Description and Applications Manual For Diesel Engines ABC Type 12/16DZC

B31
Edition: 003
release date: 30-Sep-2020
Description and applications manual

for diesel engines ABC
type 12/16DZC
Anglo Belgian Corporation

Wiedauwkaai 43
9000 Ghent, Belgium
T : +32 (0) 9 267 00 00
F : +32 (0) 9 267 00 67
E : info@abcdiesel.be
Document: B31_000_dd2020_09_30_Ed003_EN_Frontpage_Description_and_Applications_manual_12_16DZC
ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC
B31
Page 1/5
Disclaimer
LIABILITY
This document provides general information only and is not binding. ABC (and its related bodies corporate) makes
no representation or warranty, either implied or expressed, with respect to the accuracy, reliability or completeness
of the information. Even though ABC has made every effort to ensure that the document is accurate, it disclaims
liability for any inaccuracies or omissions that may have occurred.
Failure to follow the instructions or to comply with the installation instructions of the present document may result in
malfunctioning of the engine, shorter lifetime of components, personal injury or damage to property or the
environment, for which ABC takes no responsibility.
Engines and their components can cause damage or personal injury when improperly used, opened, taken apart,
fitted, lifted or transported. It is therefore essential that no one attempts to install or use the engine and its
components without the necessary knowledge and experience of the engine, various tools and commonly used
elements, materials and methods in machinery installation.
In no event ABC shall be liable for any direct, indirect, punitive, incidental or consequential damages to property or
life, whatsoever arising out of or connected with the misuse of ABC’s products, failure to follow the instructions of
the present document or from negligence or carelessness in the use of ABC’s products.
ABC will be held harmless, indemnified and defend from any claim (included third party claim) arising out of or
connected with above mentioned misuse, negligence or failure to follow ABC’s instructions.
APPLICABILITY
Take into account that this manual applies to default installations only.
This manual pertains to marine propulsion, marine gensets, industrial gensets as well as compressor and pump
sets.
This manual therefore contains information which is not necessarily applicable to your specific installation. Please
keep this in mind when interpreting the information you read.
B31
Page 2/5
UPDATES
The information included in this document may be subject to change or improvements by ABC at any time without
notice. However, ABC makes no commitment to update the information in this manual with minor alterations and
improvements to the engine’s development made between official releases.
TRANSLATIONS
The original version of this document is written in English. Only the English version is valid. ABC is not responsible
for any consequences due to incorrect translations or interpretations of the original text handed over to the
customer/user of the engine.
VERSION MANAGEMENT
This edition supersedes any previous editions of this document.
ALL RIGHTS RESERVED
All rights reserved. No part of this publication may be reproduced or copied in any form, without prior permission
from ABC.
B31
Page 3/5
INTRODUCTION
Before starting to install the engine or the genset, read these Installation Instructions carefully. Ensure that everyone
involved in the installation has these Installation Instructions available, reads them and understands them. Whenever
two branches of technic meet, problems may arise. Those problems can be solved only by collaboration.
The instructions set out here below are no more than a general survey, and they apply to normal installations. These
Installation Instructions have been prepared using the manufacturer's best knowledge and experience, taking into
account safety and environmental aspects. Experience, special knowledge and equipment of the installation-
contractor without objections are required to achieve the best installation for given conditions.
This document is based on the assumption that the installation-contractor is familiar with the installation of engines
in general and with the use of tools and commonly used elements, materials and methods therefore.
Failure to comply with these installation instructions may result in malfunctioning of the engine, short lifetime of
components, personal injury or damage to property or environment, for which the manufacturer takes no
responsibility.
Engine components involve a risk of damage or personal injury if opened, taken apart, fitted, lifted or transported in
an improper way. It is therefore essential that no one attempts to install the engine unless he has the necessary
experience of the various tools and commonly used elements, materials and methods in machinery installation.
The coordination between the two parties, the shipbuilder or genset installation-contractor on the one side and the
engine builder on the other side, is advisable whenever special requirements have to be met, whenever particular
circumstances are foreseen or whenever the installation-contractor wishes to deviate from these installation
instructions.
These Installation Instructions are worked out for marine propulsion, marine gensets, industrial gensets, compressor
and pump sets as well as for traction engines. This manual contains thus information, which is not necessary
applicable for your specific installation. Please consider carefully.
For more detailed information or if things are unclear, do not hesitate to phone our technical department.
Our number is in Belgium: phone: 09 - 267.00.00.

fax: 09 - 267.00.67.
from abroad: phone: ++ - 32 - 9 - 267.00.00.
fax: ++ - 32 - 9 - 267.00.67.
B31
Page 4/5
CONTENTS
Chapter 0 : General 12/16 DZC Ed. 09
B31
Page 5/5
This page is intentionally left blank.
GENERAL 12/16 DZC
Chapter 0 – Page 1/48
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
CHAPTER 0
GENERAL 12/16 DZC
File: B31_001_Ed009_EN_General_12_16DZC ABC owns the copyright of this document. It shall not be
copied or disclosed without prior consent of ABC.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
CONTENTS
1 DEFINITIONS AND TERMINOLOGY ...................................................................................................... 3
1.1 Engine type indication ...................................................................................................... 3
1.2 Numbering of the cylinders ............................................................................................... 4
1.3 Table of abbreviations ...................................................................................................... 4
2 TECHNICAL DATA............................................................................................................................. 6
2.1 Technical specifications according to engine type and application .................................. 6
2.2 Derating coefficients for ambient conditions .................................................................... 6
2.3 Consumption according to engine type and application................................................... 7
2.4 Nominal dimensions ......................................................................................................... 8
2.5 Valve timing – valve clearance ......................................................................................... 9
2.6 Firing order ..................................................................................................................... 11
2.7 Critical speed .................................................................................................................. 11
2.8 Temperatures (in°C) ....................................................................................................... 11
2.9 Pressures (in bar) ........................................................................................................... 13
2.10 Lubricating and cooling systems capacities (liters) ........................................................ 15
2.11 Test-bed measurements ................................................................................................ 21
3 GENERAL MAINTENANCE RECOMMENDATIONS................................................................................. 22
3.1 Warnings ........................................................................................................................ 22
3.2 Tooling ............................................................................................................................ 23
3.3 Masses of the major components .................................................................................. 23
3.4 Handling of components ................................................................................................. 26
3.5 Precautions for mounting and dismantling ..................................................................... 26
3.6 Assembly dimensions and wear limits............................................................................ 26
3.7 Standardized dimensions for reconditioning .................................................................. 26
4 -MAINTENANCE PROGRAM ............................................................................................................. 27
4.1 Maintenance (M) and overhaul (O) ................................................................................ 27
4.2 Maintenance intervals and overhaul order ..................................................................... 42
5 TIGHTENING TORQUES ................................................................................................................... 43
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
1 DEFINITIONS AND TERMINOLOGY
1.1 ENGINE TYPE INDICATION

Engine type: 12/16 DZC 1000 166 A/K C...
Reference Explanation
12/16 Number of cylinders in V-formation:
• V-angle: 45°
• Bore: 256 mm
• Stroke: 310 mm
• Stroke/bore relation: 1,21
• Cylinder center distance: 380 mm
• Bank offset: 76 mm
DZC Engine type, 4-stroke, always equipped with turbocharger and charge air
cooler
1000 Nominal engine speed in rpm
166 Code number for the main effective pressure (Pme), i.e. the Pme (bar) is
multiplied by 10.
Code Number Pme (bar)
120 12
135 13,5
150 15
166 16,6
179 17,9
A Direction of rotation counterclockwise as seen by an observer looking to the

flywheel.
K Direction of rotation clockwise as seen by an observer looking to the

flywheel.
C • C0: Standard
• C1: CCR I / IMO I
• C2: CCR II / IMO II Pme = max. 18,3 bar
• C3: UIC I
• C4: UIC II
• C5: EU IIIA loc
• C6: DF Genset
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
Reference Explanation
• C7: DF Marine / IMO II
• C8: Biofuel
• C9: IMO II Pme up to 18,8 bar
• C10: IMO II Pme ≤ 16,6 bar
• C11: EPA Tier III
• C12: Emergency genset with nuclear qualification
1.2 NUMBERING OF THE CYLINDERS

