises to the surface. 2.5 % 0.g.01 2.05. A concentration check of the chemical corrosion inhibitors under consideration of the limit values (see 1. a correction of the emulsion is necessary. If the result is confirmed. test again with fresh sample water. with hand refractometer (specialist shop laboratory equipment) . Emulsion freshening in case of concentration too low Mix required amount of oil according to diagram II (A4. Carry out emulsion test e.2005 BA020912 3/3 . Always add oil to water Fill in the mixed emulsion via the compensator reservoir.

Then put in 90 % of the required amount of water.Regulations and care Changing the cooling water M20-M601C A4.1 Cleaning the cooling water chambers before changing the emulsion Stop engine and let cooling water cool down to 30 °C.09. P3T 308 from Messrs. 1. Fill engine with an alkali solution (e. g.05.09. at least annually if the 7500 operating hours are spread over a period of more than one year due to long breaks in operation.2 Chemical corrosion inhibitors When recirculating cooling water has chemical corrosion protection the cooling water does not need changing.2005 BA020059 1/2 . Drain the cleaning solution and flush engine thoroughly with fresh water. First drain expansion tank with floating oil then drain the entire system. 1. Stop engine and let it cool down to 30 °C.11. With the remaining 10 % and the required amount of anti-corrosion oil (according to diagram II: A4.1. Attention: Always add oil to water! Add the emulsion to system via the expansion tank. Remove water inlets on the crankcase and flush out any sludge which may have formed.5 % solution) and run it for approximately 12 hours.02 1.05. 1. Henkel 0.04) prepare a highly concentrated emulsion. en / 23.1 Changing the cooling water Anti-corrosion oil emulsion The anti-corrosion emulsion must be changed at the latest every 7500 operating hours.

For summer operation. To obtain adequate corrosion protection. Only an anti-freeze agent with a corrosion protective effect may be used.02 2.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. they must be precleaned as described and flushed well with water under pressure. a reduction in cooling efficiency must be expected. The highest concentration is 50%. In cases of doubt MaK should be contacted. 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.2005 BA020059 2/2 . 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. 3. The firm which supplies the anti-corrosion material will usually be able to offer a good cleaning agent for scale.05. such as: Drew Chemical: Rohm + Haas: SAF . When an anti-freeze agent is used. Havoline XLC.11. a 30 % concentration is necessary. Afterwards flush the water chambers with fresh water. 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. Cleaning the cooling water chambers Before badly scaled cooling water chambers can be cleaned. for example BASF Glysantin G48.09.Regulations and care Changing the cooling water M20-M601C A4. This agent must be changed annually. BP Antifrost X 2270. en / 23.

en / 28.03 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.1200 = 1100 litres of condensate or fully de-ionized water.09.05.1996 BA000210 Hardness = dGH 1/1 .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 .Regulations and careÿ Diagram I M20-M601C A4.

Regulations and care Diagram II + III M20-M601C A4.05. % amount of cooling water in circuit m3 amount of cooling emulsion to be drained off water to be added in m 3 en / 28.06.09.04 Diagram II Emulsion freshening for weak concentration measured oil concentration in vol.1996 BA021428 1/1 . % amount of cooling water in circuit m3 amount of oil to be added in litres to obtain a 0.7 % oil concentration Diagram III Emulsion freshening for excessive concentration measured oil concentration in vol.

2008 AA000026 1/1 .04.Maintenance - A5 Maintenance en / 24.

00 A5.05.01.01.02.01.01.05.51 A5.05.05.01 A5.02.01 A5.05.05.05.01 A5.02.05.05.05.Table of Contents - A5.2008 AA020041 1/3 .00 A5.05.03.02.01 A5.01.51 A5.00 A5.01 A5.01.05.02.00 A5.01.02.05.01.09.01.05.02.01.02.01.02.04.03 A5.00 A5.01 Maintenance Table of Contents Introduction Safety instructions Periodical schedule Heavy fuel Engine.05.10.07.02.01.05.01.02.01.08.01.01.01.00 A5. 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.02 A5.01 A5.02.05.08.02.02.07.01 A5.50.01.01 A5.05.05.05.01.05.02 A5.05.02 A5.01.00.03.50.05.05.06.01.05.01 A5.00 A5.10.03 A5.01.06.01.05.02.00 A5.03.51 A5.02 A5.05.01.01.05.01.01.03.01.04.00 A5.09.51 en / 24.05.02.01. 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 A5.53 A5.01.05.00 A5.05.51 A5.05.01 A5.08.05.52 A5.01.03.04.05.11.02.01.03.70.01.50 A5.04.05.05.01.06.01.02.

02.02.09.01.05.06.05.01.05.09.50 A5.05.01.03.02.05.05.08.52 A5.07.05.05.04.06 A5.09.04.04.00 A5.00.50 A5.50 A5.02.03 A5.02.05.02.53 A5.01.05.04 A5.02.05.08.05. exhaust gas system/supercharging Exhaust Manifold Charge air drain A5.05.01 Piston Piston Crown Piston Replace Piston Rings and Grooves Piston pin Small-End Bush Piston Engine.04 en / 24.50 A5.01.02.06.03 A5.01.05.00 A5.09.08.10.05.01.50 A5.04.01.05.00.05.01 A5.52 A5.05.06.05.01.01.00 A5.04 A5.00.05.05.04.00 A5.01 A5.04.Table of Contents - A5.05.05.05.05. regulation Control shaft bedding Starting Valve Control shaft Compressed Air System Control Valves Compressed-Air Filter Engine.04.01.05.02 A5. housing Cooling water distributor housing Cylinder Liner Cylinder liner Cylinder Liner Engine Bolting and Unions Engine.02.04.2008 AA020041 2/3 .05.01.05. control Camshaft Bearing Camshaft Bearing Bottom part for Valve Mechanism Camshaft Timing Gear Train Governor Drive Vibration Damper on Camshaft Engine.01.08.05.00 A5.05.01.05.05.01.03.04.03.06.02.52 A5.03.09.03 A5.05.06.05.02.05 A5.07.05.00 A5.04.01.05.02.05.04.01.51 A5.03.05.51 A5.01.02.51 A5.01.04.06.03.52 A5.02.03.01.00 A5.06.

02.03.05.04.05.11.11.07.02.00 A5.03 A5.05.08.05.06.08.05.03.03 A5.11.01.05.02 A5.05.01. lubricating oil system Lubricating oil pump Protective Lube Oil Filter Oil pressure control valve Oil pressure control valve Prelubricating pump/Prelubrication Engine.12.05.51 A5.01.05.02.52 en / 24.05.01.08 A5.08.03 A5.00 A5.07.05.11 A5.01.08.01 A5.02 A5.10.07 A5.51 A5.05.03 A5.09.06.05.05.01. 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 A5.05.05.05.01.02 A5.11.05.05.04. fuel system Injection Pump Injection Pump Fuel Injector Fuel Injector Fuel Injector Fuel Distributor Manifold Engine.05.05.01 Engine.00 A5.03.07.05.05.05.15.Table of Contents - A5.07.01.00 A5.00.01.10 A5.08.10.01.08.01.05.10.12 A5.02 A5.01.01.12.07.05.11.01.04.12.03.05.56 A5.00 A5.05.05.02 A5.02.06.09.00 A5.07.52 A5.08.07.03.2008 AA020041 3/3 .05.01.04.

It is the purpose of the maintenance to replace parts subject to wear and tear or to repair these parts before they are damaged. The 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. The “Scheduled maintenance” is thereby supported by inspections according to fixed deadlines.even if the mean wearing levels are well-known . en / 27.Introduction M20-M601C A5.1 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. These inspections are decision criteria for the need and extend of maintenance and servicing. but it is left to the user to modify the maintenance schedule in accordance with own experiences. fuel qualities and their care. 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. if damage is caused by improper handling. For this reason and in the interest of clearness we did not go too much into details in the maintenance documents. The information given by us gives no rise to legal claims. 2. It is recommended to consult MaK with regard to extended intervals in order to maintain the guarantee. 2.02. But in any case a sufficient safety margin .02 1. Therefore the present interval schedule shall not be considered stringent in the long run. No claims can be raised owing to missing instructions in the maintenance documents. 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.is to be calculated in order to cover the always occurring variations.2008 AA000021 1/5 .

maintenance or repair shall be carried out.02 2.2 Maintenance system The maintenance system consists of: • • • work interval schedule job cards maintenance schedule (large-scale plan) * While the work interval schedule indicates the date when inspection. depending on equipment condition. maintenance and repair work to be carried out at the scheduled date.Introduction M20-M601C A5.2008 AA000021 2/5 . • Periodic maintenance work A list of all recurrent inspection.2. maintenance and repair work occurring up to 90. The indicated intervals are statistical mean values. • 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. operating and maintenance conditions.000 operating hours. the job cards indicate the manner in which the work is to be carried out. 2.02. Other values may be obtained. 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.1 Work interval schedule The work interval schedule shall provide for a quick summary of all intended inspection. * will be handed over by the MaK service department for commissioning of the engine en / 27.

09.05.01. B1.01.2008 AA000021 3/5 . 01.01.Introduction M20-M601C A5. 01.91 Date of issue IB000003 1/1 Registration number Language Page/number of pages en / 27.01.01.03 Operating hours/maintenance deadline M 551 / M 552 6. / 3 h skilled engine hand Heavy fuel and destillate fuel Breakdown Chapter maintenance Vol.000 Engine type Register Main maintenance group 01 See also: Spare parts list: Time requirement: Personnel qualification: Operating medium: 01.2.02.04.7.05.2104. ¬ Title of the job card Maintenance work Activity Discharge valve Inspection / Dismounting and mounting A5. A operating instructions Subchapter Job cards A5. repair and safety check.nn.2 Job cards The job cards are instructions for inspection.01.02.01.nn.04.05.05. maintenance.000 / 12.08.2220 1 Pers.01.03 Main maintenance group Maintenance group Subgroup Variant Job cards Document number en / 30.01. 01.nn B1.7.02 2.

Note: Gives the personnel information which optimize the work process.02). Spare parts sheets: For easy finding of necessary comsumables and spare parts for the maintenance group in Vol. Cylinder head Driving mechanism Engine housing Engine control Regulation Exhaust gas system/ supercharging Fuel system 08. en / 27. 13. 04.03). Safety note: Each safety note is additionally marked with a symbol attention to the text (see A5.02 The job card number consists of the index breakdown (A5.02. • The first pair of digits indicates the engine main maintenance group: 01. 11. 05. 09. 12.05) and the maintenance number (bold) subdivided into four pairs of digits. 06. B “Spare parts catalogue”. 10. The third pair of digits in the index breakdown in the spare parts number indicates the main group/register. 03. • • • • 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. See job card: Reference is made to other job cards required for maintenance work. the pair of digits on the right margin has been set as register 01 . 07. At this point the types of variants (fourth pair of digit) are marked “nn”.Introduction M20-M601C A5. The fourth pair of digits indicates the type of variant.2008 AA000021 4/5 . 02. indicating other design details in the illustrations. ~ 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. if necessary. 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. • • • • Fuel: Documenting the sold type of fuel of the engine plant (see also: introduction A0.

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

In addition. Safety instructions 1. and above all. since above 325 °C a thermal decomposition and the formation of hydrofluoric acid can occur. it is essential that neoprene gloves are worn during the clearing up operations. Skin contact with decomposed VITONR is to be avoided at all times. i.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. • Replaced seals should be disposed of immediately.e. however it should not be exposed to temperatures above 300 °C.1999 AA000022 1/4 . the gases emitted must not be inhaled.Safety instructions M20-M601C A5.g. • Any residues have to be neutralized before their disposal.12.03 1. After a fire with VITONR.1 Work safety symbol ~ 1. With normal engine operation this material is completely harmless. If this should however has happened. during combustion and welding operations. it should be taken care that this material is not overheated even by accident e. the following is to be observed: • Seals made of VITONR have been used at various locations in the engine. saturated with calcium hydroxide. 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.

1999 AA000022 2/4 . 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.03 • When work is being carried out on engines and systems. fuel. 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. steps. e. assembly)! • • Never use aggresive detergents and preservatives! • • Use non-fuzzy cleaning rags! Pressurized plant components (lube oil.Safety instructions M20-M601C A5. the switch-on devices have to be switched off and protected. 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. fuel! Clean the engine parts. fuel or preservatives before carrying out maintenance/repair (disassembly. handrails.12. During replacement work. grease. In order to prevent reconnection. Shut-off valves are to be secured by a plate “Do not open”! Mounting openings are to be protected! Perfect hoists. tools and devices are to be used only! Observe all indicating labels attached to the engine! • • • en / 01. platforms. cooling water. hydraulic oil. especially connections and threaded unions of any traces of oil.g. starting and control air) must be depressurized.

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.4 Working with hydraulic devices • Operating instructions. 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 .12.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 . thermal or chemical influences! Replace hydraulic hose lines at regular intervals. 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.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 . even if no safety relevant defects are detectable! • • • • 1.respiratory mask! • en / 01.03 1.

and other reproductive harm. The non-observance of the safety instructions may cause danger to persons and failure of important functions of engine/system! 3.6 Handling of liquid nitrogen or carbon dioxide snow • When handling liquid nitrogen or carbon dioxide snow. observe the accident leaflets including first-aid actions for dangerous substances in accordance with the regulations for dangerous substances! • • 2. 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 / 01.12. California / USA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer.1999 AA000022 4/4 . birth defects.Safety instructions M20-M601C A5. safety shoes. safety gloves and safety glasses are to be worn in order to avoid injuries.03 1.7 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.

10 Temperature Pressure A1.10 Cooling water Engine inlet.00 A3. downstream charge air cooler Charge air Upstream charge air cooler.09.05.02 Intervall Designation / Work to be carried out Remarks Doc-Nr. Temperature rise at rated output see also A1.10 Temperature A1.06 Temperature A1.06 Temperature A1. downstream charge air cooler Exhaust gas After cylinder.05.00 A3.05 Pressure A1.10 Fuel Upstream pumps Charge air Upstream charge air cooler. rating Lubricating oil Engine inlet.Periodical schedule Heavy fuel M32 A5.10 Cooling water Upstream engine see also A1.04.10 A1.07.00 A3. Temperature rise at rated output see also A1.05 A1.10 Pressure Pressure Lube oil system Cooling water system Fuel system Pressure air en / 24. 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 A1.05 A3.10.10 Temperature A1.05.05 A1. downstream turbocharger Lubricating oil At the main bearing or at the camshaft bearing see also A1.05 Pressure Pressure A1. Daily inspection and monitoring procedures (if it is not automated) -------------------------------------------------------------------------------------------------------------------------------General Engine operating data Compare with acceptance test records: Speed.10 Cooling water Upstream charge air cooler.2008 A1.00 1/9 .08.06.04.

07.05.02 Intervall Designation / Work to be carried out Remarks Doc-Nr.05.05.04. First inspection and maintenance procedures Work to be carried out after the first commissioning or after major repairs. -------------------------------------------------------------------------------------------------------------------------------24 h Lubricating oil safety filter Inspection/Cleaning A5.00 en / 24.03.51 150 h Engine bolting and unions Inspection/Checking Tight fitand leaks Compressed air strainer Maintenance/cleaning Exhaust gas turbocharger Function check see book C A5.04.01.09.00 150 h 150 h A5.2008 AA020752 2/9 .08.04.05.06.Periodical schedule Heavy fuel M32 A5.03.

00 A5.01.09.03.01.00.11.500 h 1.02 Intervall Designation / Work to be carried out Remarks Doc-Nr.09.08.00 A5.04 150 h 150 h 150 h Valve rotor Inspection/Evaluate Cylinder head Inspection/Checking Prelubricating pump/Prelubrication Maintenance/Checking A5.09.05.01.01.03 en / 24.01.01.52 1.05.09.04.01.08.01.01.06.01.05.11. Periodical maintenance procedures -------------------------------------------------------------------------------------------------------------------------------24 h 24 h Compressed air strainer Maintenance/Cleaning Charge air drain Inspection A5.03 A5.500 h Valve clearance Inspection/Adjust Starting valve Inspection/Checking Control shaft bearings Maintenance/Checking Oil mist detector Inspection/Checking A5.05.05.01.05.05.00.12.05.00 A5.01.05.02.05.00 A5.00.Periodical schedule Heavy fuel M32 A5.05.00 A5.01 A5.04.05.03.00 750 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 A4.05.00 A5.01 A5.10.500 h 1.500 h 1.05.05.10.10.2008 AA020752 3/9 .01.05.06.01.00.09.06.05.09.06.05.04 A5.06.00 A5.

01.08.52 3.03.02.500 h 7.750 h 3.05.01.500 h A5.03 7.750 h 3.01.02 A5.01.500 h 7.750 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 A5.51 A5.03 7.05.08.05.05.01.04.00 en / 24.07.07.02.05.04.05.09.500 h 1.Periodical schedule Heavy fuel M32 A5.02 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.06.500 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 A5.01.00 A5.05.52 A5.12.05.01.750 h 3.500 h 7.01.08.750 h 7.09.01.05.08.05.05.01.500 h A5. 1.05.05.04.02.06.00 A5.05.500 h 7.05.02 7.12.05.11.00 A5.03.07.01.01.01.2008 AA020752 4/9 .01.00 A5.07.52 3.500 h A5.750 h 3.500 h A5.01.

000 h 15.51 A5.03 15.01.01.52 A4.01.03.000 h A5.01.51 A5.Periodical schedule Heavy fuel M32 A5.05.02 A5.03 A5.2008 5/9 .01.000 h 15.02.500 h 7.05.000 h 15.50 15.01.01.08.09.07.11.02 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.01.03.02.08.05.000 h A5.03.04.01.11.05.04.09.05.51 A5.05.52 15.09.05.05.05.000 h 15.04.05.04.02.05.500 h 7.01. 7.05.01 A5.53 15.01.04.01.05.05.06.01.01.000 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 A5.01 A5.03 A5.000 h 15.03.01.01.000 h A5.05.04.08.02 15.500 h 7.02.08.01.00 A5.01.000 h A5.05.05.10.05.50.04.05.500 h A5.02 A5.51 en / 24.12.000 h 15.000 h 15.500 h 7.04.05.

04.2008 6/9 .51 A5.05.02.000 h 30.05.04.05.04.000 h 15.02.05.05.51 22.03.000 h 30.04.05.05.08.000 h A5.01 A5.03.05.07.02.01.000 h A5.01.05.05.000 h 30.09.000 h 15.05.04. 15.500 h Pressure switch Inspection/Replace A5.nn A5.000 h 30.00 A5.01.01.02.52 A5.03.000 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 A5.06.05.01.01.05.05.01.05.03.12.07.03 15.Periodical schedule Heavy fuel M32 A5.05.000 h A5.02.02.03 30.01 A5.01.53 30.50 en / 24.01.11.06.000 h 15.04.000 h A5.000 h A5.01.01.02 30.02 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.05.000 h 15.05.09.00 A5.01.02.10.05.000 h A5.05.09.70.03 30.05.02.00 A5.05.52 30.02.05.

05.12.02 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.02.05.04.01.000 h 30.00 90.05.04.04.52 45.05.50 30.01.05.000 h Piston Maintenance/Replace A5.02. 30.05.000 h Piston Maintenance/Replace A5.000 h 30.05.51 60.000 h Vibration damper Maintenance/Replace A5.05.06.51 A5.01.04.000 h 30.05.08.000 h A5.02.01.12.06.05.04.00 en / 24.52 A5.09.000 h A5.02.Periodical schedule Heavy fuel M32 A5.04.2008 AA020752 7/9 .12.01.04.04.00 A5.

11.02.05.01.05.01.03.01 A5.01.05.05.06.02.05.51 A5.02.05.05.51 A5.05.02.51 A5.50 A5.01.51 A5.05.02.02.05.50 en / 24.04.05.01 A5.04.07.08.01.00 A5.02.02.Periodical schedule Heavy fuel M32 A5.01 A5.04.01. 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 A5.03.02.01.01 A5.53 A5.02 Intervall Designation / Work to be carried out Remarks Doc-Nr.05.02.02.05.03.05.01.01.01.00 A5.05.06.01.05.02.02.04 A5.01.01.05.08.03.01.05.03.2008 AA020752 8/9 .01.08.08.02.02.50.06.00 A5.00 A5.

01.00.00.05.01.11.07.02 A5.02.52 A5.05.06.50 A5.15.01.01.02 A5.02.Periodical schedule Heavy fuel M32 A5.2008 AA020752 9/9 .07.01.03.05.03.07.05.05.04.02.01.04.06.00 A5.04.05.12.03 A5.08.02 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.05.52 en / 24.03 A5.01.06.00.06.05.10.06.03 A5.02.11.04 A5.03.05.02.04.06.04.05.00 A5. A5.07.07.04.05.04 A5.09.05.07.56 A5.08.01.01.05.05.05.52 A5.09.50 A5.

4 + 0.nn B1.3 1.05. 15 minutes after shutting down the engine. i. Open indicator valves.01.4 Adjust valve bridge. Sequence of operations: 1.e. Turn the crankshaft until the piston of the cylinder to be adjusted comes into the ignition dead center position./ 0.2006 IB020905 1/2 .01. 1.1 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.09. Engage the barring gear.01. 1/S): Inlet: Outlet: 0.1 + 0.1 1.2 1. Remove cylinder cover hoods without damaging the gaskets. Tools: Feeler gauge * not available as figure W2 * 1. 01.01. en / 14. if required.05.00 1500 02.2107 1 Pers.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 1.9075-003 Note: The valve clearance should only be measured with warm engine.1 mm 1.9.01.500 hours and adjusted.Valve Clearance Inspection / Adjust M32 A5. Valve clearance (Fig.

6 1.9 Check absence of clearance at „X“ and „Y“ with feeler gauge of 0. 1/1).01.7 1. Thereby press the pushrod down.05.00 1500 Release valve bridge of rocker arm (Fig. 1/S) with a feeler gauge. At this position of the valve bridge screw in setting bolt (4) until contact at „Y” without any clearance is reached. 2. 2/3) and unsrew setting bolt (4) until a contact in „X” without clearance is reached.5 01 1.09. Tighten the counternut (5) with M = 250 Nm in order to fix the position of the adjusting screw. Measure the clearance (Fig. Enlarge clearance „S“ and/or flap back rocker arm (1). Adjust valve clearance. Hold tight setting bolt (4) and tighten locknut (3) with M = 150 Nm. 1.01.2 2.3 2.5 Check clearance again after countering. Disengage the barring gear and close the indicator valves. Valve bridge must not be tited.02 mm (W2).2 2. 2. Loosen counternut (5). Turn the valve adjusting screw (2) until the stipulated clearance has been attained.1 2.2.Valve Clearance Inspection / Adjust M32 A5.2.8 1. Release locknut (Fig. Correct clearance "S".2. en / 14.1 2.2.4 2.2.2006 IB020905 2/2 . Afterwards adjust valve clearance „S“ as per instruction. 01.

02. 1.9.20 h 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench 100 . 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.Rocker Arm Bracket Maintenance / Disassembly and reassembly M32 A5. Blow through oil overflow holes with compressed air.2107 1 Pers.400 Nm Ring wrench SW30 * not available as figure W1 * W2* 1.4 1. en / 18.01.3 Disassembly Engage the barring gear. Reassembly Clean the supporting surfaces of the rocker arm bracket (3).1 2.01. Remove fastening nuts (1). Turn piston to TDC.01.01./ 0.2005 IB022290 1/2 .01 See also: Spare parts list: Time requirement: 01. Dismount the cylinder head cover. rocker arms are unloaded. 01.nn B1.2 2.9459-030 Auxiliary material: Molykote paste "G-Rapid Plus" ** ** or a product of equal standard Sequence of operations: 1.2 1.1 1.5 2.9454-400 1. Remove rocker arm bracket (3) with rocker arm shaft (2) and inlet and exhaust valve rocker. Inlet and exhaust valves are closed.05.3 1. 2.05.02.

2005 IB022290 2/2 .01.01.5 2. 01.05.nn).6 2.01 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.Rocker Arm Bracket Maintenance / Disassembly and reassembly M32 A5.01.7 2. Check the oil flow.8 Adjust valve clearance (01. Mount cylinder head cover (check gasket!). en / 18.02.02. Disengage the barring gear.

01. 01.nn. 1.01.1 Disassembly Remove securing rings (Fig.2 Note: All additional maintenance work is identical for the intake and exhaust valve rocker arms. 2.02. 01./ 0.2107 1 Pers.2001 IB022284 1/2 .03.06.000 h Note: The liners may only be lubricated with oil.02. en / 12.01 30000 01.02.02. Blow out oil bores with compressed air and check to ensure that they are clear.Valve Rockers Maintenance / Disassembly and reassembly M32 A5. Remove the intake valve rocker arm (1) and the exhaust valve rocker arm (2) from the rocker arm shaft (3).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. 1/4) and thrust washers (5) from the rocker arm shaft (3).nn B1.9. Clean all parts and check for damage.05. Molykote paste may not be used for installing the bushings.05. 1. Procedure: 1.

02 . 01.0.01.02. en / 12.2001 IB022284 2/2 . 1/1) and exhaust rocker arms (2) and the rocker arm shaft and slide the rocker arms onto the shaft carefully. Reinstall the rocker arm bracket and rocker arms on the cylinder cover (01.159 Wear limit (mm) 0. Assembly Note: Rocker arm shaft must be undamaged and may have no burrs or scratches. 5.02.02.02.01 30000 Check the bearing surfaces of the ball pin (Fig. Measure the rocker arm bush (Fig.05.2 Oil the contact surfaces of the intake (Fig.06. 3. Cool ball pins to -195 °C with liquid nitrogen and slide into place. Do not tilt the rocker arms.25 5. Attention! Note and follow all safety instructions when handling liquid nitrogen.nn). 1/3) and replace the bush when the clearance meets or exceeds the wear limit (01. 01 ~ 4.1 5. New clearance (mm) 0. 2 /13) and shaft (Fig.03. Replace parts as necessary. 2/10) and the adjusting screw (12) for wear and damage.nn) and check the oil flow through the components.Valve Rockers Maintenance / Disassembly and reassembly M32 A5.

