Maintenance
A5
-
Maintenance
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Table of Contents
A5.01
-
Maintenance
A5
Table of Contents
A5.01
Introduction
A5.02
Safety instructions
A5.03
Periodical schedule Heavy fuel
A5.04.02
Engine, cylinder head
A5.05.01
Valve clearance
A5.05.01.01.01.00
Valve Rocker Brackets
A5.05.01.02.01.30
Valve Rockers
A5.05.01.02.02.00
Valve Rocker Bush
A5.05.01.02.03.00
Valve Rotor
A5.05.01.03.01.00
Valve guide/Oil scraper ring
A5.05.01.05.01.01
Media guiding system
A5.05.01.05.50.01
Cylinder Head
A5.05.01.06.01.30
Nozzle sleeve
A5.05.01.06.50.03
Relief Valve
A5.05.01.06.70.01
Inlet and Exhaust Valve Cone
A5.05.01.07.01.03
Inlet and Exhaust Valve Cones
A5.05.01.08.01.00
Valve Seat Ring
A5.05.01.08.02.00
Valve Seat Ring (Intake/Exhaust)
A5.05.01.08.03.00
Starting Valve
A5.05.01.09.01.00
Starter Valve
A5.05.01.09.02.03
Cylinder Head
A5.05.01.10.00.00
Cylinder Head
A5.05.01.10.01.01
Cylinder Head
A5.05.01.11.01.30
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Table of Contents
A5.01
-
Engine, gear
A5.05.02
Running Gear / Engine Timing
A5.05.02.01.01.00
Crank Web Deflection
A5.05.02.02.01.00
Bearing Shells and Bearing Bushes
A5.05.02.03.03.01
Bearing Shells
A5.05.02.03.07.01
Big End Bearings
A5.05.02.04.01.30
Big End Bearings
A5.05.02.04.02.30
Hydraulic Jack
A5.05.02.04.51.00
Main Bearings
A5.05.02.05.01.30
Main Bearings
A5.05.02.05.02.30
Main Thrust Bearings
A5.05.02.05.05.30
Main Thrust Bearings
A5.05.02.05.06.30
Piston
A5.05.02.06.01.30
Piston Crown
A5.05.02.06.02.04
Piston Rings and Grooves
A5.05.02.07.01.01
Piston Pin
A5.05.02.08.01.00
Small End Bearing
A5.05.02.09.01.01
Piston
A5.05.02.10.01.30
Balance weight
A5.05.02.11.00.00
Measures for emergency operation
A5.05.02.12.00.00
Engine, housing
A5.05.03
Explosion relief valve
A5.05.03.01.01.02
Coolant Distributor Housing
A5.05.03.02.00.00
Cylinder Liner
A5.05.03.03.01.01
Cylinder Liner
A5.05.03.04.01.00
Cylinder Liner
A5.05.03.04.02.00
Engine Fasteners and Connections
A5.05.03.07.01.00
Engine, control
A5.05.04
Camshaft Bearing
A5.05.04.01.01.00
Camshaft Bearing
A5.05.04.01.02.00
Bottom part for Valve Mechanism
A5.05.04.02.00.30
Camshaft
A5.05.04.04.01.08
Timing Gear Train
A5.05.04.08.01.02
Timing Gear Train
A5.05.04.08.02.02
Governor Drive
A5.05.04.08.03.02
Vibration Damper on Camshaft
A5.05.04.09.01.00
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Table of Contents
A5.01
-
Engine, regulation
A5.05.05
Control Shaft Bearings
A5.05.05.01.02.00
Starting Valve
A5.05.05.02.01.02
Control Rod
A5.05.05.08.01.00
Compressed-Air Filter
A5.05.05.09.06.00
Compressed-Air Filter
A5.05.05.09.06.01
Engine, exhaust gas system/supercharging
A5.05.06
Exhaust Line
A5.05.06.01.01.12
Charge Air Cooler
A5.05.06.04.02.30
Exhaust gas turbocharger
A5.05.06.05.00.30
Exhaust gas turbocharger
A5.05.06.13.01.30
Turbocharger
A5.05.06.14.01.00
Engine, fuel system
A5.05.07
Injection Pump
A5.05.07.02.01.00
Injection Pump
A5.05.07.03.01.03
Deflector Bolts
A5.05.07.03.02.00
Pressure Valve
A5.05.07.03.03.00
Injection Pump
A5.05.07.04.01.00
High-Pressure Injection Pipe
A5.05.07.05.01.00
Fuel Injector
A5.05.07.07.01.02
Fuel Injector
A5.05.07.08.01.30
Fuel Injector
A5.05.07.09.01.30
Fuel Duplex Filter
A5.05.07.12.01.08
Fuel Distributor/Collector Line
A5.05.07.15.01.30
Fuel Pressure Damper
A5.05.07.17.00.01
Engine, lubricating oil system
A5.05.08
Lubricating Oil Pump
A5.05.08.03.02.04
Lubricating Oil Duplex Filter
A5.05.08.04.01.01
Oil pressure control valve
A5.05.08.05.01.01
Prelubricating pump/Prelubrication
A5.05.08.10.00.00
Engine, starting system
A5.05.10
Stop Piston
A5.05.10.03.01.00
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Table of Contents