The numbering of the cylinders for bank A and bank B begins with the cylinder closest to the
flywheel:
Ref. Sense of rotation

A Counter-clockwise
K Clockwise
Fig. 0.1 Numbering of the cylinders
1.3 TABLE OF ABBREVIATIONS

Abbreviation Explanation
°CA Degrees crank angle
BDC Bottom dead center
BI Beginning of injection
CCW Counter-clockwise
Con rod Connecting rod
CW Clockwise
EC Exhaust closes
EO Exhaust opens
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
Abbreviation Explanation
FO Fuel oil
FW Fresh water
HT High temperature
IC Inlet closes
IO Inlet opens
LT Low temperature
LW Limit of wear
MM Maintenance manual
OD Original dimension
OM Operating manual
PPE Personal protective equipment
R1 First undersize/oversize
R2 Second undersize/oversize
RL Reworking limit
rpm Revolutions per minute (rev/min)
SW Sea water
TC Turbo compressor
TDC Top dead center
TKP Turbo side pump-side
TKV Turbo side flywheel
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
2 TECHNICAL DATA
2.1 TECHNICAL SPECIFICATIONS ACCORDING TO ENGINE TYPE AND

APPLICATION
Parameter Abbreviation Unit

Continuous rating power Ne kW
ISO3046/1
Nominal revolutions/minute N rev/min
Mean effective pressure Pme bar
Maximum combustion Pmax bar

pressure
Mean piston speed at Cm m/s

nominal engine speed
2.2 DERATING COEFFICIENTS FOR AMBIENT CONDITIONS

The power under ambient conditions, called the power in situ (Px), can be derived from the
reference power Pr using ambient correction factors (derating coefficients). The power in situ
can be calculated as follows:
Px = [1 - (A + B + C)] x Pr
with:
• A = Ambient air temperature derating coefficient
• B = Charge air coolant temperature derating coefficient
• C = Altitude/ Total barometric pressure derating coefficient
The reference power Pr is defined under standard reference conditions. The reference
conditions used by ABC differ from the standard reference conditions defined in ISO 3046-
1:2002.
The table below gives an overview of the reference conditions:

Reference condition ABC ISO 3046-1
Ambient air temperature 32°C 25°C
Charge air coolant temperature 45°C 25°C
Altitude/ Total barometric pressure 800 m 0m

Relative humidity 30 % 30 %
Fig. 0.2 to Fig. 0.4 show the ambient derating coefficients under ABC reference conditions for
the engine.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
Derating Ambient Temp Derating Coolant Temp

12,00 10,00
Derating coefficient A [%]
Derating coefficient B [%]

10,00 8,00
8,00
6,00
6,00
4,00
4,00
2,00 2,00
0,00 0,00
25 35 45 55 65 30 40 50 60 70 80
Ambient air tem. [°C] Cooling water temp. at inlet aircooler [°C]
Fig. 0.2 Derating ambient temperature (A) Fig. 0.3 Derating charge air coolant temperature
(B)
Derating Heigth
8,00
7,00
Derating coefficient C [%]
6,00
5,00
4,00
3,00
2,00
1,00
0,00
600 800 1000 1200 1400 1600
Height above sealevel [m]
Fig. 0.4 Altitude (C)
2.3 CONSUMPTION ACCORDING TO ENGINE TYPE AND APPLICATION

• Fuel consumption at nominal power with fuel according to ISO3046/1 and a lower
calorific value of Hu 42,7 MJ/kg is expressed in g/kWh (tol. +5 %). Specific for each
engine type on demand.
• Consumption of lube-oil at nominal power: g/kWh
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
2.4 NOMINAL DIMENSIONS

Parameter Value
Number of cylinders 12 or 16 in V
Swept volume per cylinder 15,95 dm³
Compression ratio 12,1 : 1
Total swept volume:
• 12 cyl. 191,4 dm³
• 16 cyl. 255,2 dm³
Bore 256 mm
Stroke 310 mm
Diameter:
• Main bearing shell 240 mm
• Connecting rod bearing shell 200 mm
• Piston pin 110 mm
• Camshaft bearing 82 mm
• Injection pump piston 20 mm
Thread cylinder head stud: M24 x 2
Length:
• Connecting rod (center to center) 620 mm
• Tappets 738 mm
• Cylinder block studs 376 mm
Width:
• Main bearing 78 mm
• Connecting rod bearing 72 mm
• Connecting rod bush 65 mm
Height:
• Chrome-plated fire ring 5 mm
• Compression ring 4 mm
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
Parameter Value
• Oil scraper ring 8 mm
Lift:
• Inlet valve 20,40 mm
• Exhaust valve 20,40 mm
• Injector nozzle needle 0,6 mm
• Inlet cam 18,3 mm
• Exhaust cam 18,3 mm
• Injection cam 18 mm
Distance between cylinders 380 mm
Number per cylinder:
• Inlet valve 2
• Exhaust valve 2
• Top piston ring 1
• Compression ring 2
• Oil scraper ring 1
2.5 VALVE TIMING – VALVE CLEARANCE

Real opening and closing times in°CA.
6DZC 8DZC
Inlet
Opens before TDC 60° 70°
Closes after BDC 40° 40°
Exhaust
Opens before BDC 62° 62°
Closes after TDC 55° 65°
Valve overlap 115° 135°
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
For these angles, the valve clearances in cold conditions have been taken into account. These
are:
• Exhaust: 0,20 mm
• Inlet: 0,20 mm
Exhaus Expansion
t
Compressio Inlet
n
Fig. 0.5
The meaning of the abbreviations used in the above diagram are listed in “1.3
Table of abbreviations” (page 4).
Setting value of BI: According to the required emission demands (see maintenance manual,
chapter “Injection system”).
Adjustment tolerance = ± 0,5° in function of thickness difference of shims (0,1 mm).

As the cam profile of the inlet and outlet cams is provided with a starting inclination
according to a harmonic curve, it is very difficult, in practice, to measure the above-
mentioned opening and closing times.
The control can be limited to the measurement of the crank position in regard to the
TDC, when both valve bridges are at the same height, this is the theoretical crank
angle measured at the crankshaft for:
• 12DZC: 2°30’ before TDC – lifting ca. 12 mm
• 16DZC: 2°30’ before TDC – lifting ca. 16 mm
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
2.6 FIRING ORDER

• 12 cyl.:
− A: B1-A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4
− K: B1-A4-B4-A2-B2-A6-B6-A3-B3-A5-B5-A1
• 16 cyl.:
− A: B1-A1-B3-A3-B7-A7-B5-A5-B8-A8-B6-A6-B2-A2-B4-A4
− K: B1-A4-B4-A2-B2-A6-B6-A8-B8-A5-B5-A7-B7-A3-B3-A1
2.7 CRITICAL SPEED