Oil the new bush lightly and press into rocker arm. Drive out the bush (1) with the proper copper punch (W1).02. 01. Attention: Note the position of the oil bores (2) and the separating joint (3) when pressing the new bush into place. The rokker arm must protrude past the liner (Z) s = ca.02.06.9.03.02.02.01.05. 2.02. 2. Procedure: 1.2107 1 Pers.01./ 0.nn.02.01 See also: Spare parts list: Time requirement: Personnel qualification: Operating medium: 01. Be careful not to damage the plastic coated contact surface. 0.1 2.40 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.2 Measure the rocker arm bush (1) and (01. 01.nn B1. Replace.2001 IB022287 1/1 .2 mm on both sides. en / 12. Molykote paste may not be used for installing the liners.05.nn).Valve Rocker Bush Inspection / Replace M32 A5.

00.11.2107.07. 2. Attention: Do not apply too much lubricating oil/gas oil mixture.nn B1. B1.9.01. 1/1).05.2225 1 Pers.01. the valve rotator must be replaced.01. See mark "X" on spring plate (Fig. 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.05. if a uniform engine speed-dependent rotation can be detected. n ≤ 1 min-1. Danger of lubricating oil dilution! en / 02.01.1 If at nominal engine speed the rotational speed goes down to approx. The valve rotator works properly.10./ 0.05. Use this rotational speed for further reference.03. Open lock cap of cylinder head cover and check valve rotation. 01. 01.Valve Rotator Inspection / Evaluate M32 A5. Remedy: Inject a gas-oil/lubricating oil mixture drop by drop onto the valve stem. Note: Deceleration of the valve rotation can also be caused by hard motion of the valve stem in the valve guide.9.nn.00 150 01. Fig.1998 IB002320 1/1 . 2.10 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. Sequence of operations: 1.

01. 1/1) from the groove with a sharp-angled wire.01.nn.4 Clean groove.05.Valve Guide / Oil Scraper Ring Inspection / Replace M32 A5.3 1. Remove the O-ring (Fig.01.01 15000 01.07./ 0.nn. The ring must not be twisted in mounting position.2107 1 Pers.000 h Auxilary material: Molykote paste "G-Rapid Plus"** ** or product of equal standard Sequence of operations: 1.05. Lubricate new O-ring slightly and carefully place in groove. clean stem thoroughly. Fig. 1 en / 29. 01. 1.2 Replacement of oil scraper rings (O-rings) Dismount valve cone. 01. 1.05. 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.9. 01.01.05. 01.01.02.nn B1.20 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.nn.2000 IB020926 1/2 .1 1.01.01.06.

0. Measure the inside diameter of the guide bush in traverse direction of the engine.35 Measurement of the valve guide clearance Measure the outside diameter of the valve stem in the guide zone of the bush.1 2.05.01. en / 29.01 15000 01 2.2000 IB020926 2/2 .35 0.05. 2.17 Limit clearance (mm) 0. 01. 0. There is a risk of damaging the cylinder cover when the old valve guide is knocked out.0. Replacement of the valve guide Note: If possible.24 0.11 .Valve Guide / Oil Scraper Ring Inspection / Replace M32 A5.3 Normal clearance (mm) Outlet Inlet 3.2 2.18 .05. replace the valve guide during cylinder head maintenance in the workshop of an MaK dealer.

nn./ 0. 07. 2/10) and disassemble the connecting flanges (fig.05.25 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 B1.11.01.01. en / 20. 1/2.1 Safety note: The system must be depressurized before assembly! Loosen the cheese head screws (fig.2144 1 Pers.9.2002 IB022850 1/4 .05.Media guiding system Maintenance / Disassembly and reassembly VM32 A5. 01.03.nn. Disassembly ~ 1. 3) together with the sleeves (11).51 See also: Spare parts list: Time requirement: 01.50. 01.06.05.01.01.02.

2 1. 3). 01.4 en / 20.2002 IB022850 2/4 . Check the O-rings (15).Media guiding system Maintenance / Disassembly and reassembly VM32 A5. 01 1.05. 3) as well as the gaskets for the connecting flanges (fig.03. 1/4 and 5) and the blank flanges (1).51 1. Clean the sealing surfaces.3 Pull the sleeves (fig.50.05. 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. Replace faulty O-rings (15). 2/11) out of the connecting flanges (2.

03.6 1. Replace O-rings (33) and clean all sealing surfaces.7 1.05. Replace O-rings (32).05.50. 3/30) out of the media block (31 and 35).51 1. Remove media block (31 and 35).8 Pull the sleeves (fig. 01 en / 20.Media guiding system Maintenance / Disassembly and reassembly VM32 A5.2002 IB022850 3/4 . 01.5 1.

2/2 and 3) with inserted sleeves (11). Replace faulty gaskets (fig. Replace faulty gaskets (16) beforehand. Mount the blank flanges (fig.50. 2 and 3. 3. refit the connector and dip the tip of the alarm probe into a medium. 01 Attention: Make sure that all gaskets (16) are centred properly by the dowel pins (17)! 3.03. 4.1 Functional check of the alarm probe for leak fuel (fig.nn). 2/16) beforehand.1 4. acknowledge the alarm and.4 Reassembly Mount the connecting flanges (fig.02. leak fuel is found on cylinders 1. If an alarm is triggered. Identification of the defective fuel delivery pipe in the event of a "leak fuel" alarm.3 2.05. remove the screw (fig. replace the alarm probe and repeat the test. Put the connecting flanges (4 and 5) onto the sleeves (30) and mount them.Media guiding system Maintenance / Disassembly and reassembly VM32 A5. 3. beginning with cylinder 1. Mount the media block (fig. then replace the fuel delivery pipe for cylinder 3 ((07. 4. 3/31 and 35).05.2 When a "leak fuel" alarm is given. en / 20. for example. 3/20). Mount the alarm probe. Dismantle the alarm probe.01. Insert sleeves (30) with new O-rings (32). Replace faulty gaskets (16) beforehand. 2/12) with gasket (13) on each cylinder.2 2. 01. 2.3 Mount the screw (12) with a new gasket (13). Check the bore in the connecting flange (2) for leak fuel. 1/1). acknowledge it. 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.2 4.51 2. but not on cylinder 4.1 2.2002 IB022850 4/4 . If. If no alarm is triggered.

Secure the engine against accidental starting.01./ 0.9203-004 0.2002 IB023645 1/5 . remove cylinder head cover and pump covering.51 See also: Spare parts list: Time requirement: 01. 01.Cylinder Head Maintenance / Disassembly VM32 A5. 1/3) of the respective cooling water distributor housing and drain the residual cooling water.9. turn the piston to top dead center. Sequence of operations: Open indicator valves. 02.nn. Loosen the screw plug (fig.nn.9203-110 9.50 h 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Hydr.9203-112 0.9203-106 0.01. 06. ~ 1. Use only hydraulic oil.02. 3.9203-211 0.9221 D Attention: The actual bending radius of the high-pressure hoses must not fall below the minimum bending radius r = 120 mm.9205 B 0.nn. 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. 2.01. 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. 03.01.2107 1 Pers.01.9213 C 0. set of devices consisting of High-pressure pump High-pressure hose (1 m) Hydr.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.04. The devices are to be stored protected against corrosion.06. en / 30.01. 4.05.01.9203-221 0.05.06. Safety note: Do not place any parts of the body over pressurized devices.9204 D 0.nn B1.

en / 30. 01.01. 7.01. Loosen the six cylinder head nuts with the hydraulic tightening device. Remove covering cap between exhaust pipe and cylinder head.Cylinder Head Maintenance / Disassembly VM32 A5. Disassemble rocker arm bracket (01.02.01. the complete rocker arm bracket must be disassembled. Loosen union nut of nozzle holder one turn and turn 90° to the right. 6.2002 IB023645 2/5 .01. Loosen the union nut of the fuel delivery pipe on the injection pump.51 01 5.06.nn). Note In order to avoid damages and ensure trouble-free assembly and disassembly. Loosen clamp ring on the exhaust pipe (06.01.05. 8. 3/10) must not be project above upper edge of the cover.nn). Attention: Stroke limit indicator (Fig.

5 mm of the threaded sleeve to top edge of jack (W3) has been reached. 8.01. Make sure the slits (13) are easily accessible. Turn round nuts back by at least eight holes. 01 8.2002 IB023645 3/5 .4 8. 2/W3) connected with support rings (W7) and threaded sleeves (W8) over round nuts (Fig.6 8.2 8.Cylinder Head Maintenance / Disassembly VM32 A5. 01.5 Connect hydraulic jack (Fig. 2/W3) connected with support ring (W5) and threaded sleeve (W6) over round nut (Fig. 3/12). 3/12) setzen.05. Screw threaded sleeves (W8) onto cylinder head screw (11) until a step S = 3.51 8. en / 30.7 Loosen round nuts (Fig.5 mm of the threaded sleeve to top edge ofjack (W3) has been reached.01.1 Place hydraulic jack (Fig. 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. Make sure the slits (13) are easily accessible.3 Place hydraulic jacks (Fig. 3/12) with pin (W9).06. 4/W3) and distributor (W4) to high pressure pump (W1) via high pressure hoses (W2). Screw threaded sleeve (W6) onto cylinder head screw (11) until a step S = 3.

8 Relieve jacks.01. remove hydraulic devices and unscrew round nuts. en / 30.Cylinder Head Maintenance / Disassembly VM32 A5. 01 8.06. In the case of a further pressure increase.05.01. there is a risk of the round nut getting stuck due to the expansion of the bolt thread. 01.2002 IB023645 4/5 .51 Note: If a loosening of the round nuts is not possible. then the pre-stressing of the cylinder head screw can be increased by 50 bar.

pushrods. 5/W10)into the cylinder head and attach to the lifting device (W11). cylinder head screws. Lift the cylinder head with crane.2002 IB023645 5/5 .Cylinder Head Maintenance / Disassembly VM32 A5. fuel delivery pipe and charge air connecting piece. 10.05. Place the cylinder head on wooden base.06. Screw the eye bolts (Fig. 01.01.51 9. en / 30.01. Pay attention to pushrod guide! 01 Attention: Risk of damage to transfer ports.

nn. consisting of: wrench bush torque wrench 100 . Place wrench (5) with bush (6) on nozzle sleeve (1) so that nozzle sleeve and wrench (5) are engaged.06.05.05.9.2107 1 Pers.9454-400 1. 07. 01.50 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 15.9023-017 Auxiliary material: Vaseline ** Adhesive and sealant “ Loctite 510 “** ** or a product of equal standard 5* Sequence of operations: 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. 6* 3 4 1 1.05.01.06. 1.01.2007 IB020933 1/2 .nn B1.07.50.2 2 * = W1 en / 30.000 h Tools: Dismounting and mounting device.400 Nm reducer extension brass mandrel * no illustration W1 W4* W5* W6* W7* 9.9220 C 1.00 15000 01.1 Dismount nozzle sleeve (1).Nozzle sleeve Maintenance / Disassembly and reassembly M32 A5./ 0.01.

05. 01 1.2 Use a brass mandrel (W7) and carefully drive out the nozzle sleeve.4 2.06. Attention: Do not exchange the position of the O-rings. Apply a film of vaseline to the new green O-ring. Insert the nozzle sleeve and tighten it by means of wrench (5) at a torque of M = 300 Nm. 2.2007 IB020933 2/2 . Apply a film of vaseline to the new blackish brown O-ring. Remove O-rings (3 and 4).50. insert O-ring in groove (3) and make sure the O-ring is not twisted. 2. Mount the nozzle sleeve (1).insert O-ring in groove (4) and make sure the O-ring is not twisted.05. en / 30. observe the mounting instructions. 01.3 2.3 1.Nozzle sleeve Maintenance / Disassembly and reassembly M32 A5.1 2.4 Apply a film of “Loctite 510 “ to the threads of the nozzle sleeve.00 15000 Attention: The threads of nozzle sleeve and cylinder head must be exposed.

01.01.05.05. Unscrew hexagon nut (1).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. en / 09.2001 IB023036 1/2 . 2.03.00 30000 01./ 0.nn B1.Relief Valve Maintenance / Replace M32 A5.9.70.06.2107 1 Pers.000 h Auxiliary Material: High-temperature thread paste “Dag S 5080“ * * or a product of equal standard Sequence of Operations: 1.06. Remove cover (2). 01.

2001 IB023036 2/2 . 5. 4. 01. 3. 7. Lubricate the thread of the new relief valve with high-temperature thread paste “Dag S 5080“. 01 en / 09.05. Firmly tighten hexagon nut (1).70. Mount cover (2). Mount new relief valve (3) with new joint ring (4). Firmly tighten the relief valve by means of a wrench.06.03.00 30000 Slacken relief valve (3) by means of a wrench and remove it.Relief Valve Maintenance / Replace M32 A5. 8. In doing so mind disc spring (5). 6.

nn B1.2 Disassembly Dismantle cylinder head (01. operating conditions of the plants and the quality of the repaired valve cones/seat rings and therefore differ from plant to plant. 01. 01. every time the valve cones are dismantled (01.05.01. remilled.9.500 h Maintenance: of all in and outlet valve cones after 15.01. Sequence of operations: 1./ 0. 01.000 h Tools: Valve spring clamping device W1 9.02 15000.01.nn.05.nn. 01.02.02. For this reason the user must stipulate the repair intervals depending on the conditon of the inspected valve cones.07.08.01.01.01. 01. 7500 01. if necessary.1 1.nn).In and Outlet Valve Cone Inspection / Disassembly and reassembly M32 A5.01.06. The seat geometry is to be checked.01.nn.06.02.nn).01.08.nn) and lift valve bridge.05.9222 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.nn.2107 1 Pers.08.2001 IB022833 1/2 . Dismantle rocker arm (01. en / 22.50 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 7.03. 1.

2.nn).01.01. en / 22.02 15000. Carefully unload valve spring (3).8 1. 1. spring plate (2). 7500 Screw off clamping sleeve (5) by hand until it can be placed on valve stem (9). The re-assembly is effected in a reverse dismantling sequence.05.nn).In and Outlet Valve Cone Inspection / Disassembly and reassembly M32 A5. valve spring (3) as well as the valve turning device or valve spring disk from the cylinder cover. 01.05.3 1.nn/01.08.4 Reassembly Check valve guide clearance. renew O-rings (01.9 Safety note: Spring tension Lift off valve spring clamping device (W1). Remove circlip (10).01.02. 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. Pull valve cone out of cylinder head.2001 IB022833 2/2 .7 ~ 1. slowly unload the valve spring and make sure that the cone clamp halves are sitting properly. 1. Screw down by hand clamping sleeve (5). Compress valve spring (3) and remove cone clamp halves (4). Repairing valve cone/valve seat (01. 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).1 2.5 Coat the contact surface (X) of the valve spring clamping device (W1) with „G-Rapid Plus“Molykote paste before use.2 2.3 2.08.03. Lubricate burr-free valve stem before fitting and put in valve cone screwing so that the O-ring is not damaged.07.4 01 Note: The receptacle of sleeve (5) must engage in the groove of valve stem (9) 1. Projecting burr must be removed before dismantling such valve cones.6 1. After putting in the cone clamp halves.

en / 02.00 h 01 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Valve refacer W1 6.07.1998 IB002338 1/5 .05.2107 0 Pers.02.01. no crack formation is established at the valve cone face.nn. using illuminated magnifying glass (8-fold magnification) or powderspraying procedure (Met L'Check) and/or in the flux procedure. Sequence of operations: 1.01.1 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.nn B1. damaged sealing faces.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 4.9224 B Auxiliary material: Diamond paste Dp 30/10 . 01.02.08. in case of negative result. 01. uneven contact reflexions of valve cone/seat.Valve Cones Repair / Checking M32 A5.01.00 See also: Spare parts list: Time requirement: 01.g.08. deep scars./ 0. e. 1. Refinishing of the valve cones (according to operating sequence 3) may be necessary in the following cases: • • after extended operating times.9.05.

1). 01.00 • when the deviation from the straightnesss does not exceed the following values (Fig.006 Fig. en / 02. the stem transition and valve head s • the underside of the valve head • corrosion pits and mechanical damage • excess of limit dimension for refinishing.2 The valves cannot be reused in the following cases • the valve cone face is damaged (cracks. 1 1. 2) Fig.05.1998 IB002338 2/5 . 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: — 0.08.08 AB 20 20 A s 0.03 AB B — 0.01.04 0.Valve Cones Repair / Checking M32 A5.02. 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 > 1.5 mm (Fig. 2 indicates severe pitting (formation of socalled "paving stones") in zone of the valve stem.

inlet valve). 3a. If no such machine is available.3 3. blasting with glass beads. the valve cones should be taken to a MaK workshop for regrinding. 3a 3. 3.1998 IB002338 3/5 .02. Cleaning with sharp-edged tools as well as pickling with inorganic acids (hydrochloric acid.08. Outer edge rounded with stone. the valve seat ring must also be refinished (01. outlet valve. 01.g.2 = Fig.08. 3 = Fig. The valve cone is to be resplaced when the actual dimension falls below the minimum dimension (Fig.) is not allowed. Repairing (refinishing of the sealing surface) Note: In all cases the refinishing must be carried out professionally on precision spindle grinding machines. 3).nn).4 Attention: When the valve cone is refinished. en / 02. Do not refinish existing concave fillets.Valve Cones Repair / Checking M32 A5.00 01 2. 3. 3 The appropriate information of the grinding machine manufacturer is to be observed when grinding is carried out. 3a Fig.01. Outlet valve cone Inlet valve cone 3. Fig.02. 3. 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.05. Cleaning Clean the valve spindles e. Fig. sulphuric acid etc.1 Regrind sealing surface in accordance with the prescribed angle (Fig.

1998 IB002338 4/5 . rotating the device. 01.01.15 µm with a syringe to the fitting surface of the new or remachined valve cone and distribute the paste evenly (Fig. 5 en / 02. Insert the lubricated valve stem into the guide.1 Maintenance (Checking contact reflexion/grinding) Apply small dots of diamond paste Dp 30/ 10 . 4. 6/a) which is visible due to the light grinding process should not exceed 30 .05. 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. Fasten the device (Fig. 4.08. The contact reflexion (Fig. 4).02.50 % of the seatwidth "b" starting from the outside diameter. 4 Fig.Valve Cones Repair / Checking M32 A5.2 Fig. 5/W1) to the valve head and grind the valve cone face and seat by hand applying a moderate pressure. Thereafter.00 01 4.

3 When the contact reflexion is poor. however.01.05. the valve must not be reground anymore.2 a b a Fig.00 01 4. 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.08. both sealing surfaces are to be refinished by machine. 5. 6 en / 02.4 5. 01.Valve Cones Repair / Checking M32 A5.1 5. Ensure that the components (valve cone and seat ring) refaced to one another stay together.02. Final check Ensure that the refinishing limits are maintained.1998 IB002338 5/5 . 4.

9.07.Valve Seat Ring Repair / Checking M32 A5.01. en / 05.05. 01. both sealing faces must be refinished.2107 0 Pers.g.00 See also: Spare parts list: Time requirement: 01.15 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. e./ 0. deep scars.02.05.08.9224 A Auxiliary material: Illuminated magnifying glass (8-fold magnification) Diamant paste Dp 30/10 .01. 01.9224 YY 9. New or refinished valve seats are to be ground in accordance with operating sequence 4.nn.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 1.07.01. damaged seat face.2001 IB002340 1/5 . Refinishing of the seats may be necessary: • • after extended operating times in case of negative result.08. uneven contact reflexions of valve seat/cone (Fig. 1 and 2).nn B1.

07. 01.Valve Seat Ring Repair / Checking M32 A5. Checking of condition The hardness of the valve seat is designed in such a manner that a certain adaptability is present.02. en / 05. Carbon desposits are therefore a normal indication and not hazardous if good cooling is present (Fig.05. 4 and 5).00 01 Sequence of operations: 1. with regard to the valve cone.08. 3.2001 IB002340 2/5 .

Maintenance (refinishing of valve seat rings) Note: Remachining is to be carried out professionally with the MaK precision seat grinding machine (W1).1 3.07.Valve Seat Ring Repair / Checking M32 A5. Unnecessary material removal is to be avoided. Insert centering disk (4) with guide mandrel (5) and tighten with star handle (6). hard touchdown can also damage the valve seat face. Alternatively. • cracks are present in the seat face • burn holes are present • the refinishing limits have been exceeded. Refer to special operating instructions.08.1 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. Cleaning Remove residues from the seat faces. 01.05.2 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. 6/W2). the seats may be refinished by means of the MaK valve seat milling device (Fig.02. Remove O-ring from guide bush. if they are present in the contact area.00 1. 3. cutters are sensitive to impact. Attention: Handle the cutter head (2) with care. 3. en / 05. carbon pockets are only to be repaired.1.1.2001 IB002340 3/5 . 2.2 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).1 3.

02. at the same time rotating the cutter head.00 3.6 Maximum permissible dimension Ø (x) for refinishing (Fig. 7 Fig.2001 IB002340 4/5 .1. The cutting of the cutters has to be noticeable. 3. 01. 6 Fig. 7a en / 05.07.1. Rotate valve seat clockwise uniformly and slowly and remill the seat in one operation pass. 7 = Fig.Valve Seat Ring Repair / Checking M32 A5. screw in knurled screw (1) until resistance can be felt.4 Attention: The machine will rattle when the contact pressure is too low and/or the cutting speed is too high.08. 7a Fig.05.1.1. 6/2) on greased guide mandrel. 3.5 Prior to finishing the cutting process. 7): 107+0. Set the contact pressure according to touch. slowly unscrew the knurled screw (1). 01 3.2 a = no material removed Outlet valve seat ring Inlet valve seat ring = Fig.3 Place cutter head (Fig.

8 4.15 µm with a syringe to the seat face of the new or refinished valve spindle and distribute the paste equally. spray the total surface of the seat ring with diluting agent DIAPLASTOL (01. the cutter head is to be sent to the MaK for refinishing.00 01 3.02. rotating the device.01. The contact reflexion "a" which is a visible due to the light grinding process should not exceed 30 . Thereafter.3 4.2 en / 05.1 When the milling cutters are blunt. 4.05. Fasten the device (W1) (01.nn) to the valve head and grind the cone and seat by hand applying a moderate pressure.01.08.1. Ensure that the components (valve cone and seat ring) reface to one another stay together.2 When the contact reflexion is poor.Valve Seat Ring Repair / Checking M32 A5.7 3.2001 IB002340 5/5 .nn). 5.4 5. 4. Insert the lubricated valve stem into the guide bush. Final check Check whether the refinishing limit dimensions are observed.50 % of the circumferential seatwidth "b" starting from the outside diameter (01. 4.1. however. Checking of contact reflexion/grinding Apply small dots of diamond paste Dp 30/10 . Grind sharp edges with fine emery cloth.01.08. the valve must not be reground anymore. 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.08. both sealing faces must be refinished by machine.nn).07.08. 01.1 5. Dismount the milling device.

1 en / 02. 1/1) and bevel the resulting cutting surface (2) to avoid buckling. Turn valve head to approx.01. 1 1 2 2.05.1998 IB002354 1/2 . 4. 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.01. 01.2107 1 Pers.02. Shrink the new seat ring in.06. Grease cylinder cover bottom outside of seat ring in order to prevent damage by spraying of welding beads.01.02.nn.00 h 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Pressure applying device W1 9.07.9222 C Auxiliary materials: Diamond paste Dp 30/10 . with a serated disk (260). 4. 3.05./ 1.08. Cut off the unusable valve cone at the shaft end (Fig.15 µm * Molykote paste “G-Rapid“ * * or a product of equal standard Sequence of operations: 1.03.08. 83 mm (inside diameter of seat ring). 01. Fig.nn. Connect cone and seat ring with welding bead around total circumference (electro welding unit). Drive the valve seat ring out by striking the valve spindle forcefully. the cylinder head to 130 ° C.nn B1. 01.9. Insert the valve cone into the valve seat ring and hold in the shown position.Valve Seat Ring (Inlet/Outlet) Repair / Replace M32 A5. Cool the seat ring to at least -20 ° heat C.00 See also: Spare parts list: Time requirement: 01.

hold the seat ring in this position with the pressure applying device (W1) until the cylinder head has cooled down.08. Fit valve cone. 01 5. W1 1 Fig.08. 6. 2/1) with Molykote paste “G-Rapid“. 2 en / 02. with valve seat grinding machine or valve seat milling machine.g.15 µm and check the contact reflexion (01.03. e.nn). Tighten nut (1) with M=150Nm .Valve Seat Ring (Inlet/Outlet) Repair / Replace M32 A5.2 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. After that.00 4. Slightly grease thread and contact face of nut (Fig. Grind the valve cone lightly with diamond paste Dp 30/10 . Slightly refinish the seat ring.1998 IB002354 2/2 .02. 01.02.05.

