@ M 20Mak Engineer's Handbook M20 Contents Camshaft Camshaft bearing 2 Dismounting - mounting 30-31 Tightening torques 30 Vibration damper 32 Charge air cooler mounting Cleaning 6 Dismounting - mounting 46 Tightening torques 4 Connecting rod Gap 2 Piston pin bush 2 Reference dimension 2 Tightening torques a Crankshatt Counterweight B26 Crank web deflection B Gap B Marking a Norrnal main bearing - located main bearing 4 Tightening torques 2 Cylinder head Exhaust gas manifold 7 Fuel injection valve 1213 Guiding bolts for the valve bridges 12 Tightening torque 6 Valve bridge - setting 8 Valve clearance 8 Valve guide 8 Valve rocker 7 Valve rocker bracket 6 Valve seat ring W Valve stem 9-10 Engine data 5 Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 1Mak Engineer's Handbook M20 Contents Firing sequences 6 cyl. engines ry] 8 cyl. engines a7 9 cyl. engines 47 Flywheel mounting Dismounting - mounting 40 Gear rim on flywheel for pneumatic starter 40 Flywheel variants a ( Fuel injection pump Check of commencement of fuel delivery 36 Dismounting - mounting 36 Fuel distributing and collecting pipe 3335 Tightening torques 334 Gear train Backlashes 2 Gear wheel on camshaft 2 Gear wheel on crankshaft 2 Intermediate wheel - end clearance 28 Intermediate wheel - mounting 21-28 Lub. oil injectors for the gear drive 28 Governor drive Backlashes a End clearance 9 Governor drive gear 2 Liner . Canyon 18 ° Fire ring 20 Mounting 19 Nominal size 8 Pocket 18 Score 18 Wear limits 18 Wedge shape 18 Indication 4 Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 2Mak Engineer's Handbook M20 Contents Lower valve drive 37 Miscellaneous items Regulating shaft 38 Fuel indicator 38 Cooling water distributing pipe 39 Opposite site of coupling Vibration damper 2 Piston Piston rings 16-17 Removal 7 Tightening torques Mahle 14-15 Tightening torques MHW 15-46 Pump carrier with attached pumps Backlashes 4 Cooling water pump 43-44 Fuel feed pump 43.44 Lub. oil pump 43-44 Pump cartier B Pump carrier plate B Sizes and weights 48-43 Valve timing Inlet and exhaust valve 47 Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 3Mak Engineer's Handbook M20 | Indication By constructional measures on the injection system and by simple and permanent setting of the ignition timing and the fuel rack reading - already during assembly of the engine - adjustment of the firing pressures during the test bed run can be avoided. Therefore, firing pressures and compression pressures are not stated in the acceptance test records. ‘On the occasion of checks and measuring trips later on indicating shall not be carried out. Only in exceptional cases and only after consulting the technical service CKT the setting of the injection pumps may be changed. The following values serve for judgment on possible failures: 1. Engine speed 2. Fuel rack reading 3. Lubricating oi! tinlet engine 4, Fresh water tinlet engine t inlet charge air cooler ‘outlet turbocharger 5. Charge air temperature t before cooler 6. Exhaust gas temperature t after cylinder 7. Lub. oil pressure 8. Fresh water pressure 9. Charge air pressure after charge air cooler 10. Differential pressure at the charge air cooler toil cooler inlet t outlet engine t outlet charge air cooler thefore engine tafter turbocharger Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 4__Engineer’s Handbook M20 Engine operating data Stroke = 300 mm Tomperatures Bore = 200 mm — tub. oil Speed, rpm = 900-1000 Engine intet 50-55°C (stationary engines) 50-60°C Main bearing Temperature rise 6- 10°C Inside = 180 mm Fresh water circulation cooling Outside B = 190 mm a Engine outlet 80- 85°C Big end bearing Temperature rise 7-10°C Inside @ = 152 mm Charge air Outside = 161 mm Engine inlet 45-60°C Valves, inlet and exhaust Pressures Length = 26 mm Lub. oil Shaft 0 = 14.05. mm At the last main bearing 4.0 4.5 bar Valve disk = 6 mm Fresh water circulation cooling Valve guide > 25 bar Length = 15 mm With attached 20 Inside @ 2M mm ataenes pumps vA Nozzle cooling 1.5 - 3.0 bar Fuel pressure before injection pumps 1.5- 4.0 bar forrated engine output and nominal speed. Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 5Mak Engineer's Handbook M20, { Cylinder head Tightening torque The tightening torque for inserting the tie bolts is —> M = 300 Nm Lengthen bolts with —> P= 600 7 bar and tighten nuts with pin by hand. Check: Reduce pressure to. > P= 50 bar Loosening the nuts must not be possible any more. The pressure must remain constant it the pump is not operated, otherwise faulty tightening. Dismounting: It the cylinder head nuts cannot loosened with P » 600 bar, an increase by 50 bar is possible. Further pressure increase involves the risk that the thread will expand and the nuts will jam. At the control bore 1 - leakages between cylinder head, flame ring and cooling water distributing housing can be detected. Valve rocker brackat The tightening torque for inserting the studs - 4 -is > Tighten nuts - 1- with > The tightening torque for inserting the studs - 2-is —> Tighten nuts = 2- with > 1 M = 6 Nm 2 allan NG a PL WZ Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 6Mak Engineer's Handbook M20 { Cylinder head ] Valve rocker (inlet and exhaust) Original size. —> Clearance limit —> Zz 3 Reference size for the bush after pressing-in® —> co ae mm The bush shall recede after pressing-in by —> 0.20 mm Before pressing-in slightly coat the bushes with oil, Molykote must not be used. When shrinking:in new ball pins by supercooting attention must be paid to the accurate position - 1 - in order to guarantee perfect oil supply. (Supercooling to -195 ° € with nitrogen) Exhaust gas manifold Tighten screws to cyl. head alternately. — . ist step up to > M = 60 nm J and Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 7Mak Engineer's Handbook M20 [ Cylinder head Sotting of valve bridges and valve clearances 1. Turn out adjusting screws - 1 of the valve rockers to obtain a sufficient clearance. 2. Turn out adjusting screws - 2 - of the valve bridges to obtain a clearance when valve bridges ..X” touches .¥". 3. Screw in adjusting screws - 2 until the valve bridges rest ‘on the valves without clearance. 4. Hold adjusting screws - 2 - fast and lock them. 5, Adjust valve clearance The valve bridges were moditied. On modern engines visual checks allow to ascertain if the valve bridge fits on the valve stem. Valve clearance Setting under hot running conditions, abt. 15min after stopping the engine. Inlet > Exhaust. > After repairs in cold engine condition: Inlet > Exhaust —> Valve guide {olet - Exhaust Nominal clearance —> Clearance limit —> 2 Valve bridge Oil supply / x 0.60 mm 0.80 mm 0.60 mm 065 mm 0.40 mm Measure diameter of the valve shatt in the guide area, Measure guide in cross direction of engine. The valve guides are inserted in the cylinder head after cooling them down to -195 ° C (liquid nitrogen) Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 8Mak Engineer's Handbook M20 | Cylinder head | Grinding of inlet and exhaust valves Apply small dots of the diamond paste Dp 30/10-15 my with a syringe to the new or remachined valve cone and distribute the paste equally. Thereafter 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. Insert the oiled valve stem into the guide bush. Fasten the device at the valve disk and grind the valve face and seat by hand applying a moderate pressure, rotating the device. The contact reflection ,,a" which is visible by the smooth grinding process shall not exceed 30% of the seat width starting from the outside diameter. If the bearing characteristics described above are not reached, remachining of both sealing surfaces is necessary. After machining both seats have to be checked with a luminous magnifier. The fillet must not be refinished. After machining round off the outside edge with a stone. The dimensions specitied in the sketch are to be observed. | Deviations from the true running The deviation from true running on the valve stem must not exceed 0.04 mm on the measuring distance "S" of 200 mm. J The deviation from true running on the valve Q 5 0 cone must not exceed 0.02 mm. a For both measurements the valve stem must lie in the measuring device at points A and B, Reuse of a valve stem is not possible if: 1. there is severe pitting on the bottom side of the valve head {formation of so-called “paving stones") 2. there are corrosion pits and mechanical damages in thearea of the valve, stem, stem transition, and valve head, 5 the limit for refinishing is exceeded. be +—ol 2 4. In case of corrosive material wear of 2 % from the valve disk diameter. In case of high - temperature corrosion" $ " of 1.50 mm, Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 9Mak _Engineer’s Handbook M20 ( Cylinder head The valve stems are used as specified below: Inlet exhaust Generator ship HFO —1,10.7-22.10.01-01 / -03 1.10.7-22.10.01-01 MDO = 1.10.7-22.10.01-01 / -03 1.10.7-22.10.01-01 Generatorstation HFO — 1,10,7-22.10.01-01 /-03 1.10.7-22.10.01-02 i) MOO — 1.10.7-22.10.01-01 /-03 1.10.7-22.10.01-01 Main engines HFO —1,10.7-22.10.01-01 / -03 1,10.7-22.10.01-02 MDO = 1.10.7-22.10.01-01 / -03 1,10.7-22.10.01-01 Engines built from the middle of 1997 generally have the valve stem 1.10.7-22.10.01-03 in the inlet. Edition ~~ Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 10M20 Fitting of valve seat rings 1. Cool valve seat ring down to -195°C (liquid nitrogen). 2. Insert inlet and exhaust valve seat rings. 3. When the vaive seat rings are tight, press them on with hydraulic device. 4. Check of the bearing surface .