Every installation is checked for critical engine speeds. These calculations indicate if, at
particular speeds, dangerous torsional vibrations occur. This is important as these vibrations
can lead to catastrophic failure of the crankshaft, coupling, propeller shaft or generator shaft,
damage to gears and bearings, overheating of the vibration damper or inadmissible irregularity
of the driven electric machines.
Continuous running at those speeds is very dangerous and those speeds must be marked on
the engine speed indicator as forbidden areas. ABC cannot be responsible for failures arising
from the non-observance of those forbidden areas.
IN CASE OF MODIFICATIONS EFFECTED AFTER THE INSTALLATION (FOR EXAMPLE,

ALTERATION OF THE PROPELLER OF GEARS) THE COMPLETE INSTALLATION HAS TO BE
RECALCULATED FOR CRITICAL SPEEDS. FOR THIS PURPOSE, IT IS NECESSARY TO CONTACT
ABC.
2.8 TEMPERATURES (IN°C)

Parameters Value
Exhaust gases:
• Cylinder heads °C (See test sheet)
• Before turbine °C (See test sheet)
• After turbine °C (See test sheet)
Supercharging air:
• Before air cooler °C (See test sheet)
• After air cooler °C (See test sheet)
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
Cooling system Double cooling circuit

Split cooling circuit
(engine outlet) (HT +LT)
Normal working 80°C (76,5-85) – 85°C (82-89) 80°C (76,5-85) – 85°C (82-89)
Warning signal 90°C 90°C
Stop signal 95°C 95°C
Preheating 40°C – 45°C 40°C – 45°C
Lubrication circuit Double cooling circuit

Split cooling circuit
(engine inlet) (HT +LT)
Normal working 71 – 79°C 71 – 79°C
Warning signal 80°C 80°C
Stop signal 85°C 85°C
Preheating 35°C – 40°C 35°C – 40°C
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
2.9 PRESSURES (IN BAR)

Opening pressure Working pressure Proof pressure
Description
(gauge pressure) (gauge pressure) (gauge pressure)
Cylinder head:
• Combustion space - Max. 130 150
• Cooling water - Max. 3,5 5

space
Cylinder block:
• Cooling water - Max. 3,5 5

space
Air cooler:
• Water space - Max. 2,5 5
• Air space - Max. 3 5
Oil cooler:
• Water side - Max. 2,5 7
• Oil side - Max. 5 7
Fuel injection pump:
• Plunger and liner - Max. 1200 -
• Body - - 7
Fuel supply - Gasoil max. 2,5 -
HFO max. 3,5
Injection pipes - Max. 1200/1500 -
Opening injection needle 275 - -
Safety valve (cylinder head) 150 ± 2 - -
Safety valve (crankcase) 0,1 - -
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
Opening pressure Working pressure Proof pressure

Description
(gauge pressure) (gauge pressure) (gauge pressure)
Lube-oil pressure (entrance
engine) at normal engine
working temperatures:
• 400 rev/min - 2-2,5 -
• 500 rev/min - 2,5-3 -
• 720 and - 4,85 -

750 rev/min
• 900 and - 5 -
1 000 rev/min
Starting air - Max. 30 -
Cooling circuit: in order to obtain the minimal hydrostatic pressure for the soft-water pump inlet,
the underside of the expansion tank must be at least 2 m above the engine’s center line but no
more than 10 m (see operating manual, chapter “Description and supervision of the cooling
water circuits”).
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
2.10 LUBRICATING AND COOLING SYSTEMS CAPACITIES (LITERS)

2.10.1 Lubrication system
Oil sump 12 cyl. (l) 16 cyl. (l)

Type 1 (standard wet sump)
(h = 600 mm)
Min. 450 500
Max. 850 1000
Type 2 (extra deep wet

sump)
(h = 760 mm)
Min. (gasoil) 500 600
Min. (HFO) 350 600
Max. 850 1100
Property 12 cyl. (l) 16 cyl. (l)

Standard oil pipes on According to engine type According to engine type
engine and/or application and/or application
Governor:
UG8 1,4 1,4
UG25+ 2,1 2,1
Heinzmann - -
2.10.2 Cooling systems
Property 12 cyl. (l) 16 cyl. (l)

Engine capacity (basic 500 600
engine)
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
2.10.3 Information concerning the fabrication of important components
Component Property Information

Cylinder block Fabrication Sand-cast
Material GGG 40 – 50
Finishing ABC
Cylinder head Fabrication Sand-cast
Material Lamellar cast iron
Finishing ABC
Pump carter Fabrication Sand-cast
Finishing ABC
Connecting rod Fabrication Forged in a matrix
Material Steel 34CrNiMo6
Finishing ABC
Crankshaft Fabrication Forged in a matrix
Material Steel 42CrMo4V
Finishing By supplier
Cylinder liner Fabrication Centrifugal cast
Material Perlitic cast iron with P and Mo
Finishing Machined & plateau honed at ABC
Cylinder-head gasket Material Brass
Piston Fabrication Cast
Material Nodular cast iron
Finishing By supplier (+ hardened grooves)
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
Component Property Information

Piston rings Fabrication Cast: top ring with chrome ceramic coating
1st tapered compr. ring chrome-coated
2nd tapered compr. ring
Oil scraper ring chrome coated with spiral spring
Valves Material Intake X45CrSi9V

Exhaust X45CrSi9V (MDO/Gasoil)
Exhaust X45CrSi9V + Nimonic 80A (HFO)
Insert Fabrication Centrifugal cast
Material Centrifugal cast iron
Valve guide Fabrication Centrifugal cast
Material Special cast iron (Metal Roger)
Finishing ABC
Gear wheels Fabrication Forged in a matrix
Material Steel 17CrNiMo6MQ & GGG
Finishing ABC and/or supplier hardening & grinding
Camshaft Fabrication Forged in a matrix
Material 15CrNi6
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
2.10.4 3D illustration with identification of important components
A B C D1 D2 E F G
K
R
L M N O P Q
Fig. 0.6
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
Ref. Description
A Turbocharger
B Cylinder head
C Crankcase breather
D1 Water return pipe

D2
E Exhaust manifold
F Integrated charge air manifold
G Oil cooler
H Charge air cooler
I Speed governor
J Support charge air cooler
K Flywheel
L Integrated gear case for camshaft gear drive
M Crankcase
N Injection pump
O Oil pan
P Fuel filter
Q Pump drive gear case
R Box engine control unit
S Oil filter
T Water pump
U Oil pump
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
2.10.5 Cross-section engine
E
A
D
2
D1
I
Fig. 0.7
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
Ref. Description
A Elbow intake manifold
B Camshaft tunnel
C Main oil collector
D1 Hydraulic tightened main bearing cap studs and con rod studs
D2
E Cover charge air manifold
F Integrated charge air manifold
G Integrated water inlet manifold
H Stiff intermediate deck
I Cross bolting main bearing cap
J Oil pan
2.11 TEST-BED MEASUREMENTS

The measurements made on the testbed are given on the sheet of the engine reception test.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
3 GENERAL MAINTENANCE RECOMMENDATIONS
3.1 WARNINGS
• Prevent the engine from starting or turning during any maintenance.
• Open the decompression valves before beginning any repairs to moving parts.
• Make certain that the crankshaft can turn without danger to the men working on the
engine or driven machines (alternators, reversing gear, etc.).
REMEMBER THAT THE REMOVAL OF OBJECTS (PISTON/CONNECTING-ROD ASSEMBLIES)

CAN UNBALANCE THE CRANKSHAFT, CAUSING IT TO ROTATE UNEXPECTEDLY.
• Inspect the nuts and bolts and their attachments as well as the air, water and oil
pipework before starting the engine.
• When rotating the engine with a bar, make sure all moving parts can move freely.
• Speed governors: It is forbidden to disassemble or re-adjust speed governors
overspeed devices or any other component which controls or limits the dynamic
conditions of the engine unless this is expressly allowed and approved by ABC and this
may only be done by authorized personnel.
• Injection nozzles: When testing the nozzles outside the engine with the nozzle tester,
observe the following precautionary measures:
• KEEP HANDS AWAY FROM THE NOZZLE SPRAY. THE SPRAY FROM A
NOZZLE CAN PENETRATE DEEP INTO THE FLESH OF THE FINGERS OR HAND AND
DESTROY TISSUE. FUEL OIL ENTERING THE BLOOD STREAM CAN CAUSE BLOOD
POISONING.
• USE ONLY CLEAN GASOIL OR TEST OIL FOR TESTING.