01. Note: Do not move spindle (5) by turning locknut (6).09. If the parts do not move freely. rust.Starting Valve Inspection / Checking M32 A5.500 h Attention: When performing work on starting system close main valves on compressed-air bottles. The piston and spindle should move freely when doing so.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. Tighten fixing screws (1). Push down piston (4) and spindle (5) approx.2107 1 Pers. 4./ 0. 7 mm using the handle of the hammer. vent lines.9.05. block start valve. Fit cover (2) with new sealing ring (3). 5 5. 2.00 1500 01. dirt or other soiling between the cover (2) and piston (4). Ensure that the piston und spindle return to the original position quickly and easily.nn B1.2000 IB020953 1/1 . Loosen fixing screws (1) and remove cover (2) with sealing ring (3). 01. Procedure: 1.01. 1 2 3 6 4 3.01. lubricate the piston (4) and guide in the cylinder head with engine oil. bank A all 1.05.05.01. en / 29. Note: If there is moisture. the treatment / dehumidification of the starting air should be checked.

2 Disassembly Loosen fixing screws (Fig./ 0.50 h See also: Spare parts list: Time requirement: 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Remove starting valves.05.2107 1 Pers.nn.01.03 15000 01.nn B1. Loosen locknut (3) while holding valve spindle (4) with spanner. 01. 1/10) and remove cover (1) with sealing ring (2).05.2000 IB020969 1/3 . 01.9. Procedure: 1. regrind every 15. dismantle and if necessary.000 h Tools: Insertion ring for starting valve piston Starting valve reseating tool * not shown W1 * W2 9.Starting Valve Maintenance / Disassembly and reassembly M32 A5. vent lines.01. 1.09. block start valve and engage turning unit.01.9227-001 9.11.06.02.1 1.9224 C Aid: Molykote paste "G-Rapid" ** ** or equivalent product Attention: When performing work on the starting system close main valves on compressed air bottles.05. en / 29.

2 1. sealing rings (11) and valve seat (9). Then tighten adjusting screw another 1/4 turn to set cutting pressure.1 1.6. 2/W2). Lightly oil valve canon.4 1.6. Tighten adjusting screw (20) until a slight resistance is felt. Rework starting valve seat with reseating tool (Fig. 1/5).02.3 01 21 20 W2 2 en / 29. Check step piston (6). Carefully smooth of scored step piston (6) with fine emery cloth. Loosen adjusting screw (20) on reseating tool (W2).5 1.6.6 1.09.05. Carefully clean all parts in gas oil. 1.03 15000 Remove disk (Fig.05.Starting Valve Maintenance / Disassembly and reassembly M32 A5. step piston (6). spring block (8). and valve spindle (4) from cylinder head.3 1. spring (7). Carefully clean valve seat and guide of valve spindle.2000 IB020969 2/3 . 01. Insert reseating tool in valve guide and fix with spanner (21).

6. distribute ring joints evenly around periphery.6 2. Repeat process until valve seat is clean.03 15000 Turn reseating tool evenly and slowly without additional pressure. repeat steps 1.1 to 1. To do so.6. 2. 1.2000 IB020969 3/3 . Maximum size for rework (Fig. Then tighten with a rotation angle of 45°. Press valve spindle onto valve seat and turn through max.6. Repeat process until valve seat is clean. Turn reseating tool evenly and slowly without additional pressure.05. Tighten locknut (3) until a frictional connection between the valve spindle (4) and locknut (3) is obtained.05. apply a thin layer of try-out paste to valve spindle.4 01 1.1 2.09. 90°. 01. Replace sealing ring (2). 3/X).Starting Valve Maintenance / Disassembly and reassembly M32 A5.2 Assembly Lightly rub in Molykote paste "G-Rapid" on step piston.02.6.6. Check using ° M = 50 Nm en / 29. Insert piston using insertion ring (W1). ° If the appearance of the bearing surface is not satisfactory.5.5 1.

1 3. 01.2 3.03.nn). Check valve springs for damage.01.03.01. If a proper sealing cannot be obtained.01.nn). In case of lubeoil leakage. loosen the cylinder head screws and tighten again according to regulation (01.01. cylinder liner and cooling water distributor housing at the inspection hole (1) for combustion gas leaks or cooling water leakage.2 3.4 Check cylinder head externally for leakage.01.nn.00. Observe conformability of valve movement. 3.01.01.11.nn.11. 2.1998 IB002636 1/1 .01. Replace seals if necessary. inspect cylinder head upper side.Cylinder Head Inspection / Checking M32 A5.06.1 2. 01.10. Irregularities can be seen better at low engine revolutions. 2. check retaining screws for tightness.2107 1 Pers.06. In case of leakage at the wedge parts of the media supply.nn. remove cylinder head .clean sealing surfaces and check .replace with new O-rings. if necessary and tighten according to regulation (01.01. Remove cylinder head cover. Check lube oil supply of valve lever and valve lever bearing.05. 01.05. 1 en / 02.9.3 3.nn.07.nn). In the case of leakage. Check function of the valve rotating device (01.01 150 01.02. check the retaining screws of the cylinder head cover for tightness and check profile rubber for damage. 01.11. Check the gasket between the cylinder head.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.nn B1./ 0. 07.

2.02.2000 IB020982 1/1 .01.nn. outlet valve. Clean cooling water inlet ports and cooling water outlet. 7. 01.10. Sequence of operations: The following parts have been removed: Inlet valve. Clean the sealing surface for the injection valve.Cylinder Head Maintenance / Cleaning M32 A5. 6.05.01 15000 01.01.2107 1 Pers.nn B1. especially at the valve webs.nn. en / 29.01. 1). 4.nn. injection valve. starting valve and rocker arm bracket. 01. Wash the cylinder head with a cold cleaner. for cracks. Check underside of cylinder head.05.9.05.07.09.06. 1. 01./ 1.01. Clean the inlet and outlet ports and the cylinder head underside (not the valve seats!) of carbon deposits with a wire brush or scraper. Do not damage seat recess. 01. 5. (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.01.02. Check in and outlet holes of the media supply for free passage. 3.00 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.

nn.Cylinder Head Repair / Reassembly VM32 A5.nn. ~ Safety note: Do not place any parts of the body over pressurized devices. 03.01./ 1. 01.nn.nn B1.01.01. 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.05.01.06.01. en / 30.01.11.04.01.01. 06.06.2107 1 Pers. Use only hydraulic oil as operating medium.2002 IB023653 1/5 .9.05.00 h 01 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: See maintenance sheet 01.51 See also: Spare parts list: Time requirement: 01.

05.Cylinder Head Repair / Reassembly VM32 A5.nn). 01 en / 30. Renew the following O-rings. Clean sealing faces and contact surfaces of cylinder head and liner thoroughly and check for damage. at the cooling water connection to the starting air inlet. 1/1) into cylinder liner collar. Insert new sealing ring (Fig. Upper O-ring on cylinder liner collar (2). at the pushrod sleeve (4).01.51 Sequence of operations: 1. Check and clean sealing surface on exhaust pipe (06.11. at the control air inlet and at the charge air inlet port (5).2002 IB023653 2/5 . 3. on the cylinder head (3).01. 01.01. Turn piston to ignition top dead center. 2.01.

install the round nuts (Fig. 01 5.1 Install hydraulic pulling elements (Fig. Insert pushrods into cylinder head. Align connections for cooling water and starting air vertically in cooling water distributor housing and check completeness.2002 IB023653 3/5 . 01. 3/12) with pin (W9) alternately fingertight. Caution: The indicator max.2 en / 30. take care that the cylinder head is resting firmly on the cylinder liner.01. 4. Failure to do this can cause damage to the hydraulic equipment.51 Note: Coat all O-rings with petroleum jelly or green soap and insert in the grooves without twisting.nn). 6.01. 3/12).01. 2 / W3) connected to backup rings (W5/W7) and threaded bushes (W6/W8) over round nuts (Fig. Mount clamping ring for exhaust pipe and hook in chain links (06.11. Ensure good accessibility of slots (13) Install threaded bushes (W6/W8) on cylinder head bolts (11) finger tight. Tightening of the six (6) cylinder head screws together with the hydraulic tightening device. 6.01. 6. Ensure correct positioning towards rocker arm.05. Carefully place cylinder head onto cooling water distributor housing using cylinder head lifting device (W11) and lifting gear. Align cylinder head.Cylinder Head Repair / Reassembly VM32 A5. Grease screw with high temperature bolt lubricant "Dag S-5080" and tighten by hand (no seal). 3/10) should not project above cover upper limit. Caution: Before using the hydraulic equipment. To do this. stroke (Fig.

6. • reduce pressure by 50 bar.2002 IB023653 4/5 .Cylinder Head Repair / Reassembly VM32 A5. 01. • it should no longer be possible to loosen the round nuts with the pin.4 Connect hydraulic pulling elements (Fig.11.6 Tighten round nuts (Fig.7 Unload hydraulic pulling elements and dismantle. 4/W3) and distributor (W4) to high pressure pump (W1) via high pressure hoses (W2). 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.51 6. otherwise a pulling error could occur. 6.01.3 6. en / 30. 3/12) with pin (W9).5 6.01. 01 Caution: The pressure must remain constant when the pump is not used.05. Make sure parts move easily. Check the firm positioning of the round nuts.

nn) and mount pump compartment paneling. 13. Insert the pushrods into the cylinder head. Tighten clamping ring for exhaust pipe. Make sure the tension pins are properly positioned. 12.05. Venting at cooling water return flow pipe from turbocharger.11.nn).01. The position of the clamping ring is fixed at the lower part by a retaining screw (06.Cylinder Head Repair / Reassembly VM32 A5.2002 IB023653 5/5 . 14. Assemble rocker arm bracket (01. 01. Check sealing of all connections after bringing engine into service. Adjust valve clearance (01.01. 9.01.01. Mount the removed connecting flange of the media supply with new seals.02.51 7. Connect fuel pressure pipe with corresponding injection pump.01.nn). 8.01.01. 10. Mount the removed pressure gauge lines and fill up with cooling water. 11. 01 en / 30.

bearing metal particles.2003 IB020989 1/1 . Remove camshaft cover. detached paint). Visually check screws and nuts.nn). cloths etc. 3.nn. after shutting down the engine. 10 min.00 3750 03.1112 1 Pers. 01.03. pitting or other damage.01. Carry out lubrication oil flow check and check oil delivery at bearing points.2 8.1 7. 4.05. Check seals of all crank case and sealing lids and refit cover.nn B1. 04.01. 9.01. Open crank case cover approx. The remaining tasks are to be carried out after allowing a period of ventilation. corrosion.05.Running Gear / Engine Timing Inspection / Checking M32 A5./ 0. Turn engine and check bearing surfaces of cams and rollers for scoring.nn.10.08. Check cylinder liner surface on engine side. 6.01. 5.01. Check wheel mechanism (04.50 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. Check crankshaft bearings and big end bearings for even and normal temperatures. Check screws of camshaft components and the lower valve mechanism for proper tightness. Sequence of operations: 1. en / 28. Check extent of soiling of the engine room (silt deposits.01.9. Open indicator valve and engage turning gear. Check oil tray and crank case for left-behind tools. 02.08. 7. Check lubricating oil flow for camshaft bearing and valve mechanism.01. 2. 7.01.

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. Depending on the location of the engine. e.9425-300 Note: Crank web deflection is the change in distance beween a web pair during one rotation of the crankshaft (Fig.: • after the collision of a ship • signs of the foundation subsiding • bearing or crankshaft damage • before and after docking of a ship.02. the rigidness of the foundation and the ship. It is therefore suggested to collect the measurement sheets extra so that the chronological allocation of the values and changes are visible.01. B1. In the event of unpermissible changes.1110 2 Pers.1998 IB002366 1/4 .00 See also: Spare parts list: Time requirement: B1. 02.03.02.05. the installation must be realigned and the respective main bearings inspected. a) Initial position b) Negative deflection c) Positive deflection en / 02.2520.05.g.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.Crank Web Deflection Inspection / Measuring M32 A5./ 1. 1). Measurements should therefore be carried out when the engine is warm.9.9. Tools: Crank web measuring device W1 1. different values are given in comparison with loaded and unloaded condition of the ship as well as warm or cold engine.

Watch the gauge continuously and read the values at the measuring points 2 .00 Sequence of operations: 1.TDC) (crank pin . 02. 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. 3. record this value. so that the crank pin turns in the direction of the exhaust side and the gauge towards the camshaft side. 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 . Turn the crankshaft.05. the purpose of the latter is only to indicate the space in which to use the measuring tips.1998 IB002366 2/4 .exhaust side) (crank pin . then at the stipulated measuring point. 4. If a higher value is read before or after the measuring point.02.02. Fig. 2/1st measuring point). Set the pointer to the scale value 20 on the measuring gauge: 1st measuring point (initial position).01. Where punch holes are found. 02 2.BDC camshaft side) en / 02.Crank Web Deflection Inspection / Measuring M32 A5.5 .camshaft side) (crankshaft pin . do not place the measuring tips on the centring marks.

02.0.Crank Web Deflection Inspection / Measuring M32 A5. 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 + 0.06 / .13 mm + 0.00 Note: Crank web deflection is primarily a criterion for the alignment of the engine with the shafting.01.0.04 / .05.02.09 mm + 0. The values given below must be observed if it is impossible to obtain the permissible limits for the plant from MaK. Values from a cold engine are of secondary importance.0.06 / . Only the values measured on an engine at operating temperature can be used for the assessment. This means that the permissible deflection is determined by the engine load.04 mm en / 02. A high load permits less deflection than a low one. 02. Heavy crank web deflection imposes additional loads on crankshaft and main bearings.1998 IB002366 3/4 .

1998 IB002366 4/4 .02.05. 02.01.00 02 en / 02.02.Crank Web Deflection Inspection / Measuring M32 A5.

01.07.nn.9.05.02. 02.05. solid foreign matters and water are the cause of 85 % of all cases of bearing damage.. B1. 02. Attention: When replacing the bearings in the drive unit.03. 02.05 and A1.09.05.Bearing Shells and Bearing Bushes Inspection / Evaluate M32 A5. CuPb.06 for specifications of the lubricating oil temperature and pressure See A4.08.08.03.05.nn.01.7 to 1. 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.03.08.00 h 02 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Note: Contaminated oil..02. AlSn.nn for recommendations of lubricating oil treatment See A4.Sn) or aluminium/tin layer (Fig.01 See also: Spare parts list: Time requirement: 02.01.1998 IB002410 1/2 . 1.04.nn.nn B1. They consist of a steel back (layer strength up to 10 mm thickness) and a running-in layer of approx.05.05.05.03. the bearings may be more rapidly worn so that they must be renewed sooner./ 0.nn for renewal/supplement of the lubricating oil (additives) When the engine is frequently started and stopped (mixed friction). 1..) en / 02. Dirt is the enemy to all bearings! To avoid restrictions in the service life consider the following: • • • • See A1.1110 0 Pers.9.nn for recommendations of the lubricating oil brand (viscosity classification) See A4.2601.. 0.1 mm thickness made of either: lead bronze (Fig. 02.

02.Flash 3 µm Lead bronze or AlSn.05. Shell thickness up to 10 mm en / 02.exceeding of a possibly specified limit value or .heavy scratches.01 The corrosion protection flash of the bearing (approx. 02 Layer configuration of two-metal bearings Lead bronze bearing / AlSn.03.. 3 µm) is already passed after a short running time.1. bearing Corrosion protection flash Sn . .according to the specified evaluation criteria (02.03. only for AlSn bearings).02.nn.7 . Replacement of the bearing only after .Bearing Shells and Bearing Bushes Inspection / Evaluate M32 A5. layer 0.1 mm Steel back Steel C.03.1998 IB002410 2/2 ..07..

nn B1.05./ 0. 02.05. If the depth of these scratches is neither measurable nor feelable. Fig.03.01 See also: Spare parts list: Time requirement: 02.05. 1 The contact pattern is evenly developed over the total bearing surface. 02. The scratches in running direction are caused by small foreign matter particles in the lubricating oil.Bearing Shells Inspection / Evaluate M32 A5. Assessment catalog: Criteria for reuse Fig. 3 The contact pattern is evenly developed over the total bearing surface. As experience shows.nn.9.nn. Attention: When replacing the bearings in the drive unit.02.05. depth and a big extent of the scratches impede the development of a lubricating film. both bearing shells are to be replaced.1110 0 Pers.07. 02. This bearing shell may be reused. The contact pattern is evenly developed over the total bearing surface.05. the bearing shells must generally be replaced in pairs (top and lower bearing shell)! en / 02.03.03. This bearing shell may be reused.01. the bearing shell may be reused. If the number. the scratch caused by foreign matter in the lubricating oil has negligible influence on the reliability of the plain bearing.1998 IB002418 1/4 .03. 2 Fig.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. caused by mechanical wear and overload of the bearing shells.

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

02.07.05. 02.1998 IB002418 3/4 .03.Bearing Shells Inspection / Evaluate M32 A5.01 02 en / 02.

05.07.03.Bearing Shells Inspection / Evaluate M32 A5.02. 02.01 02 en / 02.1998 IB002418 4/4 .

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. 02.06.2601 2 Pers.03.9228 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. 02.9.Big-end bearings Inspection / Disassembly VM32 A5.nn.9213 C 0.50 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 15.9205 B 0.nn B1.52 30000.05.9204 D 0.04.9203-110 0. 02. ~ Safety note: Do not position any parts of the body over pressurized devices! Secure the engine against unintentional starting! en / 25.9203-209 0.03.02.05./ 0.000 h 30.9203-004 9.9228 G W9 9.2001 IB023261 1/6 .nn.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.01.03.9203-101 0.01.06. 15000 02.07. Store the hydraulic device protected against corrosion.

2001 IB023261 2/6 . 02. The ring surface (a) of the threaded sleeve is then flush with the upper surface (b) of the hydraulic tension element. Turn the con-rod. bearing shells.Big-end bearings Inspection / Disassembly VM32 A5. en / 25. 02 Sequence of operations: 1.2 Loosen the round nuts (2) by means of the hydraulic device. The round nuts (fig.05.52 30000. 3. Place the hydraulic tension elements (W3) with the support rings (W4) above the round nuts (2).1 3.01. 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.04. Remove piston (02.01.nn). Pay attention to good accessibility of the slits. Caution: After disassembly of the piston the engine may be cranked as described below with installed con-rod holder! 2. Screw the threaded sleeve (W5) firmly onto the con-rod bolt (1) and then loosen by 3/4 of a rotation. 3. 1/2) must be freely accessible.06. New parts must be marked accordingly.06. 15000 Note: The bearing cover.

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.2001 IB023261 3/6 .01. 3.Big-end bearings Inspection / Disassembly VM32 A5. en / 25.3 02 Attention: The pin (fig.05.06. 5. 2/W3) and distributor (W7) to the high pressure pump (W1) via the high pressure hoses (W2). 02. 15000 Connect the hydraulic tension elements (fig. Turn the round nuts back by at least 8 holes. Close the valve (fig. Loosen the round nuts (fig. 1/2) with the pin (W6).52 30000. maximum stroke indicator) must not be driven out of the hydraulic tension element (W3) when extending the con-rod bolt (1)! 4. 1/9.04.

3/25) with spacers (26) and suspension (20). A further pressure increase could cause the round nut to clamp as a result of the con-rod bolt thread expanding! 6. en / 25. 9.04.Big-end bearings Inspection / Disassembly VM32 A5. The tension elements are relieved.52 30000. W4. Turn the con-rod (fig. Mount the suspension (fig.2001 IB023261 4/6 .05. Open the valve (fig. then the con-rod bolts can be pretensioned at a higher pressure of p = 50 bar. Wait for the pressure to drop completely and then dismantle the hydraulic devices (W3. 8.06. The mounting/ extraction device for the big-end bearing (W8) can also be mounted mirror-inverted. W5 and W7). 7. 15000 Note: If it is not possible to loosen the round nuts by means of the pin. 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. 02.01. 2/6)on the high pressure pump (W1).

Turn the upper big-end shell (13) by 180° on the crank pin and pull it off. Stopper (Fig. perform steps 1-11 to do so. 17. 15000 Insert the slide rail (fig. 4/28) in upper conrod bolt bore.04. Unscrew the round nuts (2) and pull off the big-end bearing cover (11) approx. 20. 13. Pull out con-rod bearing cover (11) with bearing shell and place on a suitable surface. Mount the stopper (24) and screw the con-rod to the stopper.03.Big-end bearings Inspection / Disassembly VM32 A5. 10.nn). 18.05. 12. Remove the lower big-end shell (12) from the crank pin. 02. Disassembly of con-rod: 20. if required. Dismantle the con-rod clamping device (W9). 16.3 20. Check the condition of the big-end shells (02. 160 mm from the bearing. raise and suspend in suspension (20). 11. 02 Note: The con-rod bolts (1) are not removed for disassembling the bearing shells. Remove round nuts (2) and con-rod bolts. Align the slide rail (22) with the clamp bolts (21). Disassemble con-rod clamping device (W9).52 30000. 14. 3/22) via clamp bolts (21) in the crankcase.5 28 11 4 en / 25.01. 60 mm.2 20. Insert guide tube (Fig.06. Loosen the lateral stopper fixing device (23) in such a way that the stopper can glide in the slots. 15.03. Pull the con-rod (10) off the bearing by approx.07. 20.nn and 02. It must lie flush on the con-rod (10) and the bigend bearing cover (11).1 Disassemble con-rod (10) only.03. 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.4 20. 19.2001 IB023261 5/6 .

15000 Relocate guide tube Fig.6 20.01.2001 IB023261 6/6 .7 20. 5/28).04. lift con-rod and place on suitable surface.05.52 30000.8 20. Sling con-rod to crane and remove guide tube. 20.Big-end bearings Inspection / Disassembly VM32 A5. 02. Stabilize con-rod with guide tube and pull out from engine on guiding rail.06. Disassemble stopper (24).9 02 28 24 5 en / 25.

3 1. New parts must be marked accordingly.06.2. Insert big-end bolts (1) with washer (5) and assemble stopper (24) on connecting rod (10). 02.2601 2 Pers.2001 IB023265 1/5 .Big-end bearings Inspection / Reassembly VM32 A5.1 Reassembly of the bearing shells Clean and lubricate the crank pin. Assemble washer (5) with chamfer pointing towards bottom end of connecting rod. Push the con-rod to approx. bearing shells.01. Sequence of operations: 1.nn B1.4 1.03.51 See also: Spare parts list: Time requirement: 02.2.2 1.nn.2 1.03. 2/10) to a crane by means of a sling.03. 1/X) at different positions to fix them in the con-rod/big-end bearing cover. attach the disassembled con-rod (fig.1 1.01. 02.W9 refer to 02. 1.2.05. The bearing shells must be mounted with the locating projections towards the corresponding control end (cylinder row A or B)! en / 25. 60 mm in front of the crank pin. Lubricate the bearing shells on the inside and outside. 02.02. 1.05.04.nn.04.3 Attention: The bearing shells each have a locating projection (fig. 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.nn Note: The bearing cover.50 h 02 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Tools W1 . 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).2.9./ 0.04.07. If necessary.02. Do not remove the sling! Preassemble the lateral stopper fixing device (23). Do not tighten it.

Carefully push the big-end bearing cover (fig. Attention: Pay attention that the bearing shell halves on the exhaust side and control side align axially.06. The locating projection on the bearing shell must be positioned exactly in the recess on the con-rod.04. Align it and press it into the base bore. without holes) on the crank pin and turn it under the con-rod by 180°.8 Insert the lower bearing shell (fig. Tighten the lateral stopper fixing devices (fig. Remove the sling from the con-rod.Big-end bearings Inspection / Reassembly VM32 A5. 02 1.4 1. bigend bearing cover).2001 IB023265 2/5 .6 Mount the con-rod clamping devices (W9). con-rod) and dowel pin (3. 2/4.05. They must be located at the corresponding control end (cylinder row A or B)! 1. There must be no offset between the bearing shell halves in an axial direction.7 1. 02. 2/11) against the bearing shell and the foot of the con-rod. The projection on the bearing shell must be positioned exactly in the recess on the bigend bearing cover.02.51 1. 1/b) paying attention to the locating projection (x). 2/23). Carefully press the con-rod against the bearing shell. Attention: Pay attention to the allocation of the locating hole (fig.5 Place the upper bearing shell (a. en / 25.

Check the con-rod shells on the exhaust side for any offset in an axial direction.9 1.51 1.06. 22) with suspensions (25.04. 2/W8). Assemble round nuts (fig. 3/2) by means of the hydraulic device.05. slide rails (27. en / 25. 20) and stopper (24)]. Eliminate any offset by aligning the bearing shells.11 2. see position illustrated (fig.10 1.1 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. Tighten the round nuts (fig. 02. Dismantle the mounting / extraction device for the big-end bearing [(fig. 02 ~ 2. Both round nuts (2) must be freely accessible.2001 IB023265 3/5 . 15-30°.02. 3/2) and fasten finger-tight.Big-end bearings Inspection / Reassembly VM32 A5. 3).

02.06. Connect both hydraulic tension elements (W3) and the distributor (W7) to the high-pressure pump (W1) via high-pressure hoses (W2).5 Connect the hydraulic tension element (fig. Pay attention to easy action.6 2. The tension elements are relieved. Attention: The pin (fig.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.9 Close the valve (fig. 4/2) with the pin (W6).02. 02 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! 2.51 2.Big-end bearings Inspection / Reassembly VM32 A5.2 2.7 2.8 Firmly tighten the round nut (fig. Open the valve (fig. 5/W3) at pin side (camshaft side) to the high-pressure pump (W1) via high-pressure hose (W2).04. Screw the threaded sleeves (W5) hand-tight onto the con-rod bolts (1).4 2. 4/9). 5/6) on the high pressure pump (W1) and extend both con-rod bolts IB023265 4/5 en / 25. Pay attention to good accessibility to the slits (8). 5/6) of the high pressure pump (W1). 4/W3) together with the support rings (W4) above the round nuts (2). 2.05.2001 .

nn). Check firm seating on the round nuts 02 • • 2.01.04. Wait until the pressure has dropped completely and then remove the hydraulic devices (W3. 5/6) of the high pressure pump (W1). Open the valve (fig.2001 IB023265 5/5 .10 2.12 Reduce the pressure by 50 bar. 4/2) with the pin (W6).11 Firmly tighten the round nuts (fig. W5 and W7).Big-end bearings Inspection / Reassembly VM32 A5.06. Mount the piston (02. The tension elements are relieved.51 simultaneously and gradually at a pressure of p = 1200 bar + 25 bar.10. W4. It must no longer be possible to loosen the round nuts with the pin. 02. 2.13 3.02.05. en / 25. 2. Pay attention to easy action.