A5.01
-
Engine control equipment
A5.05.11
Pressure Switches
A5.05.11.01.02.01
RPM Switch
A5.05.11.05.01.02
Lubricating Oil/Cooling Water Thermostat
A5.05.11.06.01.01
Pressure Switch
A5.05.11.06.05.02
Pressure Switch
A5.05.11.06.06.02
Crankcase Monitoring Device
A5.05.11.09.01.03
Engine auxiliary units
A5.05.12
Vibration Damper
A5.05.12.04.01.00
Vibration Damper
A5.05.12.04.02.00
Turning Device
A5.05.12.08.01.01
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Introduction
A5.02
M20-M601C
1.
General It is assumed that the engine room personnel has the necessary knowledge and experience required for the proper maintenance and servicing of diesel engines. For this reason and in the interest of clearness we did not go too much into details in the maintenance documents. No claims can be raised owing to missing instructions in the maintenance documents, if damage is caused by improper handling. All information refers to the date of printing.
2.
Explanation of the maintenance system
2.1
Scheduled maintenance Without “Scheduled maintenance” the economic operation of supercharged engine is in the long run not possible at today's state of art. The explanations are used to make the user of this engine plant familiar with the existing maintenance system of MaK and to interest and deepen the understanding of the user for the problems and importance of the “Scheduled maintenance”. It is the purpose of the maintenance to replace parts subject to wear and tear or to repair these parts before they are damaged. The “Scheduled maintenance” is thereby supported by inspections according to fixed deadlines. These inspections are decision criteria for the need and extend of maintenance and servicing. The following is used as parameter: •
data on wear and tear
•
evaluation criterion and
•
performance checks
Most of the work to be carried out does not have a fixed deadline since the service life of individual components is highly influenced by environmental and operating conditions, fuel qualities and their care. Therefore the present interval schedule shall not be considered stringent in the long run, but it is left to the user to modify the maintenance schedule in accordance with own experiences. But in any case a sufficient safety margin - even if the mean wearing levels are well-known - is to be calculated in order to cover the always occurring variations. It is recommended to consult MaK with regard to extended intervals in order to maintain the guarantee. The information given by us gives no rise to legal claims.
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Introduction
A5.02
M20-M601C
2.2
Maintenance system The maintenance system consists of: •
work interval schedule
•
job cards
•
maintenance schedule (large-scale plan) *
While the work interval schedule indicates the date when inspection, maintenance or repair shall be carried out, the job cards indicate the manner in which the work is to be carried out.
2.2.1
Work interval schedule The work interval schedule shall provide for a quick summary of all intended inspection, maintenance and repair work occurring up to 90,000 operating hours.
The interval schedule is subdivided into the following four areas: •
Daily inspection and control work
•
Initial inspection and maintenance work Work which has to be carried out after first commissioning or commissioning after major repair work.
•
Periodic maintenance work A list of all recurrent inspection, maintenance and repair work to be carried out at the scheduled date. The indicated intervals are statistical mean values. Other values may be obtained, depending on equipment condition, operating and maintenance conditions.