• DO NOT TEST THE NOZZLE NEAR A FLAME OR GLOWING OBJECT.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
3.2 TOOLING
The necessary tools include:
• Ordinary tools on the market: flat, tubular, and ring spanners, screwdrivers, etc.
• Special tools delivered with the engine
• Special tools designed by ABC and to be ordered separately
• Lifting equipment: hoisting tackle, slings, etc.
The tools needed for the mounting, dismantling or maintenance of the several engine
components, can be ordered with numbers from the maintenance book.
3.3 MASSES OF THE MAJOR COMPONENTS

Section Description Mass (kg)
01 Crankcase/cylinder block V12/4850
V16/6250
• Cylinder liner 69,5
• Cylinder head stud 1,68
• Cylinder head stud (extended) 1,76
• Bearing cap 52
• Bearing stud 5,8 (gasoil)

5,9 (HFO)
04 Main bearing line:
• Upper ½ bearing shell 0,84
• Lower ½ bearing shell 0,92
• Axial ½ thrust bearing ring 0,84
09 Piston:
• Piston in nodular cast iron (GGG) 30 – 32
• Piston pin 12,55
• Set piston rings 0,75
10 Connecting rod:
• Connecting rod with bush, bearings bolts and nuts 50
• Big end bearing shells (upper and lower together) of the 1,64
connecting rod
• Bush small end 1,60
09/10 Drive work with piston, piston pin, piston rings, piston circlips, con rod ±95 - 98
with bush, bearings, cap and bolts
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC

11 Cylinder head:
• Cylinder head with valves, bridges, rockers and support with 134,5
shaft
• Cylinder head with inserts and valve guides 105
• Inlet valve 1,10
• Exhaust valve 1,25
• Bridge rocker with pellet and adjusting screw 1,3
• Rockers with shaft and support 15,15
• Valve guides 0,27
• Rocker with bush and pellet 2,52
12 Governor:
• Woodward (UG8-L/UG8-D/UG25+) 22 – 26
• Assembly gear wheel driving Woodward governor 12
• Heinzmann actuator 15,3
13 Assembly lever adjustment injection pump 0,53
14 Fuel circuit:
• Injection pump 9,08
• Nozzle and nozzle holder 2,3
15 Pump driving:
• Gearwheel case engine driven pumps with intermediate shafts 181

and shaft drive fuel pump
• Intermediate plate ±95
• Intermediate shaft with gear wheel drive water pump 4,8
• Intermediate shaft with gear wheel drive oil pumps 10,3
16 Distribution:
• Two-parts distribution gear wheel on crankshaft 12
• Gear wheel on camshaft 21
17 Camshaft:
• Guide bearing 4
• Bearing 3,8
• Camshaft
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC

− Cylinder stud 18,6
− Begin stud 8
− End stud 15,3
18 Tappet mechanism:
• Tappet bracket 11,3
• Tappet with roll (valves) 0,94
• Tappet with roll (injection pump) 1,46
• Assembly valve pushrod 1,4
20 Turbo-compressor KBB type M40 260
21 Exhaust system:
• Expansion compensator 3,18
23 Air cooler 312
27 Standard flywheel with starting gear wheel 1029,5
29 Vibration damper type:
• ASK 3262 (H&W) 235,4
• ASK 3865 (H&W) 330,4
30 Oil circuit:
• Lubricating pump and gear wheel ±50
• Oil pressure regulating valve 10
31 Oil filter:
• Duplex oil filter 878
• Centrifugal oil filter 3,87
40/45 Soft-water circuit:
• Water pump and gear wheel 35
• Thermostatic regulating valve (nominal temp. 43°C) 35
• Thermostatic regulating valve (nominal temp. 80 – 85°C) 38
50/51 Fuel feeding:
• Fuel pump and half coupling 7,15
• Duplex fuel filter (dry weight) 20
66 Control system:
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC

• DMU (diesel monitoring unit), separate from engine 22,3
• Monitoring panel on engine 15
3.4 HANDLING OF COMPONENTS

Always use a lifting apparatus for handling important pieces, such as cylinder heads, piston and
connecting rods, and cylinders.
For specific guidelines for handling the engine, see the installation prescription manual.
3.5 PRECAUTIONS FOR MOUNTING AND DISMANTLING

During the life of the engine it is possible that it, or some parts of it, must be dismantled.
Dismantling, mounting or replacing should all be performed in a prescribed order. The executers
should be familiar with the topic and with the characteristics of the engine and its components
as described in the relevant documentation. There, you will find the procedures for the
dismantling, replacing and mounting of the important parts of the engine. Keep in mind the
following basic:
• Some parts are marked to show their position or place as mounted. Before dismantling
such a part, make sure that the marks are attached correctly. This makes it possible to
re-assemble the parts in an identical way, preventing a malfunction. Provide the
unmarked parts with a label (piston rings, bearing shells…).
• Empty the oil, water and fuel circuit according to the mounting task.
• Close the pipes and openings of the parts when dismantling them.
• Protect the components which are not immediately re-used with an anti-rust agent and
clean them before mounting.
• Renew all joints if necessary. After starting the engine again, check all joints for
leakages.
3.6 ASSEMBLY DIMENSIONS AND WEAR LIMITS

The original minimum and maximum dimensions of each part subject to wear are indicated. Also
specified are the maximum limits of wear at which the parts must be either exchanged or
reconditioned. These values are the result of long experience, they represent the point at which
the safety and proper functioning become endangered.
The values are given in the OD (original dimensions) and LW (limit of wear) columns.
3.7 STANDARDIZED DIMENSIONS FOR RECONDITIONING

Parts which can be reconditioned (e.g. crankshaft, guide bearing cap, etc.) have standardized
dimensions and tolerances. If the parts are reworked to those dimensions, parts to be fit
(bearing shells for reconditioned crankshaft, oversize half thrust rings, etc.) can be supplied
from stock.
The dimensions for the first reworking are marked R1, those for the second R2, and so on.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
4 -MAINTENANCE PROGRAM
The maintenance schedule and periodicity intervals were established by the manufacturer in
order to achieve best efficiency and reliability of the engine and lifetime of components.
Periodicity intervals are based on manufacturer’s experience.
All the maintenance jobs set out in this program are of a periodical nature. They should be
repeated at regular intervals, usually expressed in hours of service of the engine.
In order to facilitate the maintenance and to limit the time when the engine is out of service, the
operations are grouped as a small number of maintenance jobs and overhauls. They have to be
undertaken after periods of service which are multiples of each other.
The maintenance jobs of the same frequency in each group are set out in the following pages.
For each maintenance job, the basic frequency level is mentioned in running hours. Although
this is not explicitly mentioned in the table, these maintenance jobs have to be repeated each
time a multiple of the indicated running hours are passed.
4.1 MAINTENANCE (M) AND OVERHAUL (O)