05. 15000 02.9075-003 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.nn.1110 2 Pers.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 15.9204 D 0.01.9203-107 0.9203-119 0.07. 02.06.9205 B 0.Crankshaft bearing Inspection / Disassembly VM32 A5.05.03.nn B1.000 h b) exchange all crankshaft bearings every 30. en / 05.05. 02.53 30000.000 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 0.03.03.9203-110 0.9203-209 0. Store the hydraulic device protected against corrosion./ 2.9214 B Mounting / extraction device for crankshaft bearing.9.2000 IB021847 1/9 .9203-101 0.9213 M 0.03.9203-004 9.9213 C 0. consisting of: Mechanism W11 Carrier W12 Mounting device W13 * Feeler gauge * for assembly only ** not illustrated W14** 1.

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. Unscrew the protective caps (8).06.1 Dismantle the crankshaft bearing.3 W3 W4 1. Use the hydraulic device to loosen the round nuts (7) on the lateral waisted studs (6). The ring surface (a) of the threaded sleeve must then be flush with the upper surface (b) of the hydraulic tension element (W4). 2/W4) with the support rings (W6) above the round nuts (7). 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. The retaining pin of the lower bearing shell points towards cylinder row B.1 1. 23 22 1. New parts must be marked accordingly. The round nuts (fig.01.3 7 a W6 6 W8 10 b 2 en / 05.53 30000.05. 1.2 1 1. The crankshaft bearings must also be removed.2 11 1. 02.2000 IB021847 2/9 .3. Place the hydraulic tension elements (fig.3. Pay attention to good accessibility to the slits (11).Crankshaft bearing Inspection / Disassembly VM32 A5. 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. Screw the threaded sleeves (W8) firmly onto the waisted studs (6) and then slakken again by half a rotation. 1/23) of the crankshaft bearing bolts (22) must be freely accessible.3.05.

01. 1.5 Close the valve (fig. 2/7) with the pin (W3).4 02 Attention: The pin (fig. 1.3.2000 IB021847 3/9 . en / 05.06. 15000 Connect the hydraulic tension element (fig.3. 3/13) on the high pressure pump (W1) and extend both waisted studs simultaneously and gradually at a hydraulic pressure of p = 680 bar.6 Loosen the round nuts (fig.05.53 30000. 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. 2/10. 02.05.Crankshaft bearing Inspection / Disassembly VM32 A5. 3/W4) and the distributor (W10) to the high pressure pump (W1) via high pressure hoses (W2).3. Turn the round nuts back by at least 8 holes.

02. The tension elements are relieved.2000 .10 1.3.3. 2/W8). then the waisted studs can be pretensioned at higher pressure of p = 50 bar.1 to 1.8. 1/6) and unscrew them completely.8 1.3. Remove the threaded sleeves (fig.01. 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! 1.4.53 30000. 15000 Note: If it is not possible to loosen the round nuts with the pin. 02 W7 3 20* T W5 15* 19* W9 W11 T 16 * = W11 19* 24* 4 1. hydraulic tension elements (W4) and support rings (W6).9 1.3. Only loosen the round nuts (7) on the lateral waisted studs (6) on the adjacent crankshaft bearing by means of the hydraulic device. Wait for the pressure to drop completely.3.7 1.06.Crankshaft bearing Inspection / Disassembly VM32 A5.05.3.4 Open the valve (fig. 4/W11). Refer to 1. 3/13) on the high pressure pump (W1).1 Move the mechanism to the lowest position (stopper) by means of the IB021847 4/9 en / 05. Insert the mechanism (fig. Loosen the waisted studs (fig.05.

3 U 3 U 23 22 19 21 1.4. Connect the hydraulic tension elements (fig.5. Push the mechanism under the crankshaft bearing and align it. 4/15).2000 IB021847 5/9 . 1. 02. 4/W5) together with the support rings (W7) flush on the bearing block (19) and pull outwards up to the stoppers (24). Place the hydraulic tension elements (fig. 15000 threaded rod (fig. Drive the mechanism (W11) upwards until the support rings (W7) make contact with the crankshaft bearing cover (3).05. The ring surface (a) on the threaded sleeve is then flush with the upper surface (b) of the hydraulic tension element (W5).05.4 en / 05.5 20 1. The holder (fig. 6/27). 1.Crankshaft bearing Inspection / Disassembly VM32 A5.06. 7/W5) and the distributor (W10) to the high pressure pump (W1) via the high pressure hoses (W2). Lift the mechanism (W11) on the respective crankshaft bearing into the cylinder crankcase and place it in the oil sump.5. Remount the table on the bearing block (19).2 Disassemble the table (20).5. Pay attention to good accessibility to the slits (fig.2 W11 16 Attention: When driving up.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.4.1 1. pay attention that the round nuts glide properly into the support rings! Align the table accordingly if necessary! 17 5 1. 02 1.5. 5/17) engages in the reinforcement (16).01.53 30000. Loosen the round nuts (23) on the crankshaft bolts by means of the hydraulic device.

6 Loosen the round nuts (fig. 02.Crankshaft bearing Inspection / Disassembly VM32 A5. 6/26.01. 15000 Attention: The pin (fig.2000 IB021847 6/9 .53 30000.06.5. 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. 7/30) on the high pressure pump (W1) and extend both crankshaft bearing bolts simultaneously and gradually at a pressure of p = 1025 bar. Turn the round nuts back by at least 8 holes. 6/23) with the pin (W3).5 Close the valve (fig.05.05. 1.5. 22 26 b a 6 W9 W5 W2 W2 W10 30 W1 7 en / 05.

8 Open the valve (fig. 02. 15000 Note: If it is not possible to loosen the round nuts with the pin.03. 7/30) on the high pressure pump (W1). The tension elements are relieved.nn. Measure the gap.12 W11 8 en / 05. Refer to operation sequence 2.10 Remove the lower bearing shell.11 Turn the upper bearing shell towards the left-hand side of the engine (cylinder row A) and remove it. Wait for the pressure to drop completely. 02 Note: If the crankshaft bearing cover does not come off.01.nn and 02. Refer to 02. 1.1 1. then the waisted studs can be pretensioned at higher pressure of p = 50 bar. Attention: Only turn when the mechanism (W11) has been driven down to the stopper! W12 1. then screw the table (fig. Remove the support rings and the hydraulic tension elements.9 1.6. Drive the mechanism onto the crankshaft bearing cover and remove the round nuts.6 1. Drive the mechanism down to the stopper. If the pressure is increased even further.03.7 1.05.03. 8/W12) down to the stopper in the oil bore of the crankshaft. 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.Crankshaft bearing Inspection / Disassembly VM32 A5. 1.53 30000. Push the carrier (fig.6. then dismantle the threaded sleeves (W9). then there is a risk of the round nuts jamming due to the bolt thread expanding! 1.06.07.2 1.05. Drive the mechanism with the crankshaft bearing cover and lower bearing shell down to the stopper. Assess the bearing shells.2000 IB021847 7/9 .

02.10.14 The bearing shells must be replaced if the wear is > 0. Wear = dimension when new .Crankshaft bearing Inspection / Disassembly VM32 A5. K A K S 6 10 23 en / 05. Remove the waisted studs (fig.05 mm. 2.1 Measure gap.actual dim. 10/6) of the respective crankshaft bearing on both sides of the engine (cylinder rows A and B). Refer to operation sequence 1. 2. then the adjacent bearings should also be inspected.87.2000 IB021847 8/9 .0. New dimension = 8. 1.53 30000.01.05.3.05. 15000 Check the wall thickness wear at measuring points in the main strain zone (fig.13 02 1. 9/X) by means of a micrometer gauge.3 up to an including 1.015 mm Attention: If the inspection results in the bearing shells having to be changed.06.

3 en / 05.80 2. Drive the mechanism (W10) downwards.05. K = KA + KS Gap "K" mm 1.1.25 Service limit value mm 0.2 2.1. 10/23) hydraulically according to operation sequence 1. 02. Refer to 1.2000 IB021847 9/9 .01.53 30000. 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.06.6. Relieve the hydraulic extraction device and remove it.1 02 2.00 . 15000 Loosen both round nuts (fig. Then tighten the round nuts evenly and alternately by hand until the surfaces of the bearing shells just make contact.4 and 1.05.Crankshaft bearing Inspection / Disassembly VM32 A5.5.1.1.

01.05.01.Crankshaft thrust bearings/crankshaft be Maintenance / Reassembly VM32 A5.1110 2 Pers. ~ 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.50 See also: Spare parts list: Time requirement: 02.nn 100 . Damaged crankshaft bearing bolts and round nuts must be replaced together.05.02. Refer to maintenance sheet 02.03.2008 IB003361 1/8 . 02. The locking pin of the lower bearing shell points towards cylinder row B. Store the hydraulic device set protected against corrosion.00 h 02 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Tools W1 .05.W14.05.400 Nm torque wrench 1/2 Changeover ratchet * not illustrated W15 * W16 * 1.nn B1. New parts must be marked accordingly. en / 26.9454-400 1.9459-033 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.9.05./ 1.03.

1/W12) in the oil bore pushing it down to the stopper. Reinsert the upper check plate segments if they have been removed (only in the case of the crankshaft thrust bearing).03. 1. Drive the mechanism (W11) down again and remove the carrier (W12) as well as the mounting device (W13). Pay attention that the bearing shell is centred correctly.2008 IB003361 2/8 . Slowly drive the mechanism (W11) up until the mounting device (W13) lies on the bearing block (x). Fit bearing shells. W12 1 W11 1.Crankshaft thrust bearings/crankshaft be Maintenance / Reassembly VM32 A5. Tighten the round nuts (23) finger-tight.2 1.4 X 1. Dry the back of the bearing and turn the bearing shell as far as possible into the bearing. Drive the mechanism (W11) down 1. 02. 02 Note: The upper bearing shell has a lubrication groove and oil bores.7 Drive up the mechanism (W11) and remove the round nuts (23).05.3 Insert the carrier (fig. 1.6 Turn in the upper bearing shell. The bearing shells are marked on the right-hand side of the engine (cylinder row B). The mounting device (W13) is clamped. The locating nose must glide into the guide groove in the bearing block. Place the mounting device (W13) in the crankshaft bearing cover. Attention: The locating nose on the upper bearing shell points towards the left-hand side of the engine (cylinder row A). Pay attention to the lateral stopper.5 W13 Attention: Only turn the crankshaft when the mechanism (W11) has been driven right down to the stopper! 23 1.50 Sequence of operations: 1.05.02.1 Lubricate the running surface of the upper crankshaft bearing shell. en / 26.

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

en / 26.03.2008

IB003361

3/8

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

en / 26.03.2008

IB003361

4/8

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.

en / 26.03.2008

IB003361

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)!

en / 26.03.2008

IB003361

6/8

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

en / 26.03.2008

IB003361

7/8

Crankshaft thrust bearings/crankshaft be Maintenance / Reassembly
VM32

A5.05. 02.05.02.50

02

W5 W2 W2

W10

30 W1
8

en / 26.03.2008

IB003361

8/8

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

Place the hydraulic tension elements (fig. 2.05. 2/23) on the crankshaft bearing bolts (22) must be freely accessible.06.51 30000 Attention: Make sure the check plates are marked before disassembly for inspection purposes to avoid the parts being mixed up by mistake.2 23 22 2 2.3 W3 W4 11 Attention: The pin (fig. 02.05.1 2. 3/W4) with the support rings (W6) above the round nuts (7).05.1 Disassemble the crankshaft thrust bearing.2. 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).Crankshaft thrust bearing Inspection / Disassembly VM32 A5. 5 Turn the crankshaft to a favourable position. 4/W4) and the distributor (W10) to the high pressure pump (W1) via high pressure hoses (W2). Then remount the parts without delay! 02 2.2.2.2000 IB021892 3/9 . 2. 3/10. 6 7 8 2.2. Pay attention to good accessibility to the slits (11). The round nuts (fig. Use the hydraulic device to loosen the round nuts (7) on the lateral waisted studs (6): Unscrew the protective caps (8).2 2. 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 / 05.4 Connect the hydraulic tension elements (fig.

4/13) on the high pressure pump (W1).Crankshaft thrust bearing Inspection / Disassembly VM32 A5. 4/13) on the high pressure pump (W1) and extend both waisted studs simultaneously and gradually at a hydraulic pressure p = 680 bar.05.2000 IB021892 4/9 . Note: If it is not possible to loosen the round nuts with the pin. Turn the round nuts back by at least 8 holes. 02. 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! 2.7 Open the valve (fig. W2 W2 W10 13 4 W1 en / 05.06. 3/7) with the pin (W3).5 02 2.05.2. 2. The tension elements are relieved.6 Loosen the round nuts (fig.51 30000 Close the valve (fig.2.2. then the waisted studs can be pretensioned at higher pressure of p = 50 bar.05.

3 2.2000 IB021892 5/9 .3. The holder (fig. 2.3. Inserting the mechanism (fig. 02. hydraulic tension elements (W4) and support rings (W6).2.8 2.1 2.8. 2/6) and unscrew them completely.05.10 2. 6/17) engages in the reinforcement (16).2. 3/W8).05. 2. Push the mechanism under the crankshaft thrust bearing and align it. Loosen the waisted studs (fig.51 30000 Wait for the pressure to drop completely.2. Refer to 2.06.2. Disassemble the table (20).05. Remount the table on the bearing block (19).1 to 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.3.3 W7 3 20* T W5 15* 19* W9 W11 T 16 * = W11 19* 24* 5 en / 05.2. 5/W11): Move the mechanism to the lowest position (stopper) by means of the threaded rod (15). Lift the mechanism (W11) on the crankshaft thrust bearing into the cylinder crankcase and place it in the oil sump. Remove the threaded sleeves (fig.Crankshaft thrust bearing Inspection / Disassembly VM32 A5.9 02 Note: Replace the O-ring (5) during assembly! 2.

7/27).05.06. 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.Crankshaft thrust bearing Inspection / Disassembly VM32 A5. 17 6 23 2. 5/W5) together with the support rings (W7) flush on the bearing block (19) and pull outwards up to the stoppers (24).2 Attention: When driving up. Pay attention to good accessibility to the slits (fig. Connect the hydraulic tension elements (fig.51 30000 Loosen the round nuts (23) on the crankshaft bolts by means of the hydraulic device.2000 IB021892 6/9 .1 U 23 22 19 21 20 2.05.4.4. 8/W5) and the distributor (W10) to the high pressure pump (W1) via the high pressure hoses (W2). pay attention that the round nuts glide properly into the support rings! Align the table accordingly if necessary! W11 16 2. Drive the mechanism (W11) upwards until the support rings (W7) make contact with the crankshaft bearing cover (3).4. 02. 2.4 27 W7 W3 Attention: The pin (fig.4 U 3 02 2. Place the hydraulic tension elements (fig.4.3 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. The ring surface (a) on the threaded sleeve is then flush with the upper surface (b) of the hydraulic tension element (W5).05. 7/26.

5 Open the valve (fig. The tension elements are relieved.51 30000 Close the valve (fig. 8/30) on the high pressure pump (W1). then the waisted studs can be pretensioned at higher pressure of p = 50 bar If the pressure is increased even further.4.05.Crankshaft thrust bearing Inspection / Disassembly VM32 A5. 02. Note: If it is not possible to loosen the round nuts with the pin. W5 W2 W2 W10 30 W1 8 en / 05. 7/23) with the pin (W3).6 Loosen the round nuts (fig.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.06.5 02 2.2000 IB021892 7/9 .4. then there is a risk of the round nuts jamming due to the bolt thread expanding! 2. Turn the round nuts back by at least 8 holes. 2.05.

02.05 mm.1 2. then dismantle the threaded sleeves (fig.05.0. Drive the mechanism onto the crankshaft bearing cover and remove the round nuts. 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 2.51 30000 Wait for the pressure to drop completely.07. Refer to operation sequence 3. Push the carrier (fig. Refer to operation sequence 1.10 Turn the upper bearing shell towards the left-hand side of the engine (cylinder row A) and remove it.actual dim.8 2.05.2000 IB021892 8/9 . 10/x) by means of a micrometer gauge. Drive the mechanism with the crankshaft bearing cover and lower bearing shell down to the stopper.2 2. 2. 2. 1/1) and only replace them if excessive axial play has been discerned. then screw the table (fig.Crankshaft thrust bearing Inspection / Disassembly VM32 A5. Refer to 02.87.05.nn and 02.015 mm en / 05. Dimension when new = 8. 7/W9).nn.03.5. Only remove the upper check plate segments if a replacement is to be made. Measure the gap. Wear = dimension when new . Remove both lower check plate segments (fig.12 W11 2.13 The bearing shells must be replaced if the wear is > 0.03.5.6 2. Remove the support rings and the hydraulic tension elements. Measure the wall thickness at measuring points in the main strain zone (fig. Drive the mechanism down to the stopper. Assess the bearing shells.11 2.9 Remove the lower bearing shell.06.7 02 Note: If the crankshaft bearing cover does not come off.03. 9 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.

4.1.1 Measure gap.10. Loosen the round nuts further but do not move them. 02 3.2000 IB021892 9/9 .05.2 3. K A K S 6 11 23 3.1 Loosen both round nuts (23) hydraulically according to operation sequence 2. 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.25 Service limit value mm 0.3 and 2. 3.05. Refer to 2.51 30000 Attention: If the inspection results in the bearing shells having to be changed.Crankshaft thrust bearing Inspection / Disassembly VM32 A5. K = KA + KS Gap "K" mm 1. Then tighten the round nuts evenly and alternately by hand until the surfaces of the bearing shells just make contact.5. then the adjacent bearings should also be inspected. 11/6) of the crankshaft thrust bearing on both sides of the engine (cylinder rows A and B).80 3. 02.05.3 en / 05.1.2 up to and including 2. Relieve the hydraulic extraction device and remove it.06.1.1. Drive the mechanism (W11) downwards. Refer to operation sequence 2.00 .2. Remove the waisted studs (fig.

01.05.04. 1/3) from loosening while the cylinder head is lifted or during turning.30 h 02 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Assembly./ 0.9217 B 9.9223-004 9.06.9223-001 9. 02.9223 B 9. 02. consisting of: Spacer blocks (2x) Crosspieces (2x) Lever (assembly/disassembly rig.1 W1.9228 F 9.nn.9495-036 9.nn.53 See also: Spare parts list: Time requirement: 01.11. the cylinder liner must be held in place with the cylinder liner retainer (W4) at all times.Piston Maintenance / Disassembly VM32 A5.9216 H Note: In order to prevent the cylinder liner (Fig.2 W2 W3 W4 W5 W6 W7 W8 W9 W10 9.01.nn B1. 03.50. en / 27. disassembly rig. 02. piston.nn.05. 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 W1.06.02.9.9216-001 9.07.2601 1 Pers.9454-400 1.01.9223-003 1.2000 IB022760 1/4 .01.05.

06.nn).53 Procedure: 1. 3.Piston Maintenance / Disassembly VM32 A5. 8. 1/1. Bolt the crosspiece (Fig. 10. 20° before TDC. 3/W1. Attach the crane to the lever (W2) and bring the piston to BDC. 11. 9. 2/4). 12. Turn the upper piston edge to just below the gauging ring (Fig.2000 IB022760 2/4 . 5. Remove the disassembly rig (W10). Clean carbon deposits from the area above TDC for the 1st piston ring up to the gauging ring. 7.01. Press out and remove the gauging ring by turning the engine to raise the piston.11. 11 mm deep) in the piston crown. remove the crankcase cover for the respective cylinder on both sides and remove the cylinder head (01. Do not damage the cylinder liner surface. Insert disassembly rig (W10) so that the recess is inside the gauging ring.05. Note: The crane and lever must remain connected! en / 27. 02.01. Tighten the disassembly rig slightly by turning the spindle nut.1) into the crosspiece and mount the lever (W2) with the extension. 4. Open the indicator valves. 6.06. Turn the piston to TDC and rethread the threaded holes (Fig. M12.2) to the piston crown. Turn crank journal to the control side to ca. 02 2. Bolt the spacer blocks (W1.

1 13.11.06. Use the additional extension (W9) on the inside of the V. Secure the wrench above the holder with set collars. 02 en / 27. 13. Mount the piston rod clamping ring (W3) on the counterweight to secure the piston rod (22).Piston Maintenance / Disassembly VM32 A5. 4/W8) to the piston rod cap on both sides with the holder. 02.2 13. Place the flexible head wrench on the uniform strength bolts (20).53 13.2000 IB022760 3/4 .01.05.3 Split the connecting rod shank. Bolt the flexible head wrench (Fig.

01. 15. moving the crane as required. 16. Pull the piston (4) carefully.nn).01. 02.4 13.5 14. Note: Remove the connecting rod eye (Fig.Piston Maintenance / Disassembly VM32 A5. Place the piston on a suitable surface. Measure the wear of the cylinder liner (03. en / 27.06. Remove the uniform strength bolts (20) with the segments (21).03. 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.2000 IB022760 4/4 .53 Note: The engine may not be turned with the piston rod clamping rig (23) in place.05.11. Place the holding device (Fig. 02 13. 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). 17. 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.

nn). Carefully turn piston and place on suitable base.05. 02. Disassembly of piston crown Attach lifting gear for piston (W1.03.01.2601 1 Pers.2 Turn piston. 1.9.nn B1.9223-001 1.07.08.90 Nm * not available as figure W1 W2 * 9.06. connecting rod shank division) to crane.06.nn) and evaluate (02.04.nn.05. Mount second lifting gear for piston (W1) to connecting rod boss (1) and attach to second crane.08.01.nn).02.01.Piston Crown Maintenance / Replace M32 A5.3 2.02. remove piston pin (2) (02./ 0.70 h 02 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Lifting gear for pistons (2x) Torque wrench 20 . 1/W1). 02.9454-020 Auxiliary material: Molykote paste "G-n plus" ** ** or a product of equal standard Sequence of operations: 1.2 en / 18.1 2.2006 IB025305 1/3 .01.nn.1 1. 1.03. 2. Measure small-end bearing (3) (02. 02.01.04 See also: Spare parts list: Time requirement: 02.09. Attach crane to lifting gear for piston (Fig. lift piston.

2006 IB025305 2/3 . Determine length projection (IÜ) of piston screws (7) from contact surface.05. remove sliding block (10). Pay attention to cleanliness of contact surfaces of piston parts.6 2.7 Remove locking ring (9).02. 02. 2.5 mm en / 18.4 Loosen hexagon nuts (Fig.04.5 2. 2/5) and remove with piston lower part (12).04 2. Check and clean oil bores and sliding surfaces on sliding block (10) as well as piston lower part (12).06. replace piston screw if IÜ > 129. 02 Attention: Check contact surfaces for friction scars and signs of cold welding. contact Caterpillar/ MaK customer service if necessary. Clean piston crown (8) and piston lower part (12).Piston Crown Maintenance / Replace M32 A5.3 2.

2. centering hole and dowel pin (11) must coincide. Coat inner thread and contact surfaces of the hexagon nuts (5) with Molykote paste. torque: M = 10 Nm 2.9 Mounting of piston Screw piston screws (if removed) into piston crown and tighten with a torque of M = 10 Nm.15 Tighten hexagon nuts (5) crosswise with a torque of M = 35 Nm and finally turn through an angle of 90°.2006 IB025305 3/3 .12 Tighten hexagon nuts (5) crosswise with a torque of M = 30 Nm 2.04 2. 02.04.05.02. 02 2.06.Piston Crown Maintenance / Replace M32 A5.14 Tighten up tapering of piston screws (7) in piston crown.8 2.11 Mount piston lower part (12).13 Loosen hexagon nuts again. 2.16 Check: It should not be possible to turn the hexagon nuts any further at a torque of M = 100 Nm! en / 18. ° 2.10 2.

000 hours deadline. 02. 02.10.00 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.9.04.02.05.nn.08.01.07.01. A5.02.01.000/ 90.05.00 60000.06.05.06.09. 02.02.02. en / 25.06.01.01. 02.05. A5. A5.Piston Maintenance / Replace M32/VM32 A5.01. 90000 02.nn B1.10.nn. 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.01.nn = Piston rings and grooves (disassembly and assembly). 02.nn = Piston crown (disassembly and assembly)./ 0.2007 IB025688 1/1 .05.05.nn.02.01.02.06.nn = Piston (disassembly).07.02.2601 0 Pers. Please contact the Caterpillar/ Kiel Customer Service in time before reaching the 60.01.08.08.nn = Piston pin (disassembly and assembly). A5. A5.nn = Piston (assembly).05.