¥ 2", between inlet valve seat ring and cylinder head No air gap is admissible. 5. Check of the air gap .¥ 1", between exhaust valve seat ring and cylinder head, Admissible air gap 0.24°? mm. Pressure test: Cooling water spaces 10 bar for 8 min, Valve seat rings Maximum admissible dimension for refinishing the exhaust valve seat ring: Recess Y must remain palpable inlet valve seat ring: Minimum dimension ,2" must not be less than Imm by refinishing Refinishing is possible with MaK valve refacer or MaK valve seat milling device. After grinding there shall be a bearing face of 30-50 % starting from the outside diameter. Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG a]Mak Engineer's Handbook M20, { Cylinder head Guiding bolts forthe valve bridges. The tightening torque forthe guiding bolts is —> Tighten the sleeve for the fuel injecion vaive with —> M = 100 Nm Fuel injection valve The tightening torque for inserting the studs is > Mo: 4 Nm and loosen again, than tighten with —> M = 30 Nm Tighten nozzle nut with —> M = 250-20 Nm Oil lubrication Removal Loosen pressure screws - 1 - and- 2-. Loosen transverse thrust piece - 3 - with cover ~ 4 - by lever effect, then force radial thrust piece - § - out of its end position (Importantotherwise damages are inevitable.) Unscrew nuts from the injection valve. Remove flange - 6 - and mount it again inversely (180 °). Screw extractor - 7 - on adjusting screw - 8 - andioosen nozzle holder by turning against the flange - 6 -. Withdraw the injection valve from the cylinder head Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 12Mak, Engineer's Handbook M20 L. Cylinder head Sequence of installation: 5 1. Insert injection valve, tighten ace. to specification, and loosen it again 2, Fitradial thrust piece - 5 - and transverse thrust piece - 3 -. 3. First tighten pressure screw - 2-, then pressure screw - 1 - manually, then tighten pressure screw - 2 and after that pressure screw - 1 - acc. to specification. 4, Tighten injection valve ace. to specification. Tighten pressure screw - 1- and - 2- with —> M = & Nm Scews M10x 55 DIN 912 Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 13Mak Engineer's Handbook M20 { _Piston Mahle 1.10.7-26.70.00-01 The tightening torque for inserting the studs in the piston crown is —> Tighten nuts with —> loosen nuts again and check the tightening torque for inserting the studs with > Pretighten nuts with —> and tighten with > Check : Ata torque of —> ‘the nuts must not turn further. Mahle 1.10.7-26.70.00-02 / 08 / 04 / 05 The tightening torque for inserting the studs in the —— piston crown is —> M = 10 Nm Pretighten nuts with —> then tighten with —> loosen nuts again and check the tightening torque for inserting the studs with —> Pretighten nuts with —> M 15 Nm and tighten with —> Dw = 50° Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 14Mak Enginee | Check : At a torque of —> the nuts must not turn further. Coat thread and contact surface of the nuts with Molykote paste G-n. Attention : In case of reinstallation replace studs it projecting length of bottom support exceeds 71.3 mm. MHW 1.10.7-26.70.00-22 Fitting specification Insert fixing pin (spring cotter) into the piston crown. Coat thread in Coat thread of the stud with graphite paste, insert it into the the piston crown and tighten smoothly with —> Spray piston crown and skirt with corrosion preventing oil. Grease t torsionless into the piston skirt, Put the piston skirt on the piston crt the piston crown with motor oil 30 Nm he joint ring and insert it own. Grease the spherical washers as well as the nut thread with graphite paste and tighten the nut until you feel the first resistance. Check gap size between piston crown and skirt at 4 points {each time shifted by 45° in circumferential direction). Nominal value —> 0,06 + 0,02 mm Tighten nuts alternately in steps of —> M = 10 Nm upto > M = 9 Nm and loosen again. Check the tightening torque of the stud in the piston crown with —> M Nm Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 15MaAK __ Engineer's Handbook M20 Tighten nuts until you feel the first resistance and then alternately in stops of —> upto > M = 4045 Nm Wear and clearance limits Grooves Groove height Ringheight Wear limit Clearance limit 1 geor-on 495 oo0.0ms 560 065 2 5-0 495 sor0.0ns 5:60 065 3 5 1008-008 495 sor0.ons 5:60 065 4 6 1008-008 6,00 com.oors 6.50 050 1 gear oe 495 soro.oms 5:60 065 2 ganar 495 sor0.ons 5:60 065 3 1G 1006-008 6,00 poro-oms 6:50 0.50 Piston rings gas oil operation Piston 1.10.7-26.70.00-01 / -02 / -03 /-04 Ring groove ting 1 Rectangular ring 1.10.7-26.17.01-05.1 243 Compression ring 1.10.7-26.17.01-06.1 4 Oil scraper ring 1.10.7-26.17.01-03.1 Piston 1,10.7-26.70,00-05 / -22 Ring groove ting 1 Rectangular ring 1.10.7-26.17.01-05.1 2 Compression ting 