The different groups of maintenance jobs are classified under one or the other of the two
classes below:
• Normal maintenance jobs
• Partial and complete overhauls
For each maintenance job is indicated if the job is applicable for an engine execution based on
the fuel type. The three main fuel types are:
• All diesel oils – DO
• Heavy fuel oil or biofuel – HFO-BIO
• Dual fuel (gas/ diesel oil) – DF
ABC reserves the right to change these service intervals depending on the
operating condition load profile, quality and/or type of fuel and lubricating oil, and
the cooling water conditions.
The stated frequency is only to be used as a guidance, but should NOT be
exceeded during the guarantee period
The frequency can strongly be influenced by the service conditions, quality of the
fuel oil, quality of the lubricating oil, treatment of the cooling water etc.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
4.1.1 Normal maintenance jobs

Normal maintenance jobs involve partial dismantling, which can be carried out by the operation
staff.
We identify eight types of maintenance operations:
Period Mark
Every week or every 100 hours M1
Every half month or every 250 hours M1a
Every month or every 500 hours M2
Every 1000 hours M3
Every 1500 hours M4
Every ±3000 hours M5
Every ±6000 hours M6
Every year M7
4.1.2 Partial and complete overhauls

This involves substantial dismantling and more specialized work, which usually entails taking
the engine temporarily out of service. We identify three overhaul periods:
Period Mark
Condition check and partial overhaul at periods of 12 000 O1
hours
The complete overhaul at periods of 24 000 hours O2
The partial overhaul at periods of 48 000 hours O3
Under normal operational conditions, ABC permits a maximum tolerance of approximately 20 %

on the periodicity of maintenance, and a maximum tolerance of 3000 hours on the periodicity of
overhauls.
The hours of running indicated on the counter or stated in the log book may in
some cases be replaced by equivalent units that vary more or less linearly
(kilometers travelled by traction units, energy produced by pumping installations or
by electricity generating sets).
4.1.3 References
For each maintenance job, a reference to the manual that contains the maintenance procedure
is added. The following manuals are referenced:
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
Manual
Manual title
code
B33 Operating manual for diesel engines ABC type 6/8/12/16DZC
B34 Maintenance manual for diesel engines ABC type 12/16DZC
B82 Manual for dual fuel engines ABC type 6/8/12/16DZD
B83 Manual for HFO engines type 6/8/12/16DZC
4.1.4 Table of maintenance jobs

C1 – Before every start or every 24 hours
Reference DO HFO- DF
Mark Part to be maintained or checked
BIO
C1 – Check water level in expansion See B33 chapter “General X X X
01 tank and oil level engine. directives” §4.1.2
C1 – Check oil level in hydraulic See B33 chapter “General X X X

02 governor. directives” §4.1.3
C1 – Check starting air pressure. See B33 chapter “General X X X

03 directives” §4.1.4
C1 – Drain off any water from the daily See B33 chapter “General X X X
04 fuel tank and the water separator directives” §4.1.5
(in fuel line).
See B34 chapter “Engine
driven pumps” – “Fuel
filtration”
C1 – Check fuel level in the daily tank. See B33 chapter “General X X X
C1 – Check for cooling water, See B33 chapter “General X X X

06 lubricating oil, fuel oil, exhaust directives” §4.1.7
and air leaks.
C1 – Clean the compressor (air intake See B33 chapter “General X X X

07 (*) side) of the turbocharger by directives” §4.1.8
water injection.
See B34 chapter
“Turbocharger”
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
M1 – Every week or every 100 hours

BIO
M1 – Fill up the automatic lubricator on See B33 chapter “General X X X
01 the starting air pipe. directives” §4.2.2
M1 – Drain off water from: See B33 chapter “General X X X

• Compressed air
receivers
• Water separator (starting
airline)
M1 – Clean water filters, if provided. See B33 chapter “General X X X
M1 – 1 Check position of See B33 chapter “General X X X

04 contamination indicator on directives” §4.2.5
oil filter at operating
temperature and nominal
speed.
2 Replace filter elements, if
necessary.
M1 - Check free passage of blow off See B33 chapter “General X X _
05 hole on air cooler, if provided. directives” §4.2.6
M1 - Clean centrifugal filter. See B33 chapter “General _ X _

M1 - 1 Lubricate the control See B33 chapter “General _ X _

07 levers, injection pump directives” §4.2.8
control rod and link of the
governor and control
spindle bearing bushings.
2 Check if each injection
pump control rod can be
moved freely.
M1 - Check drain system of the air See B82 chapter _ _ X
08 cooler, if provided. “Maintenance
instructions” §3.1.1.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
M1a – Every half month or every 250 hours

BIO
M1a – Clean the turbine (exhaust gas See B83 chapter “Engine _ X _
01 side) of the turbocharger by components”
water injection.
M2 – Every month or every 500 hours

BIO
M2 – Replace air intake filter element. See B33 chapter “General X X X
01 (*) directives” §4.4.2
M2 – Clean centrifugal filter. See B33 chapter “General X See X

02 (Frequency depends on the level directives” §4.4.3 M1 - 06
of contamination.)
M2 – Check if renewal of the fuel filter See B33 chapter “General X X X

03 elements is necessary. directives” §4.4.4
(Frequency depends on fuel
quality and possible
contamination of the filter
elements.)
M2 – 1 Lubricate the control See B33 chapter “General X See X

04 levers, injection pump directives” §4.4.5 M1 - 07
control rod and link of the
governor and control
spindle bearing bushings.
2 Check if each injection
pump control rod can be
moved freely.
M2 – Clean the magnetic filter of the See B33 chapter “General X X X
05 turbocharger. directives” §4.4.6
M3 – Every 1000 hours

BIO
M3 – Renew fuel filter elements. See B33 chapter “General X X X
M3 – Replacing filter element of closed See B34 chapter X X X

02 crankcase ventilation breather “Crankcase” – “Closed
Crankcase ventilation” -
§3.7
M3 – Checking the proper functioning See B34 chapter “Starting X X X

03 of the automatic lubricator for the system” – “Automatic
starting air system. Clean the lubricator” – §4.7
lubricator if necessary.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
BIO
M3 – Take sample of the lubrication oil See B33 chapter “General X X X
04 and make an oil analysis. directives” §4.5.5
M3 – Check rotation of exhaust valve See B83 chapter _ X _

05 rotocaps. “Maintenance
instructions”
M4 – Every ±1500 hours

BIO
M4 – Replace oil filter elements. See B33 chapter “General X X X
M4 – 1 Check cooling water See B33 chapter “General X X X

02 quality. directives” §4.6.3
2 Adjust the water treatment
if necessary.
M4 – 1 Check intake and exhaust See B33 chapter “General X X X
03 valve clearances. directives” §4.6.4
2 Adjust if necessary.
M4 – 1 Check nozzles and See B33 chapter “General _ X _
04 opening pressure of directives” §4.6.5
nozzles and their spray
pattern.
2 Replace nozzles if
necessary.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC

BIO
M5 – 1 Change engine oil. See B33 chapter “General X X X
01 2 Replace or clean the directives” §4.7.2
crankcase and crankcase
breather element.
Frequency depends on
application/working
conditions/regular oil analysis
(see M3 – 04).
M5 – Check the alarm and security See B33 chapter “General X X X

02 devices for correct function and directives” §4.7.3
operation:
• Overspeed
• Thermostats
• Pressostats
• Microswitch for
load/overload indication
M5 – Change oil of hydraulic governor. See B33 chapter “General X X _
M5 – 1 Check combustion See B33 chapter “General X X X

04 pressures at full load and directives” §4.7.5
at idling speed.
See B34 chapter
2 Adjust if necessary. “Injection system” –
“Injection mechanism
driving the fuel pump”
M5 - 1 Check nozzles and See B33 chapter “General X See X