•
Maintenance work to be carried out independent of deadlines List of work which may be required in the scope of scheduled work which cannot be allocated to a deadline.
*
will be handed over by the MaK service department for commissioning of the engine
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Introduction
A5.02
M20-M601C
2.2.2
Job cards The job cards are instructions for inspection, maintenance, repair and safety check.
¬ Title of the job card Activity
Maintenance work
Discharge valve
A5.05.01.04.01.03
Inspection / Dismounting and mounting Operating hours/maintenance deadline
M 551 / M 552 6,000 / 12,000
01
Engine type Register Main maintenance group
See also: Spare parts list: Time requirement: Personnel qualification: Operating medium:
01.01.01.nn, 01.02.01.nn, 01.08.01.nn B1.05.01.7.2104, B1.05.01.7.2220 1 Pers. / 3 h skilled engine hand Heavy fuel and destillate fuel
Breakdown Chapter maintenance
Subchapter
Vol. A operating instructions
Job cards
Job cards Document number
A5.05. 01.04.01.03 Main maintenance group Maintenance group Subgroup Variant
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Date of issue Registration number
Page/number of pages
Language
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Introduction
A5.02
M20-M601C
The job card number consists of the index breakdown (A5.05) and the maintenance number (bold) subdivided into four pairs of digits. •
The first pair of digits indicates the engine main maintenance group: 01.
Cylinder head
08.
Lube oil system
02.
Driving mechanism
09.
Cooling water system
03.
Engine housing
10.
Starting air system
04.
Engine control
11.
Monitors
05.
Regulation
12.
Auxiliary generator sets and tools
06.
Exhaust gas system/ supercharging
13.
Additional installation
07.
Fuel system
In order to facilitate the finding of the engine main group, the pair of digits on the right margin has been set as register 01 . •
The second and third pair of digits indicates the subgroups of the main group and the titles of the job card where maintenance work is required.
•
The fourth pair of digits indicates the type of variant.
•
See job card: Reference is made to other job cards required for maintenance work. At this point the types of variants (fourth pair of digit) are marked “nn”.
•
Spare parts sheets: For easy finding of necessary comsumables and spare parts for the maintenance group in Vol. B “Spare parts catalogue”, indicating other design details in the illustrations, if necessary. The third pair of digits in the index breakdown in the spare parts number indicates the main group/register.
•
Fuel: Documenting the sold type of fuel of the engine plant (see also: introduction A0.02).
•
Safety note: Each safety note is additionally marked with a symbol attention to the text (see A5.03).
•
Attention: Marking technical regulations or measures to be strictly observed in order to avoid damage or destruction of equipment or components of the engine plant or other material.
•
Note: Gives the personnel information which optimize the work process.
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Introduction
A5.02
M20-M601C
2.2.3
•
In the maintenance sheets the checks, maintenance, cleaning and repair works of the maintenance sheets are briefly designated
•
Under the designation "tools (W)" only special and additional tools are listed with the MaK tool No. Not all of these tools are included in the normal scope of supply.
•
Together with the engine type it will be indicated for what engine the job card is valid.
•
The indicated personnel and time requirement does not define the working time of the individual person.
•
The indicated time is based on estimated mean values which may deviate according to the equipment of the plant and its maintenance conditions. Wherever the required working time depends on the number of cylinders the indicated time of the maintenance sheets refers to one cylinder unit only.
Maintenance schedule (Periodic maintenance work) A large-scale plan showing all maintenance work up to the largest maintenance interval clearly indicating all occurrences and the future work expenditure for the individual components. It would be useful to mount the plan on a wall; when this is not possible for space reasons, it has to be folded and filed in the map “maintenance forms” *. We cannot and will not give instructions for handling this plan but we will only give you some guidelines how to use this plan as an aid for the maintenance system. The work already carried out will be countersigned in fields intended for this purpose. Different colours can be used to differentiate between the results, e.g.: green = no defects/o.k.; yellow = readjustment/correction (e.g. clearances); red = damage/replacement of parts. Typical consumption parts which are replaced routinely or any time mounting is carried out (Oring seals, O-rings etc.) are not considered defective parts.