1.10.7-26.17.01-06.1 3 Oil seraper ring 1.10.7-26.17.01-03.1 Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 16MaAK ___Engineer’s Handbook M20 ( - Piston Piston rings heavy fuel operation Piston 1.10.7-26,70.00-01 / -02 / -03 / -04 Ring groove ring 1 Rectangular ring 1.10.7-26.17.01-04.1 243 Compression ring 1.10.7-26.17.01-06.1 4 Oil scraper ring 1.10,7-26.17.01-08.1 Piston 1.10.7-26.70.00-05 / -22 Ring groove ring 1 Rectangular ring 1.10.7-26.17.01-04.1 2 Compression ring 1.10,7-26,17.01-06.1 3 Oil scraper ring 1.10.7-26.17.01-03.1 Arrange the ring butts in longitudinal direction of engine alternately opposed. Fit piston rings with marking upwards. Removal In order to avoid loosening of the cylinder liner during removal of the cylinder head or subsequent turning, the cylinder liner has to be secured always in the crankcase by means of the retainer. Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 7Mak __Engineer’s Handbook M20 ( Liner Nominal size 6 (original size) —> Wear limits Wear and tear value —> Max. ovality —> Wedge shape Height —> Depth* — Wedge - shape indentation across the entire circumference, beginning at TDC 1st piston ring. Canyon Max. number —> Length — Total width —> Individual deep blow - through ducts in the area of the 1st piston ring, (TDC). 200.00 * * mm 0.80 mm mm 6.00 mm 6.00 =, 3.00 mm Score Number —> 3 J Length > wooo Depth —> 0.03 mm Hard vertical, linear friction marks. Pocket Number —> 3 Length —> 45.00 mm Width** + 15.00 mm Depth* —> 0.02 mm Areal, irregular indentations. Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 18Mak Engineer's Handbook M20 { Liner Radius r= 3 mm In circumferential direction Wedge shape —_— Pocket Score TDC 1st ring Canyon The liner must slide into the cylinder crankcase by its own weight Attention must be paid to the correct installation position, i.e. the mark - 1 - must point to flywheel side in Jongitudinal direction. On the cooling water distributing ring there is a cast lug - 2- serving as alignment aid. 1 Edition Service document of 28/11/1998 Mak Motoren GmbH & Co. KG Page 19MaK _Engineer’s Handbook M20 | Liner For dimensional checking the measuring points cr marked in the sketch shall be used. Fire ring Newer engines are equipped with fie rings in the liners In this case the broader joint ring is used between liner and cylinder head ” Old joint ring 11.8 mm ate New joint ring = = 15.0 mm Both joint rings are 5 mm thick, the oversize rings are 6 mm thick. Removal of the fire ring 1, Clean groove in the fire ring, 2. Turn piston downwards until pressure ring - 1 - of the removing device with citclip - 2 can be inserted, The circlip must rest safely in the groove of the fire ring 3. Put the finer supports = 3 ~ on a useless joint ring and tighten by hand with the cylinder head nuts. The useless joint ring serves as a protction of the sealing surface in the liner. The liner must not be lifted when turning it out. 4. Turn the piston carefully upwards, permanently observing the fie ring and the liner. pj i Cr SSS Useless joint ring as 1 protection of he sealing surface. Edition Service document of 28/11/1998 MaK Motoren GmbH & Co. KG Page 20 aMak Engineer’s Handbook M20 { Connecting rod ] Bigend bearing 1. Tighten bolts 3 and 4 (bottom) with —> mM 160 Nm 2. Tighten bolts 1 and 2 (top) with. > 3. Tighten bolts 1 and 2 once more with —> it 4, Tighten bolts 3 and 4 with > M = 350 Nm Tighten bolts 1 and 2 with > Bolts 142 = short + top Bolts 344 = long + bottom Alter tightening the big end bolts 1 and 2 to the final torque (350 Nm), tighten big end bolts, 3 and 4 once more with the final torque (350 Nm) in order to avoid loss of pretension (settling effect). Final tightening torque corresponds to tightening angle: For bolts 1 + 2 at least 13°- 16° For bolts 3 + 4 at least 17°- 19° Tightening angle gauge for big end bolts 3 and 4 Bigend bearings Together with the tool kit 2 tightening angle ‘gauges - one for the big end bolts 1-2 and one for the big end bolts 3-4 -are supplied. These tools serve for checking the tightening angles stated above. If after correct tightening of all big end bolts the «minimum degrees” are not reached, the whole tightening procedure must be repeated. Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 21Mak Engineer's Handbook M20 { Connecting rod Measurement of the gap Pretighten bolts 3 and 4 with 160 Nm. Measure dimension .X 1” by means of slide gauge. Tighten bolts 1 and 2 twice successively in the sequence 1-2/1-2 with 160 Ni. Tighten bolts 3-4/1-2 with 350 Nm, Measure dimension .X 2”. X1-X2" = gap > 0.45 - 0.65, mm eens Reference size A Poin x SS YY \ } & Camshaft sid Zyl Y Wag - ana yy Uf CEE 2 Reference size B 5 3 2 5 Reference dimension of the big ond bearings after correct tightening, Size"A" -> 152.140 "028 om) O&O Sue"B" —> IstmaB A+0.04'° mm Fitting of piston pin bush Cool the piston pin bush down to 6 - 160° C and push it into piston pin boss, taking care of the correct position of the oil bores. The lateral projection must be the same on both sides, After reaching the normal temperature the piston pin bush has to be measured The reference dimension after shrinking-in in cooled state is & 90,09 9% mm Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 22Mak _Engineer’s Handbook M20_ { Crankshaft | Tightening torque The tightening torque for inserting the studs is. > m Nm 1. Tighten round nuts for main bearings - 2 - steadily by hand. 2. Tighten hexagon screws (lateral screws] - 1 - alternately Ist step > M = 100 Nm 3rd step > (w 480 Nm Camshaft side Exhaust gas side Alternative tightening: (alternately in 3 steps} 2nd step > 3. Lengthen main bearing screws with —> P= 750 bar and tighten nuts, with a pin. This corresponds toa tightening angle of —» or 3 holes (stated for additional checking) Check : Reduce pressure to. —> P= 700 bar It must not be possible any more to loosen the nuts. The pressure must remain constant it the pump is not operated, otherwise faulty tightening. Tighten main bearing outs slways in one operation. Tighten value for hydraulic jack area: 548 cm? Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 23Mak Engineer's Handbook M20 { Crankshaft | Marking Bearing caps and bearing shells are marked on camshaft side with the relative cylinder numbers, counted from flywheel side, The parts must not be mixed up. Located = 4__ and normal main bearings are identical, for axial fixing on bearing 2 tocsted main beating) thrust washers - 1 - with > clamping pins re mounted on bearing cap - 3 -. End clearance $ 28,48, 5 82 If the main bearings cannot be loosened with P = 750 bar, pressure increase by 50 bar to 800 bar is possible. Further increase of pressure involves the risk that the thread will expand and the nuts will jam, The bottom shells of the normal main bearings have a quide groove on camshaft side. The located main bearing cap (bearing 2) has a fixing pin on exhaust gas side The bearings with the maximum stress are: 6 cyl. engine bearing 4 8 cyl. engine bearing 5 9 cyl. engine bearing 6 Normal main bearing gap > 0.50 - 0.80 mm limit value —> Located main bearing clearance limit —> 0.40 mm Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 24Mak Engineer's Handbook M20 ( Crankshaft | Measurement of the gap 1. Remove lateral bolts of the main bearing and loosen those of the adjacent main bearings by several turns of thread. 2. Loosen both main bearing nuts of one bearing pocket in one operation. 3. Tighten main bearing nuts by hand alternately and steadily until the joint faces of the bearing shells just touch, 4. Check of the projecting length of the bearing shell by measuring the gapbetween cylinder crankcase and bearing cap on camshaft and exhaust gas sides. Gapk=K,+K, Crank web deflection a. Flywheel with shaft supported externally, rigidly coupled A +2/-5 G+5/-9 b. Overhung flywheel with flexible flange coupling “9° ¢. Flywheel with single-bearing generator, rigidly coupled. A+2/-5 G +5/-8 * Limit value for cyl. 1, the other cylinders as under G A = desirable in case of realignment only for cyl. 1 G = limit value for all cylinders. Check alignment. Counterweight Tighten screws with —> Gcyl. engine — 12 counterweights Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 25Mak Engineer's Handbook M20 ( Grankshatt Bcyl. engine 12 counterweights crankpin 1 2pes. crankpin 2 Ipe., left side * crankpin 3 Ipe., right side * crankpin 4 2pes crankpin 5 2pes crankpin 6 Ipe. left side * crankpin 7 Ipe right side * crankpin 8 apes. Bcyl. engine 12 counterweights crankpin 1 2pes. crankpin 2 ‘pe. left side * crankpin 3 without counterweight crankpin 4 2pes. crankpin 5 2pes. crankpin 6 2pes. crankpin 7 without counterweight crankpin 8 Ipe., right side * crankpin 9 2pes * = seen from camshaft side Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 26Mak Engineer's Handbook M20 { Gear train Gear wheel on crankshaft Mount the gear wheel on the crankshaft cone by hand Increase pressure to. > = 500 bar with the hydraulic device and press gear wheel into its final position. The slide-on distance is : 72 ,,mm, Dimension 186 *** mm from front edge gear wheel to the end of crankshaft. Hydraulic connection The device must not be looseried earlier than 20 minutes after pressure reli. Engine start 24 hours after pressure See relief. Intermediate wheel mounting Old design New design SA yo x Tensiow bush thrust rings Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 27Mak Engineer’s Handbook M20 { Gear train Thrustwashers Thrust washers of the new type are glued in. The adhesion surface areas must be grease-free —S it