05 opening pressure of directives” §4.7.6 M4 - 04
nozzles and their spray
pattern.
necessary.
M5 - 1 Check the condition of See B34 chapter _ X _
06 injection pump cavitation “Injection system” –
plugs. “Injection pump”
2 Renew them if necessary.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC

BIO
M6 – 1 Thoroughly examine the See B33 chapter “General X X X
01 nozzles and their holders. directives” §4.8.2
necessary.
M6 – 1 Check gear wheel of the See B34 chapter X X _
02 governor, if a mechanically “Governor” – “The
driven governor is governor drive
installed. mechanism”
2 Measure backlash.
M6 – Check tappet mechanisms: See B34 chapter X X X
03 “Cylinder head” – “Tappet
• Tappets mechanism”
• Shafts
• Rolls
M6 – 1 Check the air intake circuit See B34 chapter X X X
04 (*) and compressor wheel. “Turbocharger”
2 Clean if necessary.
M6 – 1 Check the exhaust gas See B34 chapter X X X
05 (*) circuit. “Turbocharger”
2 Clean if necessary.
M6 – Measure complete crankshaft See B34 chapter X X X
06 deflection (all cylinders) and the “Crankshaft.” –
crankshaft axial clearance. “Crankshaft”
M6 – Check the differential pressure of See B34 chapter X X X

07 (*) the air cooler and clean if “Coolers” – “Air cooler”
necessary.
M6 – 1 Check the condition of See B34 chapter X See X

08 injection pump cavitation “Injection system” – M5 - 06
plugs. “Injection pump”
2 Renew them if necessary.
M6 - Check the valve wear (measure). See B34 chapter X X X
09 “Cylinder head” – “Inlet
and exhaust valves”
M6 - Check the condition the elastic See B33 chapter “General X X X

10 coupling on the flywheel and (if directives” §4.8.11
present) the PTO coupling.
M6 - Check the oil mist detection unit. See B33 chapter “General X X X
M6 - Check the preheating module. See B33 chapter “General X X X

GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
BIO
M6 - Check the gas actuator and See B82 chapter _ _ X
13 throttle valve. “Maintenance
instructions”
M6 - Check the pollution of the fuel See B82 chapter _ _ X

14 cooler. “Maintenance
instructions”
M7 – Every year
BIO
M7 – Check the gas train. • See specific _ _ X
01 manual(s)
• See B82 chapter
“Maintenance
instructions”
M7 - Check the gas detection • See specific _ _ X
02 components. manual(s)
• See B82 chapter
“Maintenance
instructions”
M7 - Check the explosion relieve See B82 chapter _ _ X
03 valves on the air collector and on “Maintenance
the exhaust collectors. instructions”
M7 - Check the knocking sensors and See B82 chapter _ _ X

04 have them calibrated. “Maintenance
instructions”
M8 - If the engine is mounted on See B33 chapter “General X X X

05 flexible supports, check the directives” §4.9.6
condition of the supports.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
Every 12 000 hours

BIO
O1 – Check the condition of the See B34 chapter X _ X
01 cylinderheads to determine if a “Cylinder head”, sections:
top overhaul of the complete
engine is necessary. If required, • “Cylinder head”
see below. • “Rocker lever
mechanism”
Perform a complete overhaul of X
cylinder heads. • “Inlet and exhaust
valves”
1 Remove the valves, if See B34 chapter “Starting
necessary, grind or renew system”, section “Cylinder
the valves and/or seats. head starting valve”
2 Check the valve guides
and renew them if
necessary.
3 Check the valve springs
and collars.
4 Check valve dimensions
and renew if necessary.
5 Perform a complete
overhaul of the valve
mechanism on the cylinder
heads (bridges rockers,
bushes and shaft).
6 Replace all joints (water,
oil, air and exhaust gases).
7 Check the opening
pressure on the relief
valves on the cylinder
heads.
8 Clean the oil ducts.
9 Renew the rocker bushes
and check shaft for
dimensions.
10 Renew the rotocaps.
11 Perform an overhaul of the
cylinder head starting air
valve.
O1 – 1 Check the injection timing See B34 chapter X X X
02 (BI). “Injection system” –
2 Check tightness of “Injection mechanism
injection pump plungers driving the fuel pump”
and of the relief valves.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
BIO
O1 – Perform an overhaul of the See B34 chapter “Engine X X X
03 seawater pump, soft-water pump. driven pumps” – “Fresh
water pump (HT water
pump)” and “Sea water
pump
O1 - 04 For viscous damper, take a See B34 chapter X X X

sample of the damper’s silicon oil “Crankshaft” – “Torsional
for analysis. vibration damper”
O1 – Visually inspect the distribution: See B34 chapter “Timing X X X

05 gear”, sections:
• Gear wheels
• Cams • Camshaft
• Camshaft bearing taps • Timing gear

wheels
• Bearings
O1 – Visually inspect the pump driving See B34 chapter “Engine X X X
06 gear wheels in the gear case. driven pumps” – “Pump
gear case”
O1 – Not applicable Not applicable _ _ _

07(*)
O1 – Perform a complete overhaul of See B34 chapter _ X _

08 the turbocharger (including “Turbocharger”
bearings).
O1 – Renew the water separator filter. See B34 chapter “Starting X X X

09 system” – “Water
separator”
O1 – Perform an overhaul of the See B34 chapter X X X

10 hydraulic stop cylinder. “Governor”, section
“Specific components
injection pump control
system” – “Automatic stop
device”
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
Every 24 000 hours

BIO
O2 – Perform a complete overhaul of See B34 chapter X See X
01 the cylinder heads. “Cylinder head”, sections: O1 -
01
1 Remove the valves, if • “Cylinder head”
necessary, grind or renew
the valves and/or seats.
• “Rocker lever
mechanism”
2 Check the valve guides
and renew them if • “Inlet and exhaust
necessary. valves”
3 Check the valve springs See B34 chapter “Starting
and collars. system”, section “Cylinder
head starting valve”
4 Check valve dimensions
and renew if necessary.
5 Perform a complete
overhaul of the valve
mechanism on the cylinder
heads (bridges rockers,
bushes and shaft).
6 Replace all joints (water,
oil, air and exhaust gases).
7 Check the opening
pressure on the relief
valves on the cylinder
heads.
8 Clean the oil ducts.
9 Renew the rocker bushes
and check shaft for
dimensions.
10 Perform an overhaul of the
cylinder head starting air
valve.
O2 – 1 Take out the pistons. See B34 chapter “Drive X X X
02 2 Measure the clearance unit (piston and conrod)
and wear of the piston ring
grooves.
3 Renew the piston rings.
O2 – 1 Measure the wear (ovality See B34 chapter X X X
03 and conicity) of the liners. “Cylinder housing”
2 Remove and hone the
liners, renew them if
necessary.
3 Replace seal O-rings.
4 Replace anti-polishing
rings.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
BIO
O2 – 1 Replace the con rod big See B34 chapter “Drive X X X
04 end bearing shells. unit (piston and conrod)
2 Check the condition of the • “Dismounting
con rod small end bush, procedures
replace if necessary.
• “Maintenance
procedures
conrod”
O2 – 1 Check the condition of the See B34 chapter X X X
05 main bearings, including “Cylinder housing” –
axial bearings. “Main bearing caps and
2 Renew if necessary. shells”
O2 – 1 Check the hydraulic or See B34 chapter X X X

06 electronic governor. “Governor system” –
2 Return it to the “Speed governor - UG”
manufacturer, if
necessary.
O2 – Perform a complete overhaul of See B34 chapter X X X
07 the fuel injection pumps. “Injection system” –
“Injection pump”
O2 – 1 Check the gear wheel See B34 chapter “Engine X X X