01.9227 B Note: If the running surfaces of all liners are without scores or high spots or any other damage.Piston Rings and Grooves Inspection / Checking M32 A5.1 1.nn B1.2 1.01.03 30000.05. pay special attention to any sharp edges of the rings.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 7.05.9.02. ring tension. but not beyond a maximum of 30.000 operating hours. if the piston rings are stuck or burnt. Sequence of operations: 1. 7500 02.01. en / 30.01.07. Draw the piston from the liner with the worst running pattern (02.06. rings sticking due to carbon deposits. Check the running surfaces of the cylinder liners from the crank chamber.10. the engine must be driven in according to the driving-in regulation A3.500 h Maintenance: of all pistons and their rings after 30.2001 IB021136 1/3 .3 Piston inspection (7.06.2617 1 Pers. the check of the other pistons can be postponed to a later date. 02.000 h Tools: Piston ring expander W1 6. Do not remove the graphite coating on the piston skirt.500 h) Open all crankcase covers.nn).nn! Built up pistons with chromium-plated first ring groove must only be reconditioned by MaK or MaK contract workshops./ 0. and if the parts of the drawn piston are in proper condition. After fitting new piston rings. Draw the other pistons too. During inspection. 1.04. all piston rings free and no heavy wear can be detected.

8 1.01.9 Clean the piston. If the chromium layer of one ring has been worn. Measure the ring thickness hR (Fig.7 1. check the rings of all pistons. Smooth light friction and seazing marks with a fine oily emergy cloth or a fine carborandum stone. 2) in the front area of the groove in the longitudinal and transverse directions of the engine. Clean the piston rings.5 1.10 hN1 = new hN2 = worn en / 30. 1. Check the chromium layer for wear. Measure the groove width hN (Fig.04. 2) at 4 opposite lying points.07. 7500 Remove piston rings only with the piston ring expander (Fig. 1/W1). ring grooves and oil return holes for the scraper ring. have the grooves reconditioned by MaK.Piston Rings and Grooves Inspection / Checking M32 A5. Renew all rings of this piston if there is no chromium visible in some spots.4 02 1.05.03 30000. When exceeding the limits. particularly at the cut and the opposite side. In case of heavy damage or deep scores renew the piston.6 1. 02. 1. Record position of ring gaps in regard to the installation position of the piston on measuring sheet.2001 IB021136 2/3 .

2.6 2. send the piston to MaK for reconditioning. Measure the groove width hN according to operation sequence 1.2 2. Fit all pistons (02.hR mm 0.3 2.1 2.6. Maintenance (30.04.4 2.03 30000.7 en / 30. Insert piston rings with inscription (Fig.01.5 2.11 02 Groove 1 2 3 1. Replace oil scraper ring and all compression rings. 02.45 10. Check the state of lubrication and appearance of the running surface of the piston and clean it. 3/X) and with the ring gaps lying alternately opposite in the ring grooves in engine longitudinal direction.5 0. 2.3 1.01.1 2.10. Record the position of the ring gaps in regard to the installation position of the piston on the measuring sheet. Remove the piston rings with the expander (Fig. Clean all ring grooves and check wear of the chromium layer. 7500 Calculate the limit tolerances and check according to the chart for standard piston ring sets.nn).2 Limit hN2 . Ring thickness hR Nominal mm 8 6 10 Groove width hN2 Wear limit mm 8.01.05.9. 1/W1).Piston Rings and Grooves Inspection / Checking M32 A5.2001 IB021136 3/3 .45 6.07.nn).12 Insert piston rings with inscription upwards (Fig.5 0.000 h) Draw all pistons (02. If the chromium layer is worn away in some places. 3/X) upwards and with the ring gaps alternately opposite in engine longitudinal direction in the ring grooves.06.

1 Attention: The holding device (W10) must lie on the piston base when being turned and must support the con-rod eye (5)!! W1./ 1.2601 2 Pers. Extract holding device (W10) for con-rod eye.11. 02.9.02.1 W1.3 W2 W10 9.Piston pin Inspection / Disassembly and reassembly VM32 A5. Attach the crane to the lever (fig. W2 W1.05.nn B1.3 1 en / 15.00 h 02 Personnel qualification: Chief engineer / skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Mounting/extraction device.3) on the con-rod eye (5) and attach to a second crane. Mount with the opening towards the corresponding control side and lock it again in the piston.1 1. con-rod eye W1 W1.05.1996 IB003363 1/4 .01.01.08.09. 1. 02.2 W1. 5 W10 W1.50 See also: Spare parts list: Time requirement: 02.nn.2 Turn the piston.9223 A Sequence of operations: 1.3 Mount turning gear (W1. consist of: Spacer Cross-piece Turning gear Lever (mounting/extraction device. cylinder liner) Holding device.01. 1/W2) and lift the piston. piston.06.2 4 1.

05. extension to control side) on the piston. Mark the installation position of the lever (W2. 02 W10 W1.01.08.4 1. 2/5). Remove the locking rings (32). A-A 30 5 31 32 2 en / 15. 2. heat up the piston to 80 °C in an oil bath.1) and lever (W2).1 A 4 5 31 2. It is possible that the clearances are insufficient in a cold condition in the case of new parts.11.4 32 A Note: If the piston pin cannot be pushed out by hand.5 Only rotate the piston around the tip of the lever (fig.Piston pin Inspection / Disassembly and reassembly VM32 A5. Mark the con-rod eye (fig. Dismantle the cross-piece (W1. Raise the con-rod eye slightly to relieve the piston pin. 1/W2) in the direction shown. The overall clearance is only given at operating temperature.2) with the spacers (W1. 02.50 1. piston (4) and piston pin (31) for assembly on the correct side. Place the piston on a suitable base and secure it! Disassemble the piston pin. The piston pin can usually be fitted and removed without heating up the piston.7 2.3 1. Push the piston pin (31) out of the piston bore and small end bearing bush (30) without using force.2 2.3 2.1996 IB003363 2/4 .6 1.

3 Check the piston pin surface for cracks and damage. 02.08.1996 IB003363 3/4 .1) and lever (W2) according to the mark on the piston. heat up the piston to 80 °C in an oil bath/freeze the piston pin.50 2.3) or to a second sling and raise the piston. 3.2) with spacers (W1.nn).01.2 Secure the piston pin with the second locking ring (32). 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. Attach the crane to the turning gear (fig.09.11. Measure the piston pin. Mount the cross-piece (W1.1 4.2 3. Reassembly Fit a locking ring (fig. small end bearing bush and piston pin bore in the piston (02.5 2.Piston pin Inspection / Disassembly and reassembly VM32 A5. 4.05. 2/W1. 02 Note: If necessary.6 3.1 3.4 4. Note: When mounting the lever pay attention that: the extension of the lever (W2) and the cylinder mark (fig. 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.01. 2/32) in the piston bore. Turn the piston to the installation position. 3/40) face towards the control side! 5 40 3 en / 15. 3.

02 Attention: The holding device (W10) must lie on the piston base when being turned and must support the con-rod eye (5)! 4. Rotate the piston in the opposite direction shown in fig.08. Mount it with the opening towards the middle of the engine and lock it again in the piston base).5 Extract the holding device (W10) for the con-rod eye.05.01. 1. Dismantle the turning gear (12) and place the piston on a suitable base.50 4.Piston pin Inspection / Disassembly and reassembly VM32 A5.4 Attach the crane to the shackle on the lever (fig.1996 IB003363 4/4 .11. 02.6 en / 15. 1/W2). 4.3 4.

9.2 Measure small-end bush Clean piston pin (Fig.02. If possible. en / 13.nn. the relevant wearing parts are to be exchanged. The clearance limits are in general decisive for assessment of the small-end bush (see table).nn B1. small-end bush (2) and piston bosses and measure the sizes A.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 30.09.03.1 1.01 30000 02.Small-End Bush Maintenance / Measuring M32 A5. 1) are reached. Sequence of operations: 1.09. 2/1).03. and C with suitable measuring device e.05.05.g. see 02. external or internal micrometer gauge. Determine axial clearance [piston boss distance (size D) and measure bearing thickness (size X)]. In case the clearance limits (see Fig.2601 2 Pers. The small-end bush in the connecting rod boss is equipped with a galvanic plated overlay.03.03. 1.2000 IB021149 1/3 .01. 02. this work should be carried out by the MaK works or a contractor.000 h if any criteria for exchange is reached Note: Exactly inserting a small-end bush is hardly possible with conventional on-board equipment. 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. B./ 1.

09.06 0.8 Limit mm 0.029 0. (mm) 0. 2 en / 13.182 0.1 Fig.01.12 0.2000 IB021149 2/3 . (mm) Piston boss Ø (A) Piston pin Ø (C) Bush Ø (B) Piston pin Ø (C) Boss distance (D) Bush width (X) 0.2 Clearance max.005 0.01 30000 02 Clearance min.Small-End Bush Maintenance / Measuring M32 A5. 1 D B 2 A Z Z X 1 C Fig.25 1.09. 02.05.

02. Fig. 3. the disassembly is carried out with a minimum of force.09. A reconditioning by MaK is generally possible.3 Insert bush into the connecting rod boss. 3/Y). corrosion pits or other damages. Connecting rod bosses with damaged bore surface may never be reused without prior reconditioning. the dimensional accuracy and the position of the oil bores and oil grooves are to be checked. remove carefully possible piled-up materials. 3. 80 °C (consider the safety provisions!). examine the bore surface of the small-end bush carefully for cracks.05.1 Assemble the small-end bush Cool a piston bush by means of CO2 snow to approx.01 30000 02 2. -60 °C and heat the connecting rod boss in clean oil bath to abt.2000 IB021149 3/3 . Disassemble small-end bush Y Note: The following work should be carried out by MaK works or a contractor.1 When disassembling the small-end bush make sure. After reaching the normal temperature. To be carried out on bord in the emergency case only! 2.01. Prior to testing. 2/Z) of the bush has to be equal on both sides! 3. 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. Use a suitable crack testing equipment as Magna-Flux and a magnifying glass. Attention: • Make sure the small-end bush in the connecting rod boss is at the right place! • The lateral projection (Fig. en / 13.09.Small-End Bush Maintenance / Measuring M32 A5. The small-end bush must not be pressed out.2 3.

02.07. 1. 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. if necessary.1 Replace piston rings.11. extension towards camshaft side) on the piston and remove the piston rings.1998 IB004703 1/5 ./ 0. 02.01.01.06.05.01.9220 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.05.01.01.9.01.05.nn B1.e. (Fig.9220 B 9.nn. Mark the mounting position of the lever (W2.nn.nn Piston mounting ring Piston guiding device (sheet-metal sleeve) W11 W12 9. 2/W2) together with cross-piece (W1. 1.50.02. 02.10. they are to be at 180° opposite each other)! Thoroughly lubricate piston rings and piston on the outside.2) and spacers (W1. Insert the new piston rings and arrange them so that every other ring joint points to an alternate end of the engine (i.1). 02.2601 1 Pers.nn)! Sequence of operations: 1. Dismantle lever (Fig.06.2 en / 27.07.W10 siehe 02.52 See also: Spare parts list: Time requirement: 01.10.50 h 02 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Tool W1 .nn.Piston Maintenance / Reassembly VM32 A5.

Grease the thread and the bolt contact surface of the tension bolt (1) with Molykote paste „G-Rapid Plus“.Piston Maintenance / Reassembly VM32 A5. Loosen the tension bolt (Fig. W11 6. 1/1) until the piston guiding device (W12) is relaxed and can be guided freely above the piston rings.1 W1. Mount the piston mounting ring (Fig.1) and lever (W2) with extension on the piston in accordance with the piston marking. 4.10.2 4 12 5 2 W5 en / 27. 7. 1/ W12) above the piston ring zone and tighten the tension bolt (1). W2 5.05. 2/ W11). Slightly beat on the piston guiding device to remove possible deformations.01. 02 3.07. Check by turning if the piston guiding device (W12) can still be moved around the piston. Mount the piston mounting/extraction device (W1) on the piston as follows: Mount cross-piece (W1. 02.1 W1. Attention: When you tighten the tension bolt make sure the piston rings do not rest on the outer edge of the ring groove.1998 IB004703 2/5 .2) with spacers (W1. Place the piston guiding device (Fig.52 2. 7.

the piston must not be tilted in the cylinder liner.05. If necessary.Piston Maintenance / Reassembly VM32 A5. Check the position of the holding device (W5). If necessary.07. 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. en / 27. 3/13) are pointing towards camshaft side 02 Attach a crane to the lever (Fig. mount it with the opening pointing towards engine centre and engage it in the piston end again. 3 22 10. 14. 12. make sure: 8. On camshaft side it must rest against the inside of the piston (opening pointing towards engine centre) and support the small end (12). Carefully lower the piston until the parallel pins (Fig. 4/W4) was removed. 11. Lower the piston. mount it again on the cylinder liner and screw the hexagon socket screw (6) against the engine block (5) only hand-tight. 2/W11) so that the guiding device is level. Place the piston guiding device (Fig.01.10.1998 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. 1/W12) onto the piston mounting ring (Fig.52 Note: When you mount the lever. 3/14) are inserted in the bores of the small end (12). the extension of the lever (W2) and the cylinder marking (Fig. pull off the small-end holding device (W5). 9. 2/W2) and lift it up. 02. align the piston with the lever (W2) and follow up with the crane. 13.

07.5 Mark the positions of the tension bolts with chalk. Place the segments (21) upon the shank partition. A B 3 20 W4 6 5 W8 W8 W6 21 W3 22 W7 W9 4 en / 27.10.1998 IB004703 4/5 . 02. Remove the con-rod clamping devices (Fig. At the side pointing towards the inside of the Vee use an extension (W9) additionally. 3/20) with Molykote. Screw the flexible head spanners (W8) at both sides onto the big-end bearing cap with the strap. insert the tension bolts and tighten the tension bolts alternately with a torque of M = 50 Nm.2 Mounting of piston and con-rod. 15.3 15.01.Piston Maintenance / Reassembly VM32 A5.52 15.4 15.05. Grease the threads and contact surfaces of the tension bolts (Fig.1 15. 02 15. 4/W3).

2 3 4 5 en / 27. Dismount the cylinder liner hold-down (Fig.6 Put the flexible head spanners onto the tension bolts (20). It must have reached an angle of rotation = approx.10.7 Tighten the tension bolts alternately with a torque of M = 250 Nm. Fix the spanners above strap by means of set collars. 2/W11). Clean the calibrating ring contact surface (fig. mount the crankcase doors and close the indicator valves. 21.05. 4/W8) and the extension (W9) together with straps and set collars. ° ° 15. 4/W4).01. 02 Attention: Do not turn the engine with spanners put on! 15.11. 17. 02.1998 IB004703 5/5 . Remove the flexible head spanners (Fig.9 16.8 Check the position of the tension bolt marking visually. 18. 19. 2/W1) and lever (W2) with extension. 50° + 10°.07. Turn the piston to TDC position whilst following up with the crane.Piston Maintenance / Reassembly VM32 A5. piston guiding device (Fig.nn).52 15.01. Lower the piston and insert new calibrating ring (2). 15. Mount the cylinder head (01. Dismount piston extraction/mounting device (Fig. 5/2) in the cylinder liner collar (3). 1/W12) and piston mounting ring (Fig. 20.

03.04. Y V 1 X X W Z 2 1 en / 28.1998 IB003365 1/4 .1110 1 Pers.10.06.50 See also: Spare parts list: Time requirement: 01. 03. 03.02.02.nn.01.nn.9.05.nn.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.01.00.03. 2/6) when the cylinder liner (03.04.05./ 0.04.nn) has been removed. 01.01.04.Cooling water distributor housing Maintenance / Disassembly and reassembly VM32 A5.nn B1.01.

2/10) together with the washers (11). Follow up with the crane accordingly! Remove the O-rings (25) on the cooling water distributor and collecting pipeline connection. 3/ 20). 1. Dismantle the corresponding cylinder head and retainer for the exhaust pipe (fig.3 Remove the hexagon bolts (fig. control air duct) into the adjacent cooling water distributor housing (1).50 1. 1 1. Push the sleeves (16.4 15 16 2 1.04.1 1. 3/23) on the cooling water distributor and collecting pipeline (24).5 15 24 Y 25 26 20 W1 20 21 22 23 1 27 20 Z 20 W1 16 14 12 3 en / 28.1998 IB003365 2/4 .05.02.Cooling water distributor housing Maintenance / Disassembly and reassembly VM32 A5. Screw the ring bolts (W1) into the cooling water distributor housing and lift the housing off by means of a crane. Remove the cheese head screws (fig. Remove the hexagon bolts (fig.2 Disassembly of the cooling water distributor housing.00. 03 12 1 13 14 10 11 1. 2/11). 03.

3/21) on the cooling water distributor housing. starting air inlet (fig. 2/12.05. 5/40) on the push rod leadthrough (fig. Reassembly of the cooling water distributor housing IB003365 3/4 en / 28.7 Pull the sleeves (fig. control air transfer are replaced when assembling the cylinder head! The sleeves (fig. air charge transfer Fig.04. 03 V Note: Insert all O-rings in the grooves using vaseline and make sure they are not twisted.Cooling water distributor housing Maintenance / Disassembly and reassembly VM32 A5. push rod leadthrough Fig. 3/14) and the opposite cooling water outlet (26) Fig. 6/50.50 1. 5/44) and O-ring (43) on the cylinder liner collar as well as the O-rings 27 24 25 Fig.1998 .00. 2/16) out of the adjacent cooling water distributor (1) housings and replace the O-rings (15). The sealing ring (fig. 30 4 W 44 22 43 42 41 21 12 U 50 6 40 5 2. 14 and 26) must be positioned vertically! The O-ring (fig.4/30) on the air charge opening and the O-ring (fig.02. 5/41) is replaced when mounting the cylinder liner (42)! 1.6 Replace the O-ring (fig. 4/27. 03. 2/13. 5/22.

2. 03 2. 1/2).01.2 Press the cooling water distributor housing against the cooling water distributor and collecting pipeline (24) and tighten the cheese head screws (20) slightly. Tighten the hexagon bolts (fig. 3/1) when the cylinder liner has been dismantled (03. Push the sleeves (fig.04.50 Attention: Only mount the cooling water distributor housing (fig. Insert the push rods in the push rod leadthrough (22).4 2.6 2. Follow up with the crane accordingly. 2/16) of the starting air duct into the correct position and secure with the hexagon bolt (10) and washer (11).05. 03.04.nn) and tighten the cheese head screws (fig. en / 28.02. Attention: Final tightening of the cheese head screws only after mounting the cylinder liner! 2.1 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.00.02.5 2. 3/20).3 2. Mount the retainer for the exhaust pipeline (fig.Cooling water distributor housing Maintenance / Disassembly and reassembly VM32 A5. 3/23) on the cooling water distributor and collecting pipeline.7 Mount the cylinder liner (03.1998 IB003365 4/4 .04.nn). Remove the ring bolts (W1) and mount the cylinder head.

nn.05.000 h of all cylinder liners after 30. 3) 1. B1.01.01.9.nn B1.03. 03. W1 1 Tools: Gauge ruler for cylinder liner W1 9. 03. 1/W1) and table (Fig.05.01.1110. Check the cylinder liner.Cylinder Liner Inspection / Measuring M32 A5. before every removal and after every fitting of the cylinder liner.03.3 Pull piston (02.2001 IB021192 1/2 . 3 1 1.2 1.1 1.9. depending on the operating time and operating conditions (see Fig.06.12.1611 1 Pers. 2 Note: Extreme wear can occur on the cylinder liners which has to be evaluated and measured.01.05.03. ** 1.9419 B * not available as figure ** or measuring instrument of equal standard Sequence of operations: 1.nn).4 Wear Measuring point 1 2 3 Ref. 2).04. dimension Longitudinal direction Transverse direction Diagonal Diagonal en / 18. Clean the cylinder liner internally (thoroughly cover the crankcase).000 h of all cylinder liners after every piston removal. transverse and 2 x diagonal to the engine axis. determined by the ruler gauge (Fig./ 0.20 h See also: Spare parts list: Time requirement: 03 Personnel qualification: Chief engineer Operating medium: Heavy fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: of one cylinder liner after 15.03 30000.2084 A Precision inside micrometer W2 *. Measure the cylinder liner with the precision inside micrometer (W2) at the measuring points longitudinal.06. 15000 02.

2) and thereafter determine the wear (d1 . 15000 Enter the measured values in the table (Fig.30 1. out-of-round Wear Gusset height depth * max.03 3 90. See also measuring sheet in the file "Forms for maintenance reports".03. replace the cylinder liner.12. Canyon Scores Pocket Irregular indentations.Cylinder Liner Inspection / Measuring M32 A5.02 Wear limit (mm) * ** *** Explanation Radius r ≥ 3mm In circumferential direction 1: gusset.00 4. number length total width number length depth number length width ** depth * 0. 4: TDC 1st ring. 3 2 4 5 ***1 4 en / 18. Cylinder liner wear chart Evaluation criteria Nominal Ø (new) 320.2001 IB021192 2/2 .00 0. Reconditioning of the cylinder liners only by Caterpillar/MaK .00 30. normally in the area of the top dead center of the piston ring (TDC 1st ring). Individual deep blow-through ducts in the area of the 1st piston ring (TDC).03 30000.). 2: pocket.0 + 0. 3: scores. or other limit values indicated in the table are reached (Fig. 5: canyon 1.01.reference dimension d3 etc.05. beginning frm the TDC of 1st piston ring.00 8.057 Max. When the wear limit. Vertical and linear scores. 03.6 TDC 1st ring Wedge-shaped indentation across the entire circumference. 4).5 03 1. 3 and Fig.00 0.03 3 8.00 3 180.00 0.

9. 03. 1/3) must be protected against damage! Sequence of operations: 1.nn B1.1 W1.1611 1 Pers.2000 IB021905 1/2 ./ 0. Note: The sealing ring (21) and O-ring (20) are replaced when mounting the cylinder head! 1. B1. 2/21) and O-ring (20) from the cylinder liner collar. 03.04.06.3 Measure the wear on the cylinder liner.1 1.06.2 W1.06.nn.05.4 Attention: All sealing surfaces of the cylinder liner (fig.2 Disassemble the cylinder liner.9. Remove the piston and cylinder liner holder (02. en / 05.3 W1.01.01.000 h Tools: Mounting /extraction device for cylinder liners consist of: Lever Clamping plate Tension rod Hexagon nuts W1 W1.50 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. Remove the sealing ring (fig.03.1110.01. 1.03.50 30000 02.03.01.Cylinder liner Maintenance / Disassembly VM32 A5.05.nn).05.

1. Carefully clean the sealing surface and groove for the O-ring and check for damage.4. Fix the clamping plate (W1. 1/W1).05. 03. Place the cylinder liner on a suitable base and secure it.4 1. Remove the O-ring (fig.2) under the cylinder liner (3).12 21 20 3 22 2 2 en / 05.9 W1. To do so: Place the lever (1) with the extension on the cylinder liner collar.Cylinder liner Maintenance / Disassembly VM32 A5.1) if necessary.4.50 30000 Mount the mounting / extraction device (fig.1) together by means of the hexagon nuts (W1.8 1. Carefully clean the cooling water area on the cylinder liner collar.7 1. Clean the cylinder liner support. Place the clamping plate (W1.2000 IB021905 2/2 .2 1.3).1 3 2 1.6 1. Do not tilt the cylinder liner. Attach the lifting gear and carefully pull out the cylinder liner (3).3 03 W1.2 W1.10 1.04.3 1 1.4.11 1.4 W1.01. 2/22) in the cooling water distributor housing (2). upper and lower fitting in the cylinder crank case.5 1.06.4) and tension rod (W1. Check all sealing surfaces for damage. Align with the lever (W1. Follow up with the lifting gear accordingly.2) and lever (W1.1 1.

05.2000 IB003373 1/3 .03.01.nn)! Sequence of operations: 1. 03.4 Auxiliary material: Vaseline * * or a product of equal standard Note: After fitting a new cylinder liner.02.3 W1.2 W1. 2.nn.03. 1/2).05. B1. If necessary.nn B1.00. Clean the inside of the cooling water manifold housing (fig.1110.05.03. replace the O-rings on the push rod lead-through and the air charge opening to the cylinder crankcase (03. en / 24.02./ 0.9.10.1611 1 Pers.04. measure the new cylinder liner before mounting the calibrating ring.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. Fit a new O-ring (22) in the groove on the cooling water manifold housing.9.1 W1. Observe the driving-in regulation (A3.04. 03.01.nn).11.50 See also: Spare parts list: Time requirement: 03.Cylinder Liner Maintenance / Reassembly VM32 A5.

Mount the mounting/extraction device (W1) on the cylinder liner which is to be installed (03.01.04. use the lever (W1.2000 IB003373 2/3 . 4. 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 A5.1 en / 24.50 Attention: Fit the O-ring in the groove using vaseline making sure it is not twisted! 03 3.05.02. Follow up with the lifting gear accordingly. Do not tilt the cylinder liner. If necessary. 5. 5.11.1) to align it.nn).04. Dismantle the mounting/extraction device (W1) from the drawn cylinder liner. 03.

Cylinder Liner Maintenance / Reassembly VM32 A5.50 Note: Insert the cylinder liner in such a way that the marking (fig. 7. 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.05. Mount the piston and calibrating ring.2000 IB003373 3/3 .02.11. 03. Dismantle the mounting/extraction device (W1) and measure the new cylinder liner. Attention: The cylinder liner must glide into the fitting on the cylinder crankcase (fig. 1/4) by its own weight! 6. en / 24.04. 03 The marking (26) on the cooling water manifold housing can be used as an alignment aid.