grooves p— a The oil grooves of the thrust washers must show to the gear wheel. Mounting of intermediate wheel The locking plate - 1 - must rest firmly in the groove root of the intermediate wheel axle - 2 -. Attention! When exchanging the O-ring on the intermediate wheel axle take care that the meshing of the intermediate wheel with the camshaft gear and the crankshaft gear remains unchanged, Otherwise there is a risk of displaced timing. Lub. oil injectors for the gear — Tighten hollow screws with —> M nD Nm Gear wheel on camshaft Tighten cylinder screws with —> M = & Nm Backlash Crankshaft gear - intermediate wheel —> 0.20 - 0.40 mm | * o intermediate wheel - camshaft gear —> 0.20 - 0.40 mm Intermediate wheel End clearance > 0.20 - 0.80 mm Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 28Mak Engineer's Handbook M20 { Governor drive Governor drive gear Tighten fixing screws - 1 - for governor drive gear with —> M = 60 Nm Tighten castellated nut for fixing the helical gear and tighten further to the next split pin hole. Backlash Small governor drive gear (helical gear wheel) - big governor drive (helical gear wheel) —> 0.15 - 0.28 mm End clearance - 3 - between governor console and coupling bush —> 0.10 - 0.30 a Between the big governor drive gear (helical gear wheel) and the end cover there must be a clearance - 4- of —> 0.30 - 0.75 mm f A y A 4 wy Z Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 29Mak Engineer's Handbook M20 { Camshaft Tighten Allen screws with > this corresponds to. —> Camshaft removal Tighten screws - 1 - for flange = 2- with —> Dismounting /fitting 1. Remove cover on pump side of the coupling. 2. Remove valve rocker brackets acc. to camshaft part. 3. Lift the rocker arms of the inlet and exhaust valve drives and secure with fixing screw = 1 -. 4. Turn the fuel cams to the highest cam lobe and remove rocker arms with fixing screw - 2 - from the cam and fix it. 5. Mount camshaft assembly device - 3 - acc. to the following schedule Dismounting Mounting Camshaft part Assembly device Cyl cyl 1 3 and 6 2 4and6 3 5 and 6 4 6 ‘Adjust assembly device - 3 - with the hexagon screws - 4 - to the camshaft flange height - 5 -. 6. Withdraw camshaft part of the last cylinder from the cylinder crankcase through the assembly hole. 7. Shift detached camshaft with assembly device to the right side by one cylinder without using force 8. Withdraw part to be dismounted to the right side from the free camshaft housing Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 30Mak Engineer’s Handbook M20 { Camshaft | Attention! During removal do not tilt camshaft part in the camshaft bearing, this involves the risk of damaging the bearing. Fitting Fitting is carried out in reverse order. After completion of fitting check lub. oil pressure. During every assembly of the camshaft take care that a eylindrical pin - 2 - is inserted up to stop position in the camshaft flanges - 1 -. The cylindrical pin must always be inserted near the flange code number - 3 - acc. to the following schedule: 6cyl. Flange code 8 cyl. Flange code Part number Part number 1 4 1 5 2 2 2 3 3 3 3 4 4 4 4 6 5 6 5 6 6 6 6 7 7 8 8 Scyl. Flange code Part number 1 1 waromsen =Noneons Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 31Mak Engineer's Handbook M20 ( Camshaft Vibration damper for camshatt 1.10.7-31.40.00-01 Tighten screws with —> M = 60 Nm 4 scraws M12 x 1,5X 55 DIN 912 1,10.7-31.40.00-02 (2 vibration dampers) Tighten screws with —> M = 60 Nm 4 screws M12 x 1,5X 60 DIN 912 1,10.7-31.40.00-03 (3 vibration dampers - 9 cyl. engines) Tighten screws - 1- and-2-with —> M = 60 Nm (Molykote} 1 = 4 Allen srews M1Zx1,5x130 DIN 912 8.8-A3C 2 = 2 Allen srews M12x1,5x45 DIN 912 8.8-A3C — Take care of the hore position Camshaft bearing Tighten fixing screws for the camshaft bearings Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 32Mak Engineer's Handbook M20 { Fuel injection pumps 0,00.6-43.12.00-72 type: DSFP 1M Tighten fastening nuts with —> Tighten screws = 1+ with —> Tighten screws - 2-with —> Tighten screws -3- with —> Tighten screws - 4-with > Fuel distributing line and fuel collecting pipe Old design Tighten screws - 1 - to fuel injection pump alternately with —> M12x DIN 931 Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 33MakK _Engineer’s Handbook M20 Injection pump 0,00.6-43.12.00-79 type: DSFP 1MW Fuel injection pumps Tighten screw - 1- and-2-with —> Tighten screw - 3- with —> Tighten baffle screw - 4- with —> Insert countersunk screws - § - with Loctite 243 and tighten with —> iil i i min 4 A) = © : i e "eg ‘eat —j—| + — I é)i ! ; INT Til Ti [ i fe H | | be 2 | i pt a ~ In , Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 34Mak Engineer’s Handbook M20 Fuel injection pumps Fuel distributing pipe for fuel injection pump