08 pump casing. driven pumps” – “Pump
2 Renew the bearings. gear case”
3 Visually check the
gearwheels and measure
the gearwheel clearances.
O2 – Perform a complete overhaul of a See B34 chapter X X X
09 viscous vibration damper. “Crankshaft”, sections:
• “Torsional
vibration
dampers”
• “Secondary PTO”
O2 – Perform a complete overhaul of See B34chapter X See X
10 (**) the turbocharger (including “Turbocharger” 01 - 08
bearings).
O2 – 1 Perform an overhaul of the See B34 chapter “Engine X X X

11 oil and fuel feed pump. Driven pumps”, sections:
2 Replace the fuel feed • “Lubricating oil
pump connection and pump and
sealings. pressure valves”
• “Fuel feed pump”
O2 – Perform a complete overhaul of See B34 chapter X X X
12 the flexible pump drive on a “Crankshaft” – “Flexible
viscous damper.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
BIO
coupling pump driving
gear”
O2 – Perform an overhaul of the main See B34 chapter “Starting X X X

13 starting air valve. system” – “Main starting
valve”
O2 – 1 Wash out the cylinder See B34 chapter X X X

14 block, remove the “Cylinder housing”
deposits.
2 Repaint the interior if
necessary.
O2 – 1 Perform an overhaul of the See B34 chapter “Engine X X X
15 HT, LT and oil thermostatic driven pumps”, sections:
valve.
• “Thermostatic
2 Renew the thermostatic valve oil circuit”
elements.
• “Thermostatic
valve water
circuit”
16

17(*) governor gear drive. “Governor” – “Speed
governor drive
mechanism”
O2 – Completely clean the oil plate See B34 chapter X X X

18 cooler. “Coolers” – “Oil cooler”
O2 – Perform an overhaul of the oil by- See B34 chapter “Engine X X X

19 pass valve. driven pumps” –
“Lubricating oil pumps
and pressure valves”
O2 – Renew the camshaft bearings, if See B34 chapter “Timing X X X

20 present. gear” – “Camshaft”

21 crankcase safety valves. “Crankcase” –
“Crankcase”
O2 – Perform an overhaul of the PTO See B34 chapter X X X

22 bearing, if present “Crankshaft” –
“Secondary PTO”
O2 – Completely clean the air cooler. See B34 chapter X X X

23 “Coolers” – “Air cooler”
O2 – Clean the expansion tank. See B33 chapter “General X X X

24 directives” §4.10
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
Every 48 000 hours

BIO
O3 – Replace the main bearings and See B34 chapter X X X
01 axial bearing. “Cylinder housing” –
“Main bearing caps and
shells”
O3 – Replace con rod bolts and nuts. See B34 chapter “Drive X X X
02 (***) unit (piston and conrod)
• “Dismounting
procedures
• “Maintenance
procedures
conrod”
03
O3 – Renew the cylinder liners. See B34 chapter X X X

04 “Cylinder housing”
O3 – Renew the insulation on the See B34 chapter X X X

05 exhaust pipe, if necessary. “Turbocharger”
O3 – Renew all bearings of the fuel See B34 chapter X X X

06 pumps control spindle. “Injection system” –
“Nozzle holder and nozzle
or injector”
O3 – Renew the pressure and thermal / X X X

07 switches (alarm & safety).
Ref. Description
* Depends on the environment (air pollution, engine room ventilation, water quality...)
** For applications with frequent load changes, the complete overhaul is

recommended at 12 000 hours.
*** Conrod bolts and nuts must be replaced, after loosening if they already have been
tightened 3 times before, or every 48 000 hours, whichever comes first.
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
4.2 MAINTENANCE INTERVALS AND OVERHAUL ORDER

Mark
Service hours
(C = Check, M = Maintenance, O = Overhaul)
Every week or every 100 M1
hours
Every half month or every 250 M1a

hours
Every month or every 500 M1 + M1a + M2

hours
Every 1000 hours M1 + M1a + M2 + M3
Every ±1500 hours M1 + M1a + M2 + M4
Every ±3000 hours M1 + M1a + M2 + M3 + M4 + M5
Every ±6000 hours M1 + M1a + M2 + M3 + M4 + M5 + M6
Every year M7
Every 12 000 hours M1 + M1a + M2 + M3 + M4 + M5 + M6 + O1
Every 24 000 hours M1 + M1a + M2 + M3 + M4 + M5 + M6 + O1 + O2
Every 48 000 hours M1 + M1a + M2 + M3 + M4 + M5 + M6 + O1 + O2 + O3
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
5 TIGHTENING TORQUES
All dynamically strained bolts and nuts as well as functionally important fastening bolts are
tightened by means of a torque wrench on a predetermined tightening torque as described in
the Tightening torque table. The nuts for fastening the cylinder block on the crankcase and for
fastening of cylinder head are tightened according to the angular displacement method. The
nuts of the connecting rod bolts are tightened on elongation. Both specific tightening methods
are described in detail in the maintenance manual.
Table 0.1 Tightening torque table

Component to be Type of Tightening torque
Bolt material
tightened or inserted thread Nm kg
Crankcase & cylinder block (sec. 1)
Bearing cap studs M42 x 2 100 10 30CrNiMo8V

(implantation)
Bearing cap stud nuts M42 x 2 Hydraulic tightening in 2 steps from 34CrNiMo6V
110 kN to 800 kN following the
procedure in the maintenance
manual, chapter “Cylinder block”.
Reference check angle rotation:
307° ± 6
Sidebolts bearing caps M27 1000 100 DIN912 – 12.9
400 40
+60° +60°
(Molykote G-N plus) Tightening in 2

steps following the procedure in the
maintenance manual, chapter
“Cylinder block”
Bolts engine supports M24 1000 100 DIN912 – 10.9

against cylinder block
Crankshaft (sec. 6)
Bolts fixing balance M30 x 2 1000 100 Regular

weights on crankshaft DIN912 – 10.9
(DIN912 or elastic bolts Tightening following the procedure screw
(35CD4/42CD4) given in the maintenance manual,
chapter “Crankshaft”. Reference
check angle rotation: 88° ± 10
M30 x 2 850 85 34CrMo4V

(35CD4) or
Tightening following the procedure 42CrMo4V
given in the maintenance manual, (42CD4)
chapter “Crankshaft”. Reference
check angle rotation: 80° to 90° Elastic bolts
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC

Bolt material
Distribution gear wheel M12 120 12 DIN931 – 10.9
bolts (spare parts
manual section 016)
Connecting rod (sec. 10)
Connecting rod studs M33 x 2 100 10 34CrNiMo6V

(implantation)
Nut connecting rod bolts M33 x 2 Hydraulic tightening in 2 steps from 34CrNiMo6V
110 kN to 510 kN following
procedure given in the
“Drive unit”. Reference check angle
rotation between 2 steps: 110° ± 10
Cylinder head (sec. 11)
Cylinder head studs M24 x 2 100 10 X5CrNiCuNb17.4

(implantation)
(Loctite no. 222)
Cylinder head nuts for M24 x 2 245 25 42CrMo4V+K

cylinder housing for
arrangement 02 +110°+110° +110°+110°
(Consult the maintenance Only tighten the nuts hydraulically!