01.nn See also: Spare parts list: Time requirement: 03 1 Pers. 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.00 150 02. en / 05./ 2.01. 03.01. Check the foundation bolts and chocks by knocking. Check for good mounting and leaks of flanged connections.nn). Check elastic bedding elements for damages. Torque values can be obtained at the MaK customer support.05. 7. Sequence of operations: 1. Check the tight fitting of the suspensions and unions in the charge air manifold.nn. Retighten the fixing bolts of the brackets of the injection pump control rods and check the locking washers and pins of the connection joints.07. 06.01. 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.02.Engine Bolting and Unions Inspection / Checking M32 A5. 5. 3.01.01.01. 4.2001 IB002385 1/1 . Measure the crank web deflection after tightening slack foundation bolts (02.02. 6.00 h Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: of all bolts. Cables and signal pipes must not scrab against any part. thermostats and pipe clamps of the following systems: • cooling water • lubricating oil • fuel • starting air • exhaust gas • pneumatic control 2. Ceck the expansion joints and screwed connections of the exhaust manifold for leaks and tight fit and the manifold itself for proper suspension (06. Check the monitoring and control equipment for good fitting. unions and screwed connections for good fitting and leaks. filters.10.nn).

B1. Measure clearance camshaft bearing / bearing neck. Check running surface of the bearing necks of the corresponding camshaft bearings.01.3123 1 Pers.50 30000.nn B1. Smooth overload along the edges is not unusual.1 1.0. en / 10. 04. 1.01.23 .05.01./ 0.9.02. 04. New clearance mm 0.2001 IB022819 1/1 .01. The load on the bearing occurs exceptionally in the lower contact area and is relatively heavy in this area.000 h 30.9.01.2 Check the camshaft bearing clearance.01.05.04.Camshaft Bearing Inspection / Checking VM32 A5. 15000 02.nn.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.37 Clearance limit mm 0.04.20 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. Open corresponding inspection glass lid of the camshaft door.3122.05. Sequence of operations: 1.000 h Note: Camshaft bearings are not subjected to load changes.

3122.9.nn B1.01.1 Dismantle the camshaft section of the respective cylinder.02.04.01.000 h - 30. Refer to 04.04. 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. B1.nn Note: The camshaft bearings are only subject to stress in the lower contact area where the stress is relatively high.04. 04.2001 IB022830 1/4 .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. 1/2) before disassembly of the camshaft bearing for the last cylinder! 1./ 0.02. 1.01.05.3123 1 Pers.9. en / 06.nn.05.000 h Tools: refer to 04.nn.04.Camshaft Bearing Maintenance / Disassembly and reassembly VM32 A5.03.01.51 30000. Check the running surface of one camshaft bearing and the corresponding bearing journal from the first cylinder onward Attention: Secure the vibration damper (fig. 15000 02.03.05.04.

Further assembly: refer 04.2001 IB022830 2/4 . 3) and insert them in the camshaft bearing correct left to right. 04.02.2 Reassembly Insert the camshaft bearing and align it with the locating screwing (4).5 1.3 Lubricate the outside of the bearing journal.6. 1. 2 /fig. 2. 2. Tighten the locating screwing (4) at a torque of M = 60 Nm. 1/7) according to the pin code (fig.01. 1/5) from the bearing journal which is to be checked.nn.51 30000. Check the camshaft bearing (1) and dismantle it in the event of: a poor contact pattern pressure on the edges scoring. Also check the back of the bearing.6 04 To do so: 1.01. 15000 Mount the mounting / extraction device for camshaft sections on the corresponding left hand / right hand camshaft section and bring it into position. Note: The bearing journals are equipped differently with straight pins according to the firing order and the cylinder to which they belong.5 Fit the bearing journals of cylinder row A and B with straight pins (fig.04.1 Loosen the locating screwing (4) and remove the camshaft bearing. 2.2 1. 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.3 1.02.Camshaft Bearing Maintenance / Disassembly and reassembly VM32 A5. 2. Remove the hexagon bolts (fig.1 2.4 2. en / 06.05.4 1.

51 30000. 04.02.02. 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.Camshaft Bearing Maintenance / Disassembly and reassembly VM32 A5.2001 IB022830 3/4 .05.01.

51 30000.02. 04.2001 IB022830 4/4 . 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.Camshaft Bearing Maintenance / Disassembly and reassembly VM32 A5.05.

05.9.2004 IB023923 1/5 . move up).10.0.01 See also: Spare parts list: Time requirement: B1.0.3502 2 Pers.00. 04.02.9104 A Also needed: “G-Rapid Plus“ ** Molykote Paste Vaseline ** * not shown ** or comparable product Sequence: 1. Take off cylinder head cover.0.nn) (if necessary.0. en / 15.Bottom part for Valve Mechanism Maintenance / Disassembly and reassembly VM32 A5.05.04.) Take off rocker arm bracket (01.3 1.1 1.2 1.9454-400 9.01./ 0.4 Disassembly Remove respective camshaft cover. 1.02. Turn inlet and outlet radial cam to the base circle position (unload rocker arm.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.

3 Remove pushrods (2).6 1.10.00.0. 1.1/1) (07.1 1.2/2) and their positions to prevent them from being switched up during assembly.5 1. Insert both oil tubes (5) a short distance into the rocker shaft bore and remove by tilting slightly.nn). spring collar (17).01 1.0. 04 Note Mark pushrods (Fig.02. Remove one retainer clip (4) each for oil tubes (5) on either side of the cam follower bracket to be removed.Bottom part for Valve Mechanism Maintenance / Disassembly and reassembly VM32 A5.2 1.05. 04.2004 IB023923 2/5 . en / 15. spring (16).) Remove respective injection pump (Abb.01.0. Take out plunger rod (15). and spring guide (18).7 Turn injection cam to base circle position (unload rocker arm.02.

Attention: Inorder to prevent damage to cam followers (9) and their rollers (10) during disassembly.Bottom part for Valve Mechanism Maintenance / Disassembly and reassembly VM32 A5. 04.05.2004 IB023923 3/5 .01 1.tigthten by hand.02.10. en / 15. cam followers (9) should be supported using timbers.00.4 Remove the two upper mounting bolts (7) with washer (8) of cam follower bracket (3) and replace 04 withmounting bolts (W2) .

en / 15. During this process.10.01 1. Remove plates (11). Attach cam follower bracket (3) to the crane using a sling and remove mounting bolt (W1).7 1. Take sling off and place cam follower bracket (3) into position with cam followers (9) (wooden support). 2.3 2.4 2.00.05.6 1. Insert lower mounting bolts (7a) with washers (8a) and tighten slightly.6 Insert mounting bolts (W2) into the upper two mounting bores and tighten by hand. 04 2. Insert plates (11) according to the illustration. Set cam follower bracket (3) down on appropriate surface.9 Remove the two bottom mounting bolts (7a) and washers (8a). Carefully pull cam follower bracket (3) up to the stop (bolt head). the cam followers (9) must be lifted so that rollers (10) come to rest on cams (12). always make sure rollers (10) are not damaged.2004 IB023923 4/5 .02. Note Treat all threads lightly with Molykote before assembly.2 Attach cam follower bracket (3) to the crane using a sling and move into place carefully.8 1.Bottom part for Valve Mechanism Maintenance / Disassembly and reassembly VM32 A5.5 1. 04. Remove mounting bolts (W2) and replace with upper mounting bolts (7) with washers (8). Check all contact areas and points for cleanliness and damage. 2.5 2.1 2. Assembly: Note When assembling can follower bracket (3).

nn) .01 2. Insert oil pipes (5) into rocker arm shaft (6) and secure with retainer clip (4). Install rocker shaft bracket (01.02. Check valve clearance (01.7 Tighten mounting bolts (7/ 7a) incrementally ”working crosswise “ until a torque of M = 300 Nm has been reached.nn).10.2004 IB023923 5/5 . spring collar (17). 04 2.00. Install injection pump (1) (07. Start pre-lube pump and check oil pipes for leaks. Install cam shaft cover. spring (16).16 Treat new O-rings (13) slightly with vaseline and insert the rings into the oil pipe grooves without twisting them. Insert pushrods (2) according to their markings (note: page 1/5.1/15).14 2. 04.01.01.10 2.01. and spring guide (18) lightly with Molykote and position parts appropriately.9 2.8 2.13 2.02.) Treat plunger rod (Fig.12 2.11 2.02.nn). en / 15.15 2.05.Bottom part for Valve Mechanism Maintenance / Disassembly and reassembly VM32 A5.01.

9.400 Nm torque wrench 1/2“ changeover ratchet Tool holder Attachment screw W1 W1.3122.01.02.05.2006 IB023956 1/6 .03.01.Camshaft Repair / Disassembly and reassembly VM32 A5.9454-400 1.05.4 W4 * W5 * W6 W 6.nn B1.2103 A * not illustrated Auxiliary material: Molykote paste "G rapid plus" ** "Dirco 610.04./ 3. 01.04.nn.1 W1.01.1 9.2 W1.52 See also: Spare parts list: Time requirement: 01. B1.9459-033 9. 04.01.9.05. 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 / 05.01.08.04.3 W1.3123 1 Pers.9230 B 1.00 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 .nn.

Remove the cover (fig.2 1. Open the indicator valves and dismantle the respective camshaft covers.nn).1 Disassembly Dismantle all valve covers on the respective side of the engine. Dismantle all rocker arms to relieve the corresponding camshaft (cylinder bank A or B) (01. the camshaft sections of cylinder bank A must only be displaced towards the free end of the engine. lift the cam follower of the inlet and exhaust valves off the cam and secure them with wire. furthermore.01. 04. in case of reIB023956 2/6 en / 05. the camshaft sections remaining in the engine must be displaced accordingly towards the free end / driving end of the engine.Camshaft Repair / Disassembly and reassembly VM32 A5.01.02.52 1.01.nn) of the respective cylinder.4 Only carry out operating sequence 1.3 1. 04 Note: To be dismantled. When dismantling a camshaft section of cylinder bank B. 1. The gear casing cover must also be removed when disassembling the camshaft section of cylinder 1.1 when working on the camshaft of cylinder bank B. 1.04.5 Dismantle the injection pump (07.2006 .05.2. 1. 1/2) at the free end of the engine and remove all sealing compound from the cover and the engine block.02.01. Dismantle the pushrods of the corresponding camshaft section.2.1 1.

05.2006 IB023956 3/6 .7 Turn the camshaft to make hidden hexagon bolts accessible. making sure that the inlet and exhaust cams are more or less in a horizontal position before loosening the last hexagon bolts. 2/18) on the camshaft section which is to be replaced and remove them.01.Camshaft Repair / Disassembly and reassembly VM32 A5.01.52 pair on Cylinder bank A Dismantle the injection pumps of all cylinders arranged in way of the free end of the engine. 04 1.6 Loosen all hexagon bolts (fig. 04.04. 1. Note: Secure the vibration damper (20) when dismantling the camshaft section of the last cylinder! Attention: en / 05. Cylinder bank B Dismantle the injection pumps of all cylinders of side B.

1) to press it down until the fine adjusting devices (W1. If necessary. 3/15). The camshaft section which is to be replaced must lie between the straight pins (fig. Insert the mounting/extraction device (W1) with adjustment bar (W1.4) into the locking position and lock it. 2/15).01. Cylinder bank B camshaft Push the remaining left-hand and righthand camshaft components. 3 /W2) as shown in the figure onto the stud bolts of the camshaft cover retainers and tighten with hexagon nuts (5).11 Attention: Do not use any force when displacing the camshaft. axially up to 10 mm to the left / right.1).52 The engine must no longer be turned! 04 1. including the bearing journal. 1. Cylinder bank A camshaft Push the remaining part of the camshaft at free end including the bearing journal.3) lie firmly (without pressure) on the camshaft section (4).2006 IB023956 4/6 .2) into the tool hoder (W6) and tighten well using attachment screws (W6.05. Check the clearance of the cam followers if there is a restriction! en / 05. adjust the fine adjusting devices and bring the locking lever (W1.Camshaft Repair / Disassembly and reassembly VM32 A5.8 Fit tool holder (fig. 04. Pull the locking lever (W1.10 1.4) and use the grip (W1. Displace the camshaft section which is to be replaced in such a way that it lies between the straight pins (fig.04.01.9 1. axially up to 20 mm to the left (free end of the engine).

without pressure.52 Note: The camshaft section which has been removed is held in the engine by the mounting/extracting device.2 2.5 Apply Molykote to the thread and contact surfaces of the hexagon bolts (fig. It must lie flush on the camshaft section.4) and lift the grip (W1.13 1. 2/18). Lock the locking lever in the adjustment bar (W1. 2. en / 05.04. Raise / lower the camshaft section towards the center of the camshaft axis by means of the fine adjusting devices and align the bore (fig.4).Camshaft Repair / Disassembly and reassembly VM32 A5.14 2. Push the rest of the camshaft including the bearing journal. if applicable. 2/23) in the flange with the straight pin (15) of the bearing journal on the free end.2) in this position. pull the locking lever (W1. Remove the sling.1) by means of the crane and roll it into the engine block as far as possible. 04 1.1 2. Lock the locking lever in the bearing block.01.2006 IB023956 5/6 . 04.4 Cylinder bank A camshaft Push the camshaft section without pressure flush against the bearing journal on the driving end. optimize the height of the camshaft section. axially. The straight pins in the bearing journals and the recesses must hold the camshaft section securely. Insert the hexagon bolts (18) as far as possible and tighten them finger-tight.3 Reassembly Place the camshaft section (4) on the grip (W1. lower it by means of the grip and raise the camshaft section (center of camshaft axis). 1. Cylinder bank B camshaft Push the camshaft gearwheel (fig. press over the casting projections on one side and lift out. 2. Note: No pressure is allowed to be applied when pushing together the camshaft sections.1) to a horizontal position. 3/W1. Set down onto a suitable surface.01. If necessary. Roll the camshaft section (4) up to the opening of the casing. 1/5) with the bearing journal (22) and. the camshaft sections from the driving end and the remaining camshaft from the free end against the camshaft section which has been fitted. Attach the camshaft section (4) to a crane by means of a sling.05. to the right (driving end). 2.12 Pull the locking lever (fig.

Check the axial play of the camshaft gear wheel (04. Mount the rocker arms (01. Turn the engine if necessary. 2.9 2.6 Dismantle the mounting / extraction device (fig. en / 05. 3/W1). 04. 2/18) and tighten them finger-tight.01. valve covers as well as the gear casing cover if it has been removed.01.02.01. 1/2) and mount it.08. All injection cam followers must be raised! Mount all injection pumps (07.nn).05.01. crosswise.12 2.52 2.2006 IB023956 6/6 . Tighten the hexagon bolts (18) by progressive stages.nn).8 2.02.03.13 Apply a thin film of sealing compound to the contact surface of the cover (fig. Check the gaskets and mount the camshaft covers.nn) and check the valve clearance. Close the indicator valves and check the lubricating oil passage. at a torque of M = 210 Nm Make the hidden hexagon bolts accessible by turning the camshaft.Camshaft Repair / Disassembly and reassembly VM32 A5.11 2. 04 Note: The engine can now be turned again! 2.10 2.7 Fit the remaining hexagon bolts (fig.04.

Timing Gear Train Inspection / Checking VM32 A5.05.1112./ 0.03.4 Check function and tight fit of oil nozzles (2).0.400 Nm Changeover ratchet 1/2" Dial gauge with holder * no illustration W1 * W2 * W3 * 1. B1.31 .000 h Tools: Torque wrench 100 . 1/1.5 Check the gaskets and mount the gear casing cover.05.9. Check the tooth faces of both camshaft gear gear wheels (Fig.04.1 1. 1.05.750 h every 15.08.05.5140.0. 4).9.01.the intermediate wheel (3) and the crankshaft gear wheel (5).51 15000.08.50 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 3.19 . Set-points 1.nn B1. 3750 02.2 Inspection of tooth faces and oil nozzles Dismantle the gear casing covers on both sides of the engine.01.43 1 X 2 5 Z 2 X 4 1.38 z = 0.3 1 1.9454-400 1.9. 04. B1.8450 1 Pers.06.5 x = 0.9459-033 Auxiliary material: Molykote-paste „G-Rapid“ ** ** or a product of equal standard A 2 3 2 B Sequence of operations: 1. Measure the tooth clearance between intermediate wheel and camshaft gear wheels (x) and between intermediate wheel and crankshaft gear wheel (z).2000 IB021951 1/2 . 1.01. en / 05.4 1.

If necessary.1 2. A-A 3 12 13 15 10 W A A W s 2 en / 05.7 Mount the protective hood on the flywheel and . Place the dial gauge on the intermediate wheel (3) and set to „O“.mount the drainage pipe (15) and the bearing blocks (12) for the control rod (13).6 mm 2. 3750 6.6 2.7 2.51 15000. Check the axial clearance „s“ of the intermediate wheel (Fig. Dismantle the protective hood for the flywheel and the cover (10) with the gasket.08.4 2. Mount the dial gauge together with the holder. 2/3).01.05. axial clearance) are not observed. Pull the intermediate wheel (3) against the cylinder crankcase towards the coupling side. Set-point s = 0.3 2. Mount the cover together with the gasket.3 .6 Check the gasket on the cover (10) and replace it. 2.2000 IB021951 2/2 . if necessary.06. 2. Push the intermediate wheel toward the opposite side of the coupling and determine the axial clearance „s“.if removed at all .0. loosen the drainage pipe (15) and the bearing blocks (12) for the control rod (13).5 04 Inform the MaK after-sales service in case the tooth faces are damaged or the allowable set-points(tooth clearance.2 2. 2. 04.Timing Gear Train Inspection / Checking VM32 A5.

1 1.2001 IB020902 1/4 .51 15000 04.01.4111 1 Pers.nn B1. bolt (6) and washer (2).2 Disassembly Loosen the governor linkage from the governor (fig.04.05.Governor Drive Inspection / Disassembly and reassembly VM32 A5. 1/1).1110.020” ** ** or a product of equal standard Sequence of operations: 1.2 en / 18. B1.9454-040 1.08.05.9459-033 Auxiliary material: Molykote paste “G-Rapid Plus” ** Sealing compound “Dirco 610.1.3 1. 1.9.03. to this end: Arrest the stop lever in stop position.1. 1.180 Nm Shift ratchet 1/2" * not illustrated W1 * W2 * 1. Remove hexagon head screws (11) and lift up the governor (10). Remove the prevailing torque type nut (1) with spacer sleeve (4).03.10.9.1.00 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 15.1 1.05.000 h Tools: Torque wrench 40 .04./ 2. Put aside the spring element (7). 04.

Governor Drive Inspection / Disassembly and reassembly VM32 A5.4 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.10.08.2001 IB020902 2/4 . 2/20) with spacers (21) and hexagon head screws (22).5 1.51 15000 Remove hexagon head screws (fig. Remove gasket (24) and clean the contact face on the engine block.6 Put the governor drive housing (fig. 04. 1. 3/30) and O-rings (31).05.03. 2/23) onto a suitable base. en / 18.3 04 1. 1. Mind the cylindrical pins (32).

8 1.05.Governor Drive Inspection / Disassembly and reassembly VM32 A5.9 Check the serration of governor drive shaft (43) and governor (fig. 1/10) for wear.03.10. Check the intermediate gear wheel (42).2001 IB020902 3/4 . 4/40.7 04 1. 04.51 15000 Check the gear flanks of the helical gear wheels (fig. if necessary clean it.08. 1. 41) for pittings. Check all oil lubrication bores for lubrication of the governor drive shaft and the helical gear wheels for free passage. en / 18. skewing or break off.

3/30) with new O-rings (31).1 2.6 Note: The serration of the governor shaft must smoothly slide into the serration of the governor drive shaft (fig.020".5 2. 3/30).Governor Drive Inspection / Disassembly and reassembly VM32 A5. Firmly tighten screws (20) and (22) crosswise. 1/11). Put the governor (fig.2001 IB020902 4/4 .03.4 2. 4/43). 2/23). 2/23) onto the engine block by means of a crane. 2/20) with spacers (21) and screws (22). en / 18. 2.3 Carefully put the governor drive housing (fig.7 2. In doing so absolutely mind the lubricating oil passage sleeve (fig.2 04 Attention: It is absolutely necessary to reuse the old gasket or use a gasket of same material thickness! 2.08. 04. Daub the contact face for the governor with "Dirko 610. 2.10. 2.05. 1/10) onto the contact face of the governor drive (fig. Put gasket (24) onto the engine block. Mount the governor linkage in reversed disassembly sequence. gasket (24) and cylindrical pins (32). If required readjust the governor (see also Governor adjustment.8 Insert and firmly tighten screws (fig. Book C).51 15000 Reassembly Provide the lubricating oil passage sleeve (fig. 2. Insert screws (fig.

2006 IB024242 1/2 ./ 1.1 1.2 Safety note! Attention. en / 30.04.3 2.09. B1. 2. Remove the hexagon bolts (3) and resilient sleeves (2).05. (Free from grease). Apply Molykote paste to the contact surface and thread of the hexagon bolts (3).Vibration Damper on Camshaft Repair / Disassembly and reassembly VM32 A5.01.000 operating hours! ~ 1.2 1.9. 04.1 2.3140 1 Pers.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 15.03.9. Support the vibration damper (1). Sequence of operations: Disassembly Completely remove the camshaft cover of the last three cylinders.05.52 15000 See also: Spare parts list: Time requirement: B1. Reassembly Clean the support surface of the vibration damper (1) and the intermediate piece (4).11. 1. Pull it off the intermediate piece (4) and remove it.05. there is a risk of injury! Never open a vibration damper.1112.00 h 04 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: 40-180 Nm torque wrench * not illustrated W1* 1.

en / 30. Mount the hexagon bolts (3) together with the resilient sleeves (2). 2.4 04 2. 2.3 2. Tighten the hexagon bolts (3) at a torque of M = 50 Nm.01.6 Check the gasket on the camshaft cover and replace if it necessary.11.05.52 15000 Push the new vibration damper (1) onto the intermediate piece (4).Vibration Damper on Camshaft Repair / Disassembly and reassembly VM32 A5. Mount the complete camshaft cover for the last three cylinders together with the gasket.09. 04.2006 IB024242 2/2 .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.

05.swivel head of spring link between control shaft and regulator Remove excessive gease.05. 2. B1.2000 IB021386 1/1 . Care has to be taken that all cleaned bearings are thoroughly greased.05. Assemble covers. B1.nn Sequence of operations: 1.4210.9. Oil all moving bearings of the swivel arm between control shaft and injection pump slightly. Note: At V-engines the swivel heads of the intermediate shaft of both control shafts are to be greased.08.swivel heads of the intermediate shaft between shaft and control station and control shaft .05.02. all bright-metallic components are to be oiled slightly. 4. Attention: After cleaning with fat dissolving agents. Remove control shaft/injection pumps and control station covers. Grease the following bearings with multi-purpose grease: .9. 3.500 h Auxiliary material: Multi-purpose grease or lubricating oil according to A4.20 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 1.00 1500 B1.01.05.05.05. 5./ 0. en / 30.04.9. Check control shaft and spindle to emergency-off lever and oil bearing areas slightly with lubricating oil.4523 1 Pers.05.05.Control shaft bedding Maintenance / Checking M32 A5.4110.

/ 1.08.nn B1. the function of the components cannot be guaranteed.05.05.9105 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.05. If other lubricants are used.2000 IB021402 1/4 .05.nn. en / 30.05.20 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 7.500 h Tools: Fork wrench * not available as figure W1* 0. 05. All pneumatic elements are lubricated with a special grease (see A4.01.02. 2/17) is under spring tension.1.02 7500 A3.4906 1 Pers. In the event of a repair only this grease may be used.05.Starting Valve Maintenance / Disassembly and reassembly M32 A5. multi-purpose grease) which ensures sufficient lubrication for several years.

2 Close the main shut-off valve on the air receiver. 1/1) and disassemble the starting valve from the engine.05. 05. 05 Disassembly: 2. Vent the air pipes on the engine.Starting Valve Maintenance / Disassembly and reassembly M32 A5. Disassemble all pipework and cable connections from the starting valve. en / 30. 1. Unscrew the screws (Fig.02 7500 Sequence of operations: 1.2000 IB021402 2/4 .05.02.1 1.01.

2 3. Disassemble the armature (5) by slackening the screw connection (6). 2/2).5 05 Note: When disassembling nut (12) and piston (13) secure the spindle (14) against being dragged along.1 3. Remove the spindle (14) completely from the casing. Disassemble piston (13) by means of the fork wrench (W1).6 3. 3. Check the sliding surfaces for rust formation. 05.02.02 7500 Disassemble the protective cover (Fig. Disassemble screw connection (11) and nut (12). en / 30. if necessary carefully rework with polishing cloth. 3. Unscrew the hexagon socket screws (16) and disassemble flange (17). Pay attention to the spring (18).7 4. Pay attention to the spring (7). To this end put a wrench through the air duct (15) on the key face of the spindle (14) and counterhold it.01.3 3. 3. Pay attention to the spring (10). Slacken the screw connection (8) and pull out the emergency actuation knob (9).Starting Valve Maintenance / Disassembly and reassembly M32 A5. Disassemble the silencer (3) and remove the solenoid (4).05.2000 IB021402 3/4 . Clean the casing by means of gas oil.4 3.05.

piston guide ring (19) and other sealing rings.02. Mount all pipe and cable connections.05. 05. en / 30. Firmly tighten the screws (Fig.1 5.01.4 5..5 5. 7. 5.05.6 6. Insert a new. Carry out a functional and leakage test with starting air. 2/2). 1/1). Mount the protective cover (Fig.3 Renew all O-rings.2 5.02 7500 Reassembly: 5. Assemble all valve parts in inverse disassembly order. 5. Assemble the emergency actuation knob (9) with a new spring (10) and a new O-ring (20). Grease the sliding surfaces slightly. completely assembled spindle (14).Starting Valve Maintenance / Disassembly and reassembly M32 A5.2000 IB021402 4/4 . 05 Note: Daub the threads of all fixing screws slightly with Molykote paste "G-Rapid". Put the finish assembled valve onto the engine. Open the main shut-off valve on the air receiver.