var. -79 Circlip - 1 - must be removed before the plug - in pipes can be axially shifted and removed. Fuel delivery pipe connection Tighten screws - 1 - for connecting housing with —> M = 3 Nm First tighten pressure screw - 2 - ,then tighten pressure 1 Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 35Mak Engineer's Handbook = M20 L Fuel injection pumps Dismounting / mounting During dismounting / mounting attention must be paid that the appertaining distance steel plates are not removed. If for any reason removal of the distance steel plates is necessary, they have to be marked with the relevant cylinder number. The thickness of the distance steel plates for each cylinder is stated in the acceptance test record. Check of commencement of fuel delivery 1. Dismount the injection pump. delivery valve. 2. Mount dial gauge with extension Commencement [EJ iring 10 3. Turn engine so that roller rests on the base circle of cam and the TDC mark is abt. 45 ° before the dead center indicator. eT 4. Set dial gauge to ,0°, turn engine in direct- delivery ion of rotation until the indication on the gauge is 5 mm (5 mm on the gauge cor respond to 11° cw on the flywheel} 5. Check the dimension on the flywheel from TDC mark to dead center indicator. Setting 1. Place the gauge with measuring device on a level support by means of the adjusting bush (dimension = 44.2 mm) and set gauge to ,0". 2. Insert measuring device into the injection pump bore in the engine housing and read value on the dial gauge (roller on the base circle of cam} 3. Indicated value = thickness of the distance steel plates. The distance steel plates are used for setting the pre-stroke. Available sizes: 2.00 mm 2.10 mm 2.20 mm 2.30 mm 2.40 mm 2.50 mm 2.60 mm 2.70 mm 2.80 mm 2.90 mm 3.00 mm 3.20 mm 3.40 mm Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 36Mak Engineer’s Handbook M20 ( Lower valve drive | The end clearance between two adjacent bearing brackets is —> mm OT | | a (Po! HE t| =) UL Vie KKK 13-——" * — _— End clearance 0.10 - 0.20 Mounting instruction ‘At the junction points of the rocking lever shafts no air is admissible. When the bearing caps are loosened, the rocking lever shafts must be pushed together from both sides. Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 37Mak Engineer's Handbook M20 { Miscellaneous items Ragulating shaft Tighten screw 1 - for the bearing bracket with —> Setting instruction 1. Connect shaft of the control stand with the regulating shaft by means of coupling. Do not yet remove assembly pin for the shaft fixing 2. Shift control rack of the injection pump at cyl. 1 so that coincidence of line mark and indication is reached 3. In this position clamp articulated lever, keeping the distance of 0.5 mm between control rack head and articulated lever. 4, Repeat procedure on all remaining cylinders ace. to instructions of points 2 and 3, 8. Remove assembly pin for the shaft fixing in the control stand. 6. Check easy motion of control linkage. 7. Seal articulated lever with lead. g 3. Assembly During assembly insert the regulating shaft with grease (do not use Molykote) Fuel indicator yy 8 Cam - 1 - must be adjusted in a way that in stop position the | center of the fuel indicator is in line with the stamped punch i mark - 2 >, po Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 38Mak ( Cooling water distributung pipe Tighten screws - 1- with —> Molykote MI6 x 100 88 -ASC Edition 28/11/1998 Service document of Mak Motoren GmbH & Co. KG Page 39Mak Engineer's Handbook M20 { Flywheel mounting Turn crankshaft into TDC cyl. 1. Insert flywheel vertically hanging into transport hole and push it on the crankshaft cone until contact is reached. Mount device, apply a pressure of —> = 1300 bar and press flywheel into the final position. Final position means flush with end of crankshaft. The slide - on distance is : 155 ,,mm and 16.5 .,, mm. (In this connection see page: 24) 1. Turn crankshaft to TOC cyl. 1. (In this position the projecting a screw heads at the gear wheel on crankshaft are pointing to ~ a the respective pickup pockets on the flywheel) 2. Insert flywheel vertically hanging into transport hole dia. 50 mm and push it on the crankshaft cone until contact is teached. 3. Press flywheel into final position by means of device and oil hydraulic: mounting 4. Final position, as shown, flush with end of crankshaft. 5. Engine start 20 min after pressure relief at the earliest. i When dismounting a flywheel, a mark should be applied on the | flywheel and on the crankshaft in order to avoid incorrect fitting Wy Gear rim on flywheel for pneumatic starter. Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 40Mak Engineer's Handbook M20 L Flywheel mounting The following flywheels are in use. Flywheel 1.10.7-73.10.01- Var. old slide-on distance replaced by var. slide - on distance -03 155 ,, mm -09 16,5. 