manual, chapter “Cylinder Use Molykote G-N plus
head” to determine the Refer to the maintenance manual,
cylinder housing chapter “Cylinder head”
arrangement of your
engine.)
Cylinder head nuts for M24 x 2 245 25 42CrMo4V+K

cylinder housing for
arrangement 01
(Consult the maintenance

+85°+85° +85°+85°
manual, chapter “Cylinder
head” to determine the Use Molykote G-N plus
cylinder housing Carefully follow instructions in
arrangement of your maintenance manual, chapter
engine.) “Cylinder head”
Studs for rocker M16 ±50 ±5 42CrMo4V

brackets (implantation in
cylinder head) (Loctite no. 245)
Nuts for fixation rocker M16 155 16 10 DIN982

bracket studs
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC

Bolt material
Central bolt for fixation M16 155 16 42CrMo4V+K
rocker bracket
Rocker shaft locking M12 85 8,6 8.8 DIN912

bolts
Nut nozzle holder M56 x 2 195 20 Ck55
(Loctite no. 542)
Safety valve in cylinder M39 x 137 14 – 15 /

head 1,5
Governor drive (Woodward) (sec. 12)
Bolts driving gearwheel M8 25 2,5 8.8 DIN912

on camshaft gearwheel
54T (Loctite no. 243)
Bolts gear 27T M8 25 2,5 8.8 DIN912
(Loctite no. 243)
Self-locking nuts fixing M10 30 3 8 DIN985

conical gears UG8,
UG25+
Fuel feeding (sec. 14, 18, 59)
Injection pump bolts M12 50 5 36NiCr6 V+K /

42CrMo4+QT+C
(Section 018)
Cap nut fixing nozzle M76 x 2 540 55 42CrMo4V

holder in cylinder head
(Molykote G-N plus)
Mount following instructions in
“Injection system”
Nozzle nut / 217 21,7 /
Coupling nuts injection /

pipe
• Type 1: M22 x 60 ± 5 6,1 ± 0,5

620.058.1100.04 1,5
• Type 2: M22 x 60 ± 5 6,1 ± 0,5

620.058.1100.05 1,5
• Type 3: M22 x 105 ± 5 10,5 ± 0,5

620.058.1100.06 1,5
/ 868-895 88,5 – 91 /
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC

Bolt material
High pressure fixation (Molykote G-N plus)
nut injection pump
Screws flange fixation M10 34,5 3,5 8.8 DIN912

extended coupling piece
Pump driving gear casing (sec. 15)
Bolts & nuts for fixation M12 85 8,6 8.8 DIN912

carter
M12 145 14,5 12.9 DIN912
M12 85 8,6 8 DIN934
Nuts & bolts fixing M10 50 4,9 8 DIN982

intermediate shafts on
gear casing M8 25 2,5 8.8 DIN7984
Lock nuts intermediate M30 x 120 12 /

shafts 1,5
Coupling bolts M10 50 4,8 8.8 DIN933

intermediate gear wheel
(Loctite no. 542)
Nut drive gear wheel oil M30 x 250 25 /

pump 1,5
Nut drive gear wheel M24 x 2 147 15 8 DIN 439-B

water pump (see (Loctite 270) (Molykote)
maintenance manual for
mounting instructions) M25 x 147 15 /
1,5 (Loctite 270) (Molykote)
(loco
appl.)
Nut connecting impeller M20 147 15 DIN934-A2 (left)

of water pump (see (left hand
maintenance manual for nut) (Loctite 270)
mounting instructions)
M24 x 3 147 15 DIN935-A4
(Right (right)
hand nut)
(Loctite 270)
(Loco
appl.)
Bots fastening water M10 39 4 8.8 DIN931

pump on gear wheel
case
Camshaft – distribution (sec. 17)
M12 120 12 10.9 DIN933
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC

Bolt material
Bolts fixing guide (Loctite no. 270)
bearing(s) camshaft to
cylinder block
Camshaft connecting M12 120 12 10.9 DIN933

bolts
Bolts camshaft bearings M12 120 12 10.9 DIN912
M8 25 2,5 8.8 DIN912
Tappet bracket fixing M12 120 12 10.9 DIN912

bolts
Fixing bolts camshaft M12 120 12 10.9 DIN 931

gearwheel
Coupling bolts M12 120 12 10.9 DIN933

intermediate gear wheel
(Loctite no. 245)
Bolts bearing cap front M12 120 12 10.9 DIN931

end (bank A)
Turbochargers and exhaust manifolds (sec. 20, 21)
Nuts attachment support M16 210 21 8.8 DIN931

on intermediate plate
Elastic bolts exhaust M16 200 20 34CrNiMo6V

collectors
(Molykote HSC)
Flywheel (sec. 27)
Flywheel bolts M30 x 2 2200 225 10.9 DIN960
(Loctite no. 572)
Vibration damper (sec. 29)
Vibration damper Hasse M20 x 640 64 10.9 DIN912

& Wrede 1,5
GENERAL 12/16 DZC
Ed. 09 – 30/09/2020 – EN
General 12/16 DZC
This page is intentionally left blank.

Description and Applications Manual For Diesel Engines ABC Type 12/16DZC

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Description and Applications Manual For Diesel Engines ABC Type 12/16DZC

Uploaded by

Copyright:

Available Formats

B31

Description and applications manual

Anglo Belgian Corporation

This edition supersedes any previous editions of this document.

ALL RIGHTS RESERVED

Our number is in Belgium: phone: 09 - 267.00.00.

Chapter 0 : General 12/16 DZC Ed. 09

This page is intentionally left blank.

GENERAL 12/16 DZC

1 DEFINITIONS AND TERMINOLOGY

1.1 ENGINE TYPE INDICATION

1000 Nominal engine speed in rpm

Code Number Pme (bar)

A Direction of rotation counterclockwise as seen by an observer looking to the

K Direction of rotation clockwise as seen by an observer looking to the

1.2 NUMBERING OF THE CYLINDERS

Ref. Sense of rotation

Fig. 0.1 Numbering of the cylinders

1.3 TABLE OF ABBREVIATIONS

BDC Bottom dead center

Con rod Connecting rod

PPE Personal protective equipment

rpm Revolutions per minute (rev/min)

TDC Top dead center

TKP Turbo side pump-side

TKV Turbo side flywheel

2.1 TECHNICAL SPECIFICATIONS ACCORDING TO ENGINE TYPE AND

Parameter Abbreviation Unit

Nominal revolutions/minute N rev/min

Mean effective pressure Pme bar

Maximum combustion Pmax bar

Mean piston speed at Cm m/s

2.2 DERATING COEFFICIENTS FOR AMBIENT CONDITIONS

The table below gives an overview of the reference conditions:

Altitude/ Total barometric pressure 800 m 0m

Derating Ambient Temp Derating Coolant Temp

Derating coefficient B [%]

Fig. 0.4 Altitude (C)

2.3 CONSUMPTION ACCORDING TO ENGINE TYPE AND APPLICATION

2.4 NOMINAL DIMENSIONS

Swept volume per cylinder 15,95 dm³

Compression ratio 12,1 : 1

Total swept volume:

• 12 cyl. 191,4 dm³

• 16 cyl. 255,2 dm³

• Main bearing shell 240 mm

• Connecting rod bearing shell 200 mm

• Piston pin 110 mm

• Injection pump piston 20 mm

Thread cylinder head stud: M24 x 2

• Connecting rod (center to center) 620 mm

• Cylinder block studs 376 mm

• Connecting rod bearing 72 mm

• Connecting rod bush 65 mm

• Chrome-plated fire ring 5 mm

• Inlet valve 20,40 mm

• Exhaust valve 20,40 mm

• Injector nozzle needle 0,6 mm

• Inlet cam 18,3 mm

• Exhaust cam 18,3 mm

Distance between cylinders 380 mm

Number per cylinder:

• Top piston ring 1