Remove bracket (6) from hinged lever.500 h Sequence of operations: 6 1.1710 1 Pers. 1.1 Dismount the bushes (1). Mounting of bushes (1). 05.1 2.Control shaft Maintenance / Disassembly and reassembly M32 A5. washers (4 and 5) and nut (2) to connect the bracket (6) to the hinged lever.2 Attention: Tighten the nut (2) until the connection between bracket (6) and hinged lever is smooth.08. Remove bushes (Fig.03. 7 8 Dismount linkage between injection pump control shaft (Fig.2 1.05. Insert new bushes (1) in bracket (6). When you tighten the nut make sure the bushes (1) are not twisted.01. 1.2000 IB021423 1/2 .00 7500 See also: Spare parts list: Time requirement: B1./ 0.50 h 05 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Maintenance: Replacement of bushes every 7. 1/7) and hinged lever (8) of control shaft.3 2. 2/1) from bracket (6).05.9.05. X 1 en / 30. Mount bolt (3). 2.

08. 2. en / 30.05.Control shaft Maintenance / Disassembly and reassembly M32 A5.01.05. When you tighten the nut make sure the bushes (1) are not twisted.2000 IB021423 2/2 . 05. washers (4 and 5) and nut (2) to connect the bracket (6) to the injection pump control shaft.00 7500 Mount bolt (3).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.

06.861n 1 Pers./ 0. The interval for draining results from the water quantity stated that depends on air consumption. All pipes are to be bent in a cold condition. The radius of pipe bends must be as large as possible. 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. Steel pipes must not be corroded nor have any other fault impairing their good operation.05. Sequence of operations: Drain pipes and air vessel.00 750 See also: Spare parts list: Time requirement: B1. 05. Water pockets which cannot be avoided must have a draining socket with plug at the lowest point.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.2000 IB022014 1/2 . The drain cocks are fitted at lowest points on the inclined side of the pipes.Compressed Air System Inspection / Checking M32/M282/M332C/M452/M453C/M551/M552C/M601/M601C A5. temperature and operating site. Notes: When fitting new pipes. Fit the bent pipes carefully and free them from any scale or other impurities before mounting them on the engine. lnspect the piping visually and check for tight fit of the fittings and tightness of the screwed connections. All pipes have to be laid as straightlined as possible without water pockets.01.10. normally an air detector will be required to find the leakages. Never fill the pipes with sand or similar material for bending. Only copper pipes are permitted for the pneumatic remote control.09.05. In rather rare cases leakages can be stated by noise.n. en / 05.

en / 05. Even the slightest dirt particles in the lines could entail failure of the control units.01.06.Compressed Air System Inspection / Checking M32/M282/M332C/M452/M453C/M551/M552C/M601/M601C A5.05. Attention: Assembly work must be done with extreme care and cleanliness.00 750 05 Keep the number of pipe connections and the resulting sealing points as low as possible. The use of red lead. 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.2000 IB022014 2/2 . 05.09. If any pipes do not properly fit together they must be rebent so that they can be laid without tension. Blow through them with compressed air after bending.

05. slacken these completely.Control Valves Inspection / Checking M32/M282/M332C/M452/M453C/M551/M552C/M601/M601C A5.10. Thoroughly clean the individual parts and exchange wear parts. lengths of levers and lever travels of. Regulating units (pressure reducers) must be checked in their circuit after maintenance work for their setting values and must be reset if required. There will result a certain cycle for control or inspection depending on kind and function of the individual control units.2000 IB022029 1/1 . section 1. actuators.g. In case of deficiencies reconditon all control 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. Do not dismantle control fittings at random since the built-in springs are sometimes prestressed.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.05.. General instructions for maintenance see “Description to Functional Diagram” in book C./ 2. en / 05.n. e. 15000 See also: Spare parts list: Time requirement: B1.09. Prior to disassembly operations and where required measure and mark the position of valves. and so on. In case there is available a screw or nut for adjustment of the prestress.05.861n 1 Pers. 05. The use of other lubricants may be in detriment of the function of the fittings.00 30000. Note: Low pressure valves: High pressure valves: < 10 bar > 10 bar Special grease for all control units see MaK Lubricant Recommendations A4. after four years of the low pressure valves. limitations by set screws. During assembly slightly grease rubber rings and their sliding surfaces with the grease prescribed.nn.05.08.

06.500 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 / 30.20 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./ 0.05.05.00 24. 05.Compressed-Air Filter Maintenance / Cleaning M20/M25/M32/M43/M453C/M552C/M601C A5.4900 1 Pers.1. 7500 See also: Spare parts list: Time requirement: B1.09.05.05.2000 IB021438 1/2 .

7500 Sequence of operations: 1. remove with guide (3) and filter element (2). Open shut-off valve in the compressed-air supply line.2 2.Compressed-Air Filter Maintenance / Cleaning M20/M25/M32/M43/M453C/M552C/M601C A5. Relieve compressed-air filter via drain plug.6 Drain compressed-air filte Loosen drain plug (7) and empty filter completely. 2.9 en / 30. Assemble compressed-air filter in reverse sequence.5 2.2000 IB021438 2/2 .00 24.05. check O-ring (1) and replace if necessary. Remove locking ring (8).06.1 1. 1.3 2.7 2.2 2. Loosen Phillips screw (4). Clean all disassembled parts and check for reuse.09. replace if necessary.8 2.4 2.1 2. Loosen housing cap (5) and remove. Close compressed-air feed line and secure. Disassemble compressed-air filter and clean Loosen drain plug (7) and drain filter completely. 05. 8 7 6 2 05 1 3 4 5 2.05. Close drain plug. Close drain plug after a short while. unscrew drain plug and check O-ring (6).

06. ~ 2.00 h 06 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: Check the exhaust manifold for leakage every 7.7260 2 Pers.01.52 7500 See also: Spare parts list: Time requirement: B1. en / 26. Remove the covering from the exhaust manifold. 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.01.2001 IB022965 1/3 . Safety note! Beware.01. A slight pretension (expansion approx. 3./ 3.05. 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.Exhaust Manifold Inspection / Checking VM32 A5. To prevent any damages to the expansion joints.9.05. Accumulation of soot on flanges and expansion joints is in an indication of leakages. "Dag S 5080" high-temperature thread paste must be used on all bolts to avoid sticking due to heat. 06. they must not be subjected to bending or radial forces during disassembly and reassembly. 3-5 mm) in an axial direction is attained during installation by tightening the expansion joints. Sequence of operation: 1.500 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.

2 4.2001 IB022965 2/3 .52 7500 Exchange damaged exhaust pippe.01. en / 26. 4.01.Exhaust Manifold Inspection / Checking VM32 A5. Do not subject the expansion joints to any stress caused by bending or radial forces! 4. Unhook the chain links (2) on both sides from the clamp bottom parts.3 Slacken hexagon bolt (1) to such an extent that both clamp top parts (3) are still connected.05. 5).1 06 4. 06. To this end: Slacken and remove adjacent expansion joints (4.01. but can be easily displaced! Displace the clamp top parts.

01. 06.5 06 4.8. Mount the lagging. en / 26. Mount exhaust pipe and clamp top parts.10 Expansion joints with cracks in the bellows must be replaced.Exhaust Manifold Inspection / Checking VM32 A5.6 4. see New gaskets (7) at the marked positions only. Length of the fitting piece x = 263 mm y = 267 mm 4. . see 4. mount expansion joint/s and screw down.4 4. Manufacture fitting pieces (x or y) for mounting the new exhaust pipe.9 4.52 7500 Lift off both clamp top parts together. All other flange connections without gasket.01.When mounting the expansion joint/s (4. 4. Remove fitting piece/s. 5) pay attention to the marked flow direction.7 4.01.2001 IB022965 3/3 . Exchange the damaged exhaust pipe.8 Screw the fitting piece/s to the new exhaust pipe.05. 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.

1/ 1) are located at the free end of the engine.04 24./ 0. Another water trap of different construction which is located at flywheel end is described in the documentation as from Book C.00.05. 750 See also: Spare parts list: Time requirement: B1. en / 24. 06.05.9.2006 IB025326 1/2 .06.05.09.20 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.Charge air drain Inspection / Cleaning VM32/GCM34 A5.8392 1 Pers.

2. and tighten it.2 Inspection of filter elements (every 750 h): Disassemble the hexagon plug (Fig.04 24. In case of a malfunction the filter has to be cleaned.2006 IB025326 2/2 . 1.5 Check the filter receptacle in the water trap (1) for dirt and clean it if necessary. 06. 750 1.06. 06 Attention: The following maintenance work may only be carried out when the engine has come to a standstill! 2. parallel to this the instructions of the manufacturer as from Book C. Insert cleaned or new filter element.05.Charge air drain Inspection / Cleaning VM32/GCM34 A5. Slightly coat thread of the hexagon plug (3) with Molykote paste.00. Note: Damaged or severely oxidized components may not be used any more and are to be replaced. mount.3 2. Carefully take out the filter element (4) and clean it.4 2.1 Functional check (every 24 h): When the water trap (1) is working properly.05. 2 en / 24. water (water steam) must continually emerge out of the drain hole (2) during engine operation.2/ 3).1 2. 2.

15.nn B1. Close the shut-off cocks and drain the fuel distributor pipe (drain cock (Fig.03.9497-030 Auxiliary material: Molykote paste "G-Rapid" ** ** or a product of equal standard Sequence of operations: 1. 07.05. 1/4) in the nozzle leakage pipe at the side of the injection pump for cylinder 1).05.07.11. 1.01.9459-033 1.01. 1. 3/ 20) of the injection pump drive is on the base circle of the injection cam.15. 07. Disassemble the fuel overflow line on the injection pump.8510. Remove the fuel distributor/collecting pipe (07.02 See also: Spare parts list: Time requirement: 07.2004 IB024739 1/3 .02.05.1 1.5 1.04.8525 1 Pers.01.6 en / 26.Injection Pump Repair / Disassembly and reassembly M32 A5. B1.2 1.nn.400 Nm Switch-over ratchet 1/2" Claw foot wrench * not available as figure W1* W2* W3* 1. B1. Remove corresponding camshaft cover on the control side.05. Turn the engine so that the rocker (Fig.3 Disassembly Open indicator valves.9.9.4 1./ 1.nn).07.9.9454-400 1.01.3580.00 h 07 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench 100 .

Injection Pump Repair / Disassembly and reassembly M32 A5.02. Loosen bracket (9) for stop cylinder (10) on the injection pump.10 1. Completely loosen pressure screw (6) and union nut (8).8 1.9 1. turn 90° to the right and lift out of the cylinder head. en / 26. Push union nut upwards. Attention: The spacer plates belonging to the cylinders (Fig.7 Loosen screwed connection (Fig. glue if necessary! 07 1. 3/23) are secured with grooved drive studs and must not be removed. forced fuel pipe) with suitable caps. 07.11. 2/16) and disconnect the connection of the injection pump control rod to the regulating shaft. Push the control rod (15) right into the injection pump. dismount the extention sleeve (17) and lift the injection pump from the cylinder crankcase.01.12 ~ 1.13 Safety note: Careful! Spring tension of the injection pump drive works against the injection pump. Loosen nuts (11) evenly.02 1.11 1. Loosen hexagon cap screw (14) and remove with leak fuel drain (13). slightly lift forced fuel pipe (5).2004 IB024739 2/3 .05. Loosen the pipe clamp (12). Secure fuel bores (injection pump.

lift slightly and place union nut (8) on injection pump. Check emergency-stop facility (operation of the stop cylinder).11.01. forced fuel pipe).Injection Pump Repair / Disassembly and reassembly M32 A5.15 2. Screw regulating shaft to control rod (15) of the injection pump. Remove seals from the fuel bores (injection pump. Open shut-off cocks.9 2. Close indicator valves and mount camshaft cover on the control side. 2/12) and bracket for stop cylinder (9).02. 1/3) in front of the injection pump.2004 IB024739 3/3 . fill up fuel system with reserve pump and vent. Insert forced fuel pipe with pressure screw (6) into the cylinder head. Tighten union nut (8) and pressure screw (6) evenly with a torque of M = 80 Nm 2.17 Check compressed-air lines for stop cylinder for leakage using compressed air. Check O-ring (7) and replace if necessary. Tighten the nuts (11) with a torque of M = 260 Nm.3 2. 3/20) of the injection pump drive must lie on the base circle of the injection cam.4 ~ 2.5 2.8 2.1 2.07. Clean the contact surfaces on the injection pump. pipe clamp (Fig. Mount the extention sleeve (17).02).10 2.05. 2/16) check the linkage for ease of movement.16 2.2 2.11 2. Assembly For assembling.7 Safety note: Careful! Spring tension of the injection pump drive works against the injection pump. turn engine if necessary. Mount the control air line (Fig.13 2. Before tightening the screwed connection (Fig. Replace O-rings (22). 07.9 (07. Tighten fuel injector nuts in two steps. the rocker (Fig.6 2. en / 26.14 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 2.01. turn. 07 Note: 2. See sequence of operations 2. Tighten union nut (8) and pressure screw (6) evenly by hand. place the injection pump over the retaining screws. the spacer plates and the spring plate (21).12 2. 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.

000 h Tools: Pressure pipe Nozzle testing device Torque wrench 40 . Lapped surfaces must be preserved and not touched with the fingers.01. make sure that the various parts of one pump. remain allocated to the respective housing. The pump must therefore be reset on a test rig.9470-051 1. pointer etc.01.9470 F 1. When repairing a pump. control rod. 7500 07. A renewal or exchange of the parts will considerably influence the fuel delivery.500 h 15. control sleeve.05./ 2.05.3597 2 Pers.03. In order to keep repair costs low.03 15000.9.9454-040 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. If there is a noticeable drop in the cylinder performance. This is the only guarantee for proper function. Piston and guide must only be replaced as a unit.05.02. 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 / 30.07. e.g.180 Nm 1/2" * not available as figure W1 * W2 * W3 * 1. 07.2000 IB021555 1/4 . any parts to be reconditioned should be shipped only complete and the possibility of a mix-up must be excluded.nn B1.Injection Pump Inspection / Disassembly and reassembly M32 A5.00 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.

17 27 30 28 29 1 en / 30.3 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. Screw the pressure pipe (W1) onto the connecting piece (Fig.1 1. 1/7). 7500 Sequence of operations: 1. Remove the baffle screws (Fig.03. 1. the tappet spring is relieved.2000 IB021555 2/4 .01.2 Checking the pressure keeping valve (Fig.03 15000. Loosen fillister head screws (18) and remove plate (17) with flange (15). Clamp the pump with the mounting flange (13) upwards.05. 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. check (see assembly) and replace if necessary. 2. pÖ = 130 +10 -20 bar Replace the pressure keeping valve if the valve ejects before the lower opening pressure. 1/6) Place the injection pump next to the nozzle tester (W2).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 1.1 2. 07.Injection Pump Inspection / Disassembly and reassembly M32 A5.3 10 11 20 19 12 2.05. do not remove! 15 16 18 X ~ 2.2 Disassembly Clean the outside of the injection pump. 2. 1/4) and connect to the test device (W2). remove the retainer ring (14) and slowly open the spindle device.

7 2.03.6 2. Scores in the running surface. Remove locking ring (10). en / 30. Barrel Buffer screws Tappet Delivery valve Pressure keeping valve Plunger foot plate Scores on the running surface. 7500 Remove plunger foot plate (20) with tappet (16). Remove control sleeve (22) with spring plate (21).16 07 Note: Place O-rings untwisted with vaseline in the grooves. A black plunger or black spots on it indicate water in the fuel.11 2. do not pull over sharp component edges. insert plate (27) and tighten hexagon sockt head cap screws (30) at a torque of M = 5 Nm 2.9 2. Unscrew hexagon socket head cap screws (30) and dismount plate (27) to replace rotary shaft seal (28) and O-ring (29).13 2. tappet spring (11) and pump plunger (12).14 2. Worn tappet guide. Remove fillister head screws (3).05. worn contact face of stud. After replacement of O-ring (29) and rotary shaft seal (28). Clean all parts with gas oil and a hard brush and blow out with compressed air. pull out retaining pin (9) and control rod (8) and check toothing. control helix worn (by cavitation or erosion). Caviation in the inner bore.12 2.10 2. Check tappet spring for possible corrosion.8 2. damage to the sealing surface of the pump element. Damaged sealing surfaces. Loosen fillister head screws (2) alternately and carefully lift off connecting piece (4). Force pump element (25) out of housing (1) with round block of wood. Pay attention to delivery valve spring (5) and valve spring (6). special attention is to be paid to the following wear phenomena: Plunger Scores in the running surface. check the toothing of the control sleeve. During visual check.05.Injection Pump Inspection / Disassembly and reassembly M32 A5.01. worn seat. Replace all O-rings and gaskets. mainly in the inlet bush.15 2. Clamp injection pump housing (1) with connecting piece (4) facing upwards.2000 IB021555 3/4 .03 15000. worn contact face of pump. worn pressure valve spring (5) and valve spring (6). 07.

24) with the lips and the metal spiral facing upwards. 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. 3.1 07 Attention: A refinishing of sealing surfaces.03.03 15000. 07.05. 2/23.05. The tooth marked on the control sleeve must be positioned between the two teeth of the control rod.2 Insert the rotary shaft seals (Fig. 2. 3.3 25 24 23 2 3. is not possible on board and is therefore not permissible! When assembling.Injection Pump Inspection / Disassembly and reassembly M32 A5. en / 30.01. 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. 7500 Assembly Assembling is carried out in reverse sequence of disassembly. it is marked with a tooth and the control rod is marked with two teeth.2000 IB021555 4/4 . as is the case with all injection parts. see Fig.4 Check free movement of the control rod. 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. 3.

9.00 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 * 9.08.2260 2 Pers.07.07.9. Bolt the injector valve pulling unit (Fig.nn. Loosen hexagon nuts (Fig.04.2 1.2005 IB023912 1/3 .01.03 See also: Spare parts list: Time requirement: 07. remove extension sleeves (10) and flange (3). ~ 1. 1/1).05. B1.1 Disassembly Remove the valve cover.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.05.5 h before working on the injection system so that the fuel injector is thoroughly flushed.4 Disassemble the high-pressure injection pipe only after complete mounting of pulling unit (W1).nn B1. Sequence of operations: 1.2107. 2/W1) securely to the adjuasting screw (Fig. the system must be switched over to distillate fuel for at least 0.Fuel Injector Maintenance / Disassembly and reassembly M32 A5. To this end: en / 07. 07./ 1. 07.01.2144 A 9. Reassemble extension sleeves (10). 1/8) of the injector valve (4). 1.01.3 1.01.05.02.

Remove hexagon head bolts (Fig.12 2.5 1.nn). 07.4. 2/20) Pull out injector valve with pulling unit.6 21 22 10 2 23 1.07. 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.10 1. 2/23) on the hexagon of the threaded rod (22).08. Place the torsional lock (Fig.4 1.nn). 1/7) is exposed.4.4. 2. Clean the injector seat (9) in the sleeve (6) by scraping with tool (W2).01. Disassemble high-pressure injection pipe (07.9 1. 25 Assembly Replace O-rings (7).11 22 24 20 1. Firmly tighten the hexagon head bolts (20).2005 IB023912 2/3 .7 1.2 Put in place the complete unit.03 1. 25 24 20 07 1. Loosen the hexagon head bolts (Fig.1 1. 2/20) a bit and firmly screw the threaded pieces (21) onto the extension sleeves (2) up to stop. mark it with the cylinder number and carry out a functional check of the injector (07.Fuel Injector Maintenance / Disassembly and reassembly M32 A5.4. Firmly screw the threaded rod (22) onto the adjusting screw (Fig.1 20 21 23 en / 07. Remove extension sleeves (Fig.05.5 1.3 1. 1/8).01. 1/10).02. Clean the inside of the sleeve.01.4.04.8 1. Remove the pulling unit completely and reassemble it.

5/12).3 Apply a thin film of high-temperature thread paste to the valve seat.04. Mount the flange (fig. 5/11) facing the exhaust side and the neck facing downwards (fig. 2.01. Make sure flange (3) is level with injection valve (4). 07. Pay attention to the position of the positioning pin (fig. 1/5) and valve stem. Check the lubricating oil and fuel circulations for leakage. 1/X).07.02.8 Mount the fuel delivery pipe (07. 1/3) with the dowel pin (fig. 1).6 2.01. contact surface of the nuts (1) and Orings (7).nn) and the cylinder head cover.03 Attention: use original MaK spare parts only! 07 2. Tighten nuts (1) in two steps with a torque of M = 60 Nm 2. nozzle element (fig.05.2005 IB023912 3/3 . Apply a thin film of Molykote paste to the stud threads (2).7 2. en / 07. 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. Mount extension sleeves (10) and tighten nuts (1) by hand uniformly.Fuel Injector Maintenance / Disassembly and reassembly M32 A5.5 2.2 2.4 Insert the fuel injector in the sleeve.

05.01.05.9.50 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. 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.2267 1 Pers. however. A drop in the opening pressure of approx. Corrosive attack and erosion.2260.07. the charge air temperature may also be too low or water in the charge air.08.07. The fuel injector should only be checked in case of a clear deviation of the exhaust gas temperature from the mean temperature.04. 20 bar is normal after a short period of operating (set of nozzle spring and needle). if the nozzle temperature is too low. this should be cleaned again thoroughly.07.9470-051 ~ 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.09. are the consequence./ 0. Previous to replacing the fuel injector.9470 F 9. en / 18.nn B1.01.9208 B 1. B1.2002 IB002481 1/2 .nn. 07. the smoking behaviour. The proper function of the fuel injectors can exclusively be assessed from the behaviour of the exhaust gas temperatures resp.01.05. 07.Fuel Injector Maintenance / Adjust M32 A5.00 See also: Spare parts list: Time requirement: 07.9.

ovalization.1 If the opening pressure is not correct.10. 2. 5. 07 Note: If a high portion of fuel is leaking. Remove carbon deposits from the nozzle with a hard brush (no wire brush). 3. Check the nozzle hole for sharp edges.01. Injector opening pressure.01. repair (07.09. corrosion and damage. en / 18. slacken the lock nut (1) and turn the adjusting screw (2) until the pressure is correct. Tighten the lock nut (1) again.08.2002 IB002481 2/2 .05. Increase the pressure gradually until the nozzle opens. Place the injector with the adapter (W2) in the tester (W1). Connect the injector delivery pipe (W3).Fuel Injector Maintenance / Adjust M32 A5.nn) or replace the injector. see acceptance test records A1. 07.00 Sequence of operations: 1. 4.04. 5.

08./ 0. All parts of the fuel injection system are manufactured with utmost precision in special workshops.09. preserved.g.420 Nm * not available as figure W1 * 1. en / 09.01.nn) reveals faults (e.08. Only this guarantees a perfect function.500 h Tools: Torque wrench 60 . leakage. low opening pressure etc.07.2267 1 Pers.05. if the test (07.01.). 07. any parts to be reconditioned should be shipped complete.08.01. and the required maintenance work should be confined to • • • Cleaning Checking opening pressure and tightness Replacement of wearing parts using original spares and components.9454-060 Auxiliary material: Hydraulic sealing compound Loctite 566 ** ** or a product of equal standard Note: Injectors should only be dismantled.00 7500 07. repair carried out by the operator is impossible.05. To keep repair costs low. and the possibility of inter-changing must be excluded. 07.07.50 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 7.01. For this reason.9.Fuel Injector Repair / Disassembly and reassembly M32 A5.2001 IB021570 1/3 .nn.nn B1.

1 2.2 1. If the needle is hanging or jammed.09.6 1. 2. When inserting into the casing (11) align the spring guide (10) to the locking screw (3). nozzle spring (4) and setbolt (5). Apply a film of lubricating oil to the thread of the fuel injector housin To assemble.00 7500 Sequence of operations: 1. anti-fluff paper. Submit nozzle spring (4) and setbolt (5) to visual inspection.Fuel Injector Repair / Disassembly and reassembly M32 A5.8 2.7 Disassembly Slacken nut (Fig. remove spring guide (10). Be aware of cylinder pin (7). locking screw (3) and unscrew adjusting screw (2) . Extract nozzle (8) including nozzle needle without damaging the lapped surfaces.5 1.3 2. 07 2 1 11 10 9 3 1. Clean the parts with gasoil. Replace defective parts. reverse the dismantling sequence. Renew O-ring-type sealing ring (9).1 1. Reassembly Wipe all sealing surfaces dry with clean. 1/1) and relieve nozzle spring (4) by unscrewing the adjusting screw (2). 1. whether the needle falls on the seat by its own weight. 07. Slacken nozzle nut (6) by turning left and unscrew.2001 IB021570 2/3 .4 1.2 2. Fit a nozzle needle with gasoil in the nozzle (8) and check.05.08.01. Submit all parts particularly seat and sealing faces to a visual inspection. replace it together with the nozzle.4 4 5 6 7 8 en / 09.3 1.

10 Check the injector according to 07.05.8 2.09.Screw the locking screw into the housing (11) with two turns.Fuel Injector Repair / Disassembly and reassembly M32 A5. Tighten the locking screw (3) with a torque of M = 20 Nm.5 2.9 Remove residues of adhesive from housing (11) and locking screw (3).08.6 2.2001 IB021570 3/3 . Apply “ Hydraulic sealing compound Loctite 566 “ to the thread of the locking screw (3). Tighten the nozzle nut (6) with a torque of M = 350 Nm 2. unscrew it and screw it in again.08.01.7 07 2.00 7500 Degrease and dry locking screw (3) and bore hole. en / 09. 2.01.nn and set. 07.