4,5 mm -04 155 », mm =10 165.44, mm -05 155 ,, mm <1 165 gg mm -06 155 4, mm +12 165.495 mm -07 155, mm =14 16545, mm 213 16,5495 mm 205 The flywheel variants are stamped at the front side on the flywheels, for instance ,,1-09". Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 41Mak Engineer's Handbook M20 { Opposite side of coupling With and without power take-off Vibration damper Pretighten fixing screws with —> M = 100 Nm With the fixing screws pump impeller carrier and gear wheel for lub. oil pump drive are fixed at the same time. The vibration damper is connected to the lub. oil system of the engine. Each spring pack has its own supply bore. When checking the vibration damper the oil bores have to be checked for free passage All tightening torques on this page are valid for the Hanged shaft mounting with or without power take-off Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 42Mak Engineer's Handbook M20 | Pump carrier plate - Tighten screws M 42 with —> Tighten screws M 8 with —> Pump carrier plate Align pump carrier plate - 1 over centering of the pump gear cartier - 2 -, and screw it at the cylinder crankcase with sealing compound and pin it Cooling water pump Tighten screw for fastening the gear wheel with —> Fuel feed pump Tighten screw for fastening the gear wheel with —> Lub. oil pump Tighten screw for fastening the gear wheel with —> Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 43Mak Engineer's Handbook M20 { Pump carrier | Lub. oil pump mounting, suction and pressure pump as well as cooling water pump mounting HT and LT circuit and fuel feed pump mounting 1. Check contact reflection on the appertaining pump gear wheel cone by blue paste. Only a contact reflection displaced to the thick end is admissible 2. Heat gear wheel up to 120°C - 130°C above temperature of the cooling water pump shaft and mount itfirmly on the pump cone up to stop position. The cone faces must be grease-free and dry. —Y 3. Fit and tighten screw - 1 = with washer - 2 ~ 1 Slide-on distance lub.oil pumps -- 0.33 - 0.41 mm Slide-on distance cooling water pumps -- 0.29 - 0.32 mm Slide-on distance fuel feed pumps =~ 0.44 mm Lub. oil pump mounting backlash —> 0.20 - 0.47 mm Fuel feed pump mounting Cooling water pump mounting backlash —> 0.20 - 0.47 mm Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 44Mak Engineer's Handbook _—iM20_ ( Charge air cooler mounting Tighten screws - 1 - with > M = 60 Nm Tighten screws - 2 with > M = 60 Nm Applicable to coupling side and opposite side. Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 45Mak Engineer's Handbook M20 [ Charge air cooler mounting | Cleaning In the acceptance test record the differential pressure before / after charge air cooler is stated. When ‘the value has reached the 1.5-fold cleaning has to be carried out. Dismounting aA Remove cooling water inlet and outlet pipes. Loosen screws - 1 - and - 3 - and withdraw the charge ~ air cooler from the casing. Fitting in reverse order, taking care of perfect fit of the sealing shims. Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 46Mak Engineer's Handbook M20 Firing sequences - valve timing Firing sequences 6cyl.engine clockwise counterclockwise Beylengine clockwise counterclockwise Seyl.engine clockwise counterclockwise 1-3-5-6-4-2 1-2-4-6-5-3 1-2-4-6-8-7-53 1-3-5-7-86-42 1-2-4-6-8-9-7-5-3 1-3-5-7-9-8-6-4-2 Valve 9 Exhaust valve opens Exhaust valve closes Inlet valve opens Inlet valve closes 60 ° before BDC 56 ° after TDC 55 ° before TOC 40 ° after BDC Edition Service document of 28/11/1998 MaK Motoren GmbH & Co. KG Page 47 ‘oMak Engineer's Handbook M20 | Sizes and weights Designation Length mm hmm — Heightmm = Weight ka 6 cyl. engine Crankcase without studs v190 Crankshaft 2428 280 6372 730 Counterweight 22 Gear wheel on crankshaft 82 6273 16 Liner 997 6277 68 Piston with connecting rod 05 Cyl. head compl. 121 Cyl. head 855 Camshaft bearing 7 8190 15 Big end bearing 69 9161 a Cooling water distribution housing 602 328 170 435 Injection pump 123 133 342 18 Camshaft piece 330 142 19 Camshaft bearing 40 8160 13 Gear wheel on camshaft 65 8533 105 Intermediate wheel 23 Housing for charge cooler 210 Charge air cooler 877 540 440 170 Lub. oil cooler 82 Pump carrier plate 78 Edition Service document of Page 28/11/1998 MaK Motoren GmbH & Co. KG 48Mak Engineer's Handbook —- M20 { Sizes and weights Designation length mm Widthmm — Heightmm = Weight kg 6 cyl. engine Starter 34 Flywheel, generator 217 6 1005 320 Flywheel, propeller 204 8 1005 (307 Gear rim on flywheel 38 6 1015 a4 Vibration damper 151 9620 263 Lub. oi! pump 404 230 245 34 Cooling water pump 354 270 335 42 5 ® | Edition Service document of Page 28/11/1998 Mak Motoren GmbH & Co. KG 4g