01. 3 turns to drain fuel distributor line./ 0. 07.9454-020 Aids: Molykote paste “G-Rapid Plus“ ** ** or equivalent product Procedure: 1.9.56 See also: Spare parts list: Time requirement: B1. en / 08.8510 1 Pers. Close shut-off valves. 1.10.1 1.180 Nm Torque wrench 20 .90 Nm *not shown W1* W2* 1.Fuel Distributor Manifold Repair / Disassembly and reassembly VM32 A5.2002 IB023870 1/3 .2 Disassembly Remove pump chamber covering.07. loosen screw plug (Fig.50 h 07 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench 40 .1/1) by approx.15.9454-040 1.05.05.

07. 2/5) can be detached from sleeves at injection pump cyl. 3/7).1.05. Remove fuel lines (4). 2/5) at injection pump cyl.6 Remove tube (Fig. 2/2).10.2002 IB023870 2/3 .Fuel Distributor Manifold Repair / Disassembly and reassembly VM32 A5.56 1.15.01.4 1. 1/6). en / 08. 10) and plate (18) with guide ring (19) to the right and left respectirely. Release cheesehead screws (8) and screwed connection (9) so that blind flange (Fig.3 1. To remove blind flange (Fig. 07 1. Shift sleeves (3) with O-rings (17.1 dismantle jet leakage pipe (Fig.5 Loosen cheese-head srews (Fig.

Tighten cheese-head screws (8) with a torque of M = 65 Nm.2002 IB023870 3/3 . Replace pump chamber covering.Fuel Distributor Manifold Repair / Disassembly and reassembly VM32 A5.7 2.10. Insert fuel lines (Fig. 17). Position blind flange (5) over sleeves of injection pump cyl. Replace them if necessary.4 2. Apply Molykote-Paste "G-Rapid-Plus" to cheese-head screws (2) and tighten with a torque of M = 25 Nm.15. 1/1). fill fuel system with spare pump and vent. 07 2. close ball valve (Fig.5 Fit tube (7). Firmly tighten connectors (15).8 Fit jet leakage pipe (Fig. 3/12) with screwdriver and tighten screwed connection (9) with a torque of M = 100 Nm. 2. 2.56 2.1 2.3 Reassembly Check O-rings (Fig. 2/4). 2/10. When doing so check conical part (16) is in correct position. Hold cone (Fig. en / 08.6 2. 17) and guide rings (19) at fuel lines (4) for damages. 2. Runddichtung (10) and plate (18) with guide ring (19) to the right and left respectirely up to limit stop.1. Shift sleeves (3) with O-rings (10.01. 07.2 2.10 Open shut-off valves.05.9 2.1/6).

02.1 1.9.6417 0 Pers./ 0. 08. Sequence of operations: 1.08.03 See also: Spare parts list: Time requirement: B1. remove the lubricating oil pump from the motor and check the gearwheels.05.90 Nm 1/2" * not available as figure W1 * 1.9454-020 Auxiliary material: Molykote paste "G-Rapid Plus" ** Silicone sealing compound "Dirco Grau" ** ** or a product of equal standard Note: If necessary. Remove suction (Fig.03. 1.Lubricating oil pump Maintenance / Disassembly and reassembly M32/VM32/GCM34 A5.10. en / 08.00 h 08 Personnel qualification: skilled engine hand Operating medium: Every fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench 20 . 1/4) and pressure line (2). gearwheel shafts and bushes for wear and replace if necessary.2 Disassembly Drain lubricating oil system.05.2007 IB022585 1/3 .

05.4 Loosen hexagon nuts (1) and pull lubricating oil pump (3) with gearwheel (6) out of cylinder crankcase. 08. splintering). 2/10) with extractor. Replace o-rings (12). slanting run.03 1. Slacken screws (16.8 Check tooth profiles for wear (pitting. en / 08.5 1. Disassemble driving gear wheel shaft (10) and impeller shaft (19).7 1.18) and remove end cover (17. 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.Lubricating oil pump Maintenance / Disassembly and reassembly M32/VM32/GCM34 A5.03.6 1.3 1.10. 08 1.21) from pump casing (20).2007 IB022585 2/3 . Note: Cool down new bushes before installing them.02. Loosen hexagon cap screw (8) and pull gearwheel (6) off drive gearwheel shaft (Fig.

Before mounting the gearwheel. 1/6) and drive gearwheel shaft cone (Fig. Check oil supply of the gearwheels. Put gearwheel (Fig. Check the distance S.2007 IB022585 3/3 . Fill in new lubricating oil (lubricating oil quality.10. 08. 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.58 . Fill up lubricating oil system and take lubricating oil prelubricating pump into service.1 2. 1/5) and coat with sealing compound. 1/8) and disk (7) with Molykote paste "G-Rapid Plus".03 2.8 2.68 mm than in cold condition.7 2. 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. check the contact reflection between gearwheel cone (Fig. see A4. measure distance S (Fig.0. en / 08.13 Clean the contact surfaces of the pump flange (Fig. Vent system. 2/10) through grinding. 1/X) and make a note of it.11 2. Contact reflection must be even and the contact reflection portion > 80 %! Clean.Lubricating oil pump Maintenance / Disassembly and reassembly M32/VM32/GCM34 A5. Heat gearwheel in oil bath to approx.5 2. Tighten the hexagon cap screw (8) with a torque of M = 60 Nm. 1/6) on drive gearwheel shaft cone. Mount suction (4) and pressure lines (2) with new seals.05. free from grease and dry gearwheel cone and drive gearwheel shaft cone. 08 2.nn) up to the respective level mark on the circulation tank. it must be smaller by 0.10 2.05.03.2 Assembly Mount lubricating oil pump in reverse sequence.02.12 2.3 2.9 2.08. Coat the thread and contact surface of the hexagon cap screw (Fig. 2/17) and the pump carrier plate (Fig. 2.4 2.6 2.

2001 IB022962 1/2 .00 h 08 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: of the protective lube oil filter every 7.05. 08.7650. b) Dirt particles freed after the possible destruction of fine filter inserts.51 7500 See also: Spare parts list: Time requirement: B1.05.9.08.04. 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.08.9.8433 1 Pers./ 1.05. en / 07.02. B1.500 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.03.Protective Lube Oil Filter Inspection / Cleaning VM32 A5.

Screw in the plug / thermometer or probe insert with new gaskets. Push in the filter insert and mount the bracket (5) with a new gasket (4).04.5 1. Dismantle the bracket (5) and pull out the filter insert (3). Replace the O-rings (6 /7).3 1.05.51 7500 Sequence of operations Unscrew the plug / thermometer or probe insert at the highest point of the pipe section to be drained.1 08 1.02. 1.03.4 1.6 en / 07. The protective lube oil filter (1) is drained via line (2).2 1. 08.Protective Lube Oil Filter Inspection / Cleaning VM32 A5. 1.2001 IB022962 2/2 . Take the standby lubricating oil pump into operation and fill the lubricating oil system. Check the filter insert and wash it out.

06). Disassembly ~ 1. Remove and dismantle the control valve (1).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 15.4 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).2 1.01.01 15000 See also: Spare parts list: Time requirement: B1.7810 1 Pers.3 1.05.1 1.01.n. washers (27).2 Safety note: Pay attention to the tension of the pressure spring (Fig. ~ 1.2008 IB022593 1/3 .2./ 1.2.000 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.05. en / 31.2.2. pressure spring (28) and ball (29). The lubricating oil pressure (see A1. engine data) is only allowed to be adjusted at the nominal engine speed (A1.1 1. Remove the screw plug (26) of the pilot control unit (A-A) with the sealing ring (25). Remove the locking ring (9) and take out the piston (11) with washer (15) and pressure spring (13).05.08. Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush (10).10) and at the specified lubricating oil temperature (see A1. Sequence of operations: 1. 1/3) on the control valve (1)! Loosen the cheese head screws (8) evenly to relieve the pressure spring (3).Oil pressure control valve Maintenance / Adjust M20/M25/M32/M43 A5.05. 08.

en / 31.01.01.05.2008 IB022593 2/3 . balls. Check the valve seats.5 Clean all parts with gas oil and check them.05. 08.4 1. 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.3 1. piston seating as well as the slide faces and grind them if necessary.Oil pressure control valve Maintenance / Adjust M20/M25/M32/M43 A5.01 15000 08 1.

2 2. Counter-clockwise: Clockwise: Oil pressure drops Oil pressure increases 08 3.01 15000 2. 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.Oil pressure control valve Maintenance / Adjust M20/M25/M32/M43 A5.01.1 2. en / 31. 08.1 3. Assembly is effected in the reverse sequence of disassembly. 2.05.3 Secure the setting with the hexagon nut (18). Adjustment Pressure to be set (see engine data A1. 3.01.05.2 3. Regulate the pressure by turning the spindle (19).3 Reassembly Check the O-rings (2 and 7) and sealing ring (14) and replace them if necessary.05).2008 IB022593 3/3 .

Oil pressure control valve Maintenance / Adjust M32/VM32/GCM34 A5.3 1.2 1. pressure spring (28) and ball (29). engine data) is only allowed to be adjusted at the nominal engine speed (A1. The lubricating oil pressure (see A1. Remove and dismantle the control valve (1).6417 1 Pers.nn B1. 08. en / 02.00 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 15.4 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).05.05.06).2 Safety note: Pay attention to the tension of the pressure spring (Fig. ~ 1. Disassembly ~ 1.05.10) and at the specified lubricating oil temperature (see A1.1 1.01.1 1.02 15000 08.04. Remove the locking ring (9) and take out the piston (11) with washer (15) and pressure spring (13)./ 1. washers (27). Sequence of operations: 1.08.2007 IB022601 1/3 .2. Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush (10).03.9.000 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.2. 1/3) on the control valve (1)! Loosen the cheese head screws (8) evenly to relieve the pressure spring (3).2. Remove the screw plug (26) of the pilot control unit (A-A) with the sealing ring (25).02.05.2.

02 15000 08 1. en / 02.Oil pressure control valve Maintenance / Adjust M32/VM32/GCM34 A5.5 Clean all parts with gas oil and check them.04.3 1. 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. balls.4 1.05. 08. piston seating as well as the slide faces and grind them if necessary.01.2007 IB022601 2/3 . Check the valve seats.05.

en / 02.05. 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.1 3.04. 2. Loosen the hexagon nut (18).05.02 15000 2. Counter-clockwise: Clockwise: Oil pressure drops Oil pressure increases 08 3.2007 IB022601 3/3 .05). 08. Adjustment Pressure to be set (see engine data A1.2 3.01. Regulate the pressure by turning the spindle (19).3 Reassembly Check the O-ring (7) and sealing ring (14) and replace them if necessary.Oil pressure control valve Maintenance / Adjust M32/VM32/GCM34 A5. 3. Assembly is effected in the reverse sequence of disassembly.1 2.2 2.3 Secure the setting with the hexagon nut (18).

Prelubricating pump/Prelubrication Maintenance / Checking M20/M25/M32/M43/M453C/M552C/M601C A5. Start the stand-by pump Turn the engine by means of the barring gear.1999 IB004168 1/1 .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.2 Carry out steps 1.05.nn 08 1 Pers.10. since the components which run on sliding bearings. en / 18.08. Damage caused by vibration during engine shut-down can only be avoided when the engine is lubricated and turned simultaneously.00.00.2 simultaneously for approx. No or only a little quantity of oil is carried to the endangered contact surfaces.1 1.10. 1. 08. 5 min. without affecting the unattended operation of the system: Sequence of operations: 1.00 150 See also: Spare parts list: Time requirement: C5. the bearings might be damaged by vibration when individual engines are shut down for more than 3 days. are not able to float in the bearing because of the prelubricating pressure.1 and 1.11./ 0. Prelubrication alone is no guarantee that damage caused by vibration is prevented.05. The following method is to be applied to avoid damage caused by engine shut-down.

9454-020 Auxiliary material: Molykote paste "G-Rapid" ** ** or a product of equal standard Note: Before disassembly.3 1. blow out with compressed air. 1.05. block starting valve and close air bottles. or the carrier (7). 1 1/2 en / 22.Starting Air Distributor Maintenance / Disassembly and reassembly M32 A5. Loosen cover (4).00 15000 See also: Spare parts list: Time requirement: B1. See operation sequence 3.1 1. Tools: Torque wrench 20 .2001 .02.10. the setting of the starting air distributor must be checked and readjusted if necessary.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. Sequence of operations: 1.4450 1 Pers. 1/1) and muffs (5).90 Nm * * not available as figure W1 1.4 Disassembly 9 5 10 Remove air pipes from the swivelling screw fittings (Fig.05. 4 3 2 7 1 14 8 Note: After replacing the shaft (3).01. inspect and replace defective parts./ 4. Loosen fillister head screws (11) and pull off starting air distributor housing (10).05. 10. control disk (2).2 1. remove and take out control disk (2) with shaft (3).! 2.9.000 operating hours. Clean all parts. Assembly IB023242 13 12 11 Fig.

Threads and contact surfaces of the loosened hexagon cap screws (8) are to be coated with Molykote and tightened.2 10 2. start engine numerous times with air.01. The housing (10) must lie flat against the cover (9) of the governor drive.5 2.2. 2 3. and tighten cover (4).3 Install starting air distributor with shaft (3) and carrier (7). loosen hexagon nut (14) (attention: lefthand thread). 2/20) of the control disk (2) must cut the bore of the 1st cylinder (Fig. coat thread of the shaft extension and contact surface of the hexagon nut with Molykote.00 15000 Reassembly is effected in reverse sequence.3 Set control disk with disk slot according to 3.2. fix control disk and tighten nut with torque M = 35 Nm.4 2. torque: M = 34 Nm 2. 10. Clamp shaft in vice with soft blocks. Fix compressed-air pipelines with new seals upon completion of assembly.6 Check setting according to 3.2001 IB023242 2/2 .3 Recheck the position of the disk and shaft and mount starting air distributor according to 2.2 3. Setting the starting air distributor Turn the piston of the 1st cylinder to ignition position.1 If necessary. 3.2 and tighten hexagon nut by hand. If necessary.1 3. Check function of starting air distributor and also check for leakage. 3. 2/c) according to the engine rotating direction a = clockwise b = anti-clockwise. en / 22.05.2 20 a c b 2 3. remove starting air distributor.02. torque: M = 17 Nm 2.05.1 2. turn by 180° and refit.Starting Air Distributor Maintenance / Disassembly and reassembly M32 A5. Disk slot (Fig. 14 Fig. Threads and contact surfaces of the hexagon cap screws (11) are to be coated with Molykote and tightened. 3. (attention: lefthand thread).2.

Check the control air lines for leakage/damage if all control rods can be pushed in.03.nn B1. Note: Check all injection pumps. Check the position of the control rods. Note: The solenoid valve is reset and the emergency stop facility is vented.12. press the control rod (2) into the injection pump by applying pressure to the saddle (1). 4.9.20 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. 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 (07.01. 2.05. 10.2005 IB021678 1/2 .00 750 07./ 0. Activate the emergency stop facility (machine control room). To do so.01. en / 07.05.Stop cylinder Inspection / Checking M32/VM32 A5. Attention: The control rods must be in the "zerofilling level" position! 2 1 3 3.01.02.nn).05. Press the "Reset" button on the safety system.02. Check the stop cylinder (3).4241 1 Pers.

In connection with this inspection work all of the emergency stop equipment on the engine is to be checked for proper function.Stop cylinder Inspection / Checking M32/VM32 A5.12. 13 1.45. If the shutdown air pressure is decreased below the switching value of 6 bar an alarm "Low shutdown pressure" will be released. Venting by loosening screw (13).01).03. (Please refer to (C5.01.10.00 750 Attention: This document only describes the pneumatic and mechanical release of an engine stop. Check the emergency stop by actuating the emergency stop lever (Fig. 10 10 1.05.nn) ). 2/T3) Measuring point 6105 (function of the safety system) in the maintenance unit (C5.23. (Fig. en / 07.05.2005 IB021678 2/2 . 3/20) on the control stand.1 2 T3 2.05.50.05. 10.05.

750 operating hours. 2 and Fig.2 Connecting the adjusting device Turn cock (Fig./ 0. B1.11.9.4842.16 bar Switching differential: Switching differential: 0.1 1.05. Note: These testing and adjusting instructions apply to the following types: Pressure range: Pressure range: 0 .2001 IB023083 1/3 . 1 2 Fig.8 bar Sequence of operations: 1. 11.254842.03. B1.50 h 11 Personnel qualification: skilled engine hand Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Tools: Adjusting device.Pressure Switches Inspection / Adjust M25/M32/M43 A5.2 bar 0. Remove plug (2) (G1/8") (depressurizing the line. soaking up fluid with a rag) and connect adjusting device to test connection according to Fig.01.05.434843 1 Pers.12. 3.11.6 bar 0 .05. electric measuring instrument Inspection: Check the set operating values of the pressure switches every 3.00 3750 See also: Spare parts list: Time requirement: B1. 1/1) of the pressure line to test position (downwards). 1 en / 12. 1.05.11.

2 2. Check the switch point with the precision pressure gauge of the adjusting device and test lamps.Pressure Switches Inspection / Adjust M25/M32/M43 A5.00 3750 1. Slowly vent the pressure switch. 3 in unit plug. 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).3 Inspection Vent pressure switch via adjusting device.3 Pneumatic connection (Fig. 2. 2 1 3 en / 12. 2).03.1 2. 11 15 10 11 12 13 Fig.05.01. P [–] [+] Fig.2001 IB023083 2/3 . 2 14 16 10 11 12 13 14 15 16 1. 3 2. 3) Connect terminals 1. 2.4 Compressed-air flange > 16 bar Pressure reducer Shut-off valve One-way restrictor Volume 1 l Precision pressure gauge Pressure switch Electrical connection (Fig. 11.12.

3 en / 12.12. Screw on housing cover and seal with lead seal.3 Remove lead seal. Removal of the adjusting device Loosen the cable connections and pneumatic connection of the test device. Fig. 11. 3.Pressure Switches Inspection / Adjust M25/M32/M43 A5. 4 20 + – 4.00 3750 3.2 3. carry out correction according to operation sequence 3.2001 IB023083 3/3 .1 4.1 3.03. 4. The pressure switch is set when the pressure is falling. 4/20) of the pressure switch. 1/1) to operating position. Correction of the adjustment 11 Note: If there is a deviation from the set value (see measurement points list in book C). Set switch point to required value according to measurement points list with a hexagon spanner (5 mm).01.2 4.05. Loosen housing cover (Fig. Seal test connection with plug and turn cock (Fig.

1 Voltage check at the plug-in socket contacts of the plug-in frame.05. 11. The automatic cut-out F 1.01.05.06.02 7500 C5. Note: The engine speed must be constant whilst testing./ 1. 2.05. Note the rpm switch point setting. 1). Turn the pointer carefully to the left towards 0 rpm.1 on the plug-in card A1 in the rpm switch installation must be switched on. the output relay will switch and the diode on the dial must light up (switch hysteresis ± 25 rpm). proceed as follows in order to locate the defect: 4.1 and F 2.00 h Personnel qualification: E-specialist Operating medium: Heavy fuel and distillate fuel -------------------------------------------------------------------------------------------------------------------------------Inspection: Check the function of the rpm switches every 7.43 See also: Spare parts list: Time requirement: 11 1 Pers.05. 5. The output relay on the plug-in card must switch and the luminous diode (3) on the dial will go out (Fig. Loosen the pointer locking plate (2) and set the pointer (1) at the highest engine speed.RPM Switch Inspection / Adjust M20/M25/M32/M43 A5.05. contact z20 positive). continue as follows: 5. At constant speed and with the setting as under point 1.500 operating hours. When reaching the engine speed. If the rpm switch does not work. Set the pointer again at the original rpm switch point and lock it. en / 25.70. Sequence of operations: 1. Supply (24 V DC at contact z16 and z20.2005 IB021724 1/2 . 3.

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

12.7 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.4 1. (30).9 en / 05. Clean all parts thoroughly. Remove O rings (20 and 21). 1.04. 1.2 1. forcing may be carried out through tapping bore holes.2001 IB022862 2/4 . Check oil flow bores and oil feed bores are clear.05. Dismantle side plates (18). Remove fastening screws (13). Dismantle the pump wheel carrier (15) and pump gear wheel (14).52 30000 Sequence of operations: 1.01.5 1.02.3 1.8 1.6 Mark the position of the damper to the crankshaft. Remove the oscillation damper and forcing screw from the crankshaft and dismantle. 1. Remove the antifatigue screws and fastening screws (1) (12).Vibration Damper Maintenance / Disassembly and reassembly VM32 A5.

Vibration Damper Maintenance / Disassembly and reassembly VM32 A5. 1/22).02. en / 05. D 80/20 G1 05043 D 80/21 G1 05044 Anzugsmoment (Pos 23) 226 Nm 226 Nm Gap "s" (mm) 0.52 30000 Measure gap (Fig.01.05. 12..18 0. 2/"s" ) between spring ends and groove flanks of the interior using a feeler gauge. 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.10 12 Damper No.2001 IB022862 3/4 . 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. Tighten hexagonal screw (23) until cup spring (22) lies flat.18 1.04.

Insert new greased O rings (20 and 21). 12. • Observe the marking of the damper position to the crankshaft! 5. If critical values have been exceeded. M16 = 130 Nm 5. Apply Molykote "G-Rapid Plus" to the screw threads and screw head plates of the screws.2001 IB022862 4/4 .04. Seal screw threads and cup springs with oil-resistant sealant. • Operate reserve lubricant pump until oil flows evenly out of the oil feed bore hole. the engine should be operated only at reduced power and avoiding critical speeds. Screw the side plates tightly with the corresponding starting torque. 4. 3.01.Vibration Damper Maintenance / Disassembly and reassembly VM32 A5. • Operate reserve lubricant pump until oil flows evenly out of the second oil feed bore hole • Wait until no more air bubbles are visible. Assembly of oscillation damper: 12 5.02.1 Bleed the air from the oscillation damper: • Turn an oil flow bore hole (30) to the highest position (30). 5. en / 05.4 Assemble lubricant piping.05. Check systems for sealing and check lubricant supply to gearwheels. Set the side plates so that the oil flow bore holes are positioned between the oil feed bore holes. 2. the damper should be replaced as soon as possible.52 30000 Note: When critical values have been reached the damper should be replaced (AT procedure)..2 Further assembly procedure takes place in reverse order from dismantling procedure.3 5. Starting torque of screws: M12 = 60 Nm . • Turn the oscillation damper through 180°. Apply Molykote "Typ 60 G" across the inner side of the side plates (18).

51 45000 A5.05.1.12.00 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 45.12. en / 04.01. Please contact the Caterpillar/ Kiel Customer Service in time before reaching the 45.03./ 0.000 hours deadline.000 h Note: We have to point out that this maintenance sheet was prepared only for the purpose of maintenance planning.Vibration Damper Maintenance / Replace VM32 A5.05.04.2004 IB024251 1/1 .05.6347 0 Pers.02.04.nn B1. 12.

01. the operating.Turning Device Maintenance / Disassembly and reassembly VM32 A5.03.52 30000.1.9. en / 08. 12. QNB 50“ * Gear oil „Shell Omala Oil 460“ * *or a product of equal standard 1. Attention: When the turning device is engaged. 3750 See also: Spare parts list: Time requirement: B1.1 1./ 0. The engine cannot be started during turning ! 1. the position switch (11) is automatically set to position “engine OFF“ .750 h 750 h 30.1 1.2 1.2001 IB022985 1/3 .12. so that the gearwheel of the turning device engages completely in the flywheel toothing.1.7330.05. Move lever (2) to position“ X“.7332 1 Pers.12.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.1.05.10 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 3.1.4 Turn the engine.9. Let off blockinglever and make sure that the blockinglever engages in position “Z“.08. 750. Operating the turning device ~ 1.05.000 h or 6 months or monthlys or 4 years Auxiliary material: Bearing grease „Klüber Altemp. B1.3 Safety note: Protect engine against unintentional start-up! Apart from these instructions.

2 1.2.1 1.2 1. 12. so that the gearwheel of the turning device is disengaged from the flywheel toothing.2.01.05. 750.3 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 / 08.2. Move lever (2) to position“ Y “.52 30000. 1.03.Turning Device Maintenance / Disassembly and reassembly VM32 A5.2001 IB022985 2/3 .08. Let off blockinglever and make sure that the blockinglever is engaged in position “W“. 3750 Disengaging the turning device Move blockinglever (1) to position “V“ and hold.

2.2 2. only the prescribed gear oil is to be used ! 2. 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 Check oil level at the oil level glas (10) and fill in gear oil ( e.52 30000.3.2001 IB022985 3/3 .2 Coat toothing of gearwheel thinly with bearing grease. Mount the breather (7) .2.3 2.3. 2.05. Shell Omala Oil 460 .g.6 Oil change Remove screw plug (5) on the driving gear of the turning device.5 2. 750.03.2.Turning Device Maintenance / Disassembly and reassembly VM32 A5. 3750 Maintenance Oil level check 2.1 Grease the notch on the output shaft (9) and the gearwheel (3) with bearing grease by means of the grease nipple (4). ca.3. Remove breather (7) on the driving gear of the turning device.1 12 Note: If a topping up should be necessary.08. Mount the screw plug (5) with new gasket (6). Attention: Grease the gearwheel toothing only if the turning device is disengaged.1 2.4 2.10 l) up to the oil level mark (10).3 2. Drain the oil from the driving gear of the turning device.g. Fill in new oil (e. 2.3. Shell Omala Oil 460 ) up to the oil level marke. en / 08. 2. 12.1.01.3.

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

01 Tools Table of contents A6 A6.04.2008 AA020050 1/1 .Table of contents - A6.01 en / 24.