*
The map will be handed over by the MaK service department for commissioning of the engine
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Safety instructions
A5.03
M20-M601C
1.
Safety instructions
1.1
Work safety symbol
~ 1.2
All texts marked with this symbol in the maintenance sheets are safety instructions which have to be observed in all cases in order to eliminate danger to life and limb of the user or of third parties!
General safety instructions The provisions of the relevant accident prevention regulations of the appropriate employer's liability insurance association are to be observed any time operation and repair work is carried out. In addition, the following is to be observed: •
Seals made of VITONR have been used at various locations in the engine. With normal engine operation this material is completely harmless, however it should not be exposed to temperatures above 300 °C, since above 325 °C a thermal decomposition and the formation of hydrofluoric acid can occur.
•
Replaced seals should be disposed of immediately, and above all, it should be taken care that this material is not overheated even by accident e.g. during combustion and welding operations. If this should however has happened, the gases emitted must not be inhaled. Skin contact with decomposed VITONR is to be avoided at all times. After a fire with VITONR, it is essential that neoprene gloves are worn during the clearing up operations.
•
Any residues have to be neutralized before their disposal, i.e. saturated with calcium hydroxide.
•
Maintenance and repair work must only be carried out by skilled and authorized personnel!
•
Use personal protective equipment as far as necessary or as required by the regulations!
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Safety instructions
A5.03
M20-M601C
•
When work is being carried out on engines and systems, the switch-on devices have to be switched off and protected. In order to prevent reconnection, the engines and systems have to be marked with a plate “Do not switch” or an appropriate pictogram plate!
•
Re-install removed guards and protecting devices on completion of work.
•
During replacement work, individual parts and large assemblies are to be carefully fastened and secured on hoists to avoid risks of accidents!
•
Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity!
•
Never work or stand under suspended loads!
•
When carrying out overhead assembly work, the specially designed or safety-oriented climbing aids are to be used only!
•
Do not use engine/plant parts for climbing on!
•
Keep all handles, steps, handrails, platforms, ladders free from dirt, e.g. oil, grease, fuel!
•
Clean the engine parts, especially connections and threaded unions of any traces of oil, fuel or preservatives before carrying out maintenance/repair (disassembly, assembly)!
•
Never use aggresive detergents and preservatives!
•
Use non-fuzzy cleaning rags!
•
Pressurized plant components (lube oil, hydraulic oil, fuel, cooling water, starting and control air) must be depressurized. Shut-off valves are to be secured by a plate “Do not open”!
•
Mounting openings are to be protected!
•
Perfect hoists, tools and devices are to be used only!
•
Observe all indicating labels attached to the engine!
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Safety instructions
A5.03
M20-M601C
1.3
1.4
1.5
Working on electrical equipment •
Work on the electrical equipment of the engine/plant must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician in accordance with the electrical engineering rules and regulations!
•
Use only original fuses with the specified current raiting! Switch off the engine/plant immediately if trouble occurs in the electrical system!
•
The electrical equipment is to be inspected/checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately!
•
Engine or plant parts on which inspection and maintenance work is being carried out have to be - if prescribed - shut off at the power supply and provided with the notice “Do not switch on” or the corresponding warning sign!
Working with hydraulic devices •
Operating instructions, tightening torques and setting dimensions specified in the appropriate job card are to be carefully observed!
•
Do not place parts of your body above/below pressurized hydraulic tools!
•
The minimum bending radii r = 250 mm of the high-pressure hoses are to be strictly observed!
•
The hose lines are to be protected against damage caused by external mechanical, thermal or chemical influences!
•
Replace hydraulic hose lines at regular intervals, even if no safety relevant defects are detectable!
Checking and adjustment of injection valve •
During testing make sure that no parts of your body are positioned in the area of the fuel jet!
•
Do not inhale the fuel mist - respiratory mask!
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Safety instructions
A5.03
M20-M601C
1.6
1.7
Handling of liquid nitrogen or carbon dioxide snow •
When handling liquid nitrogen or carbon dioxide snow, safety shoes, safety gloves and safety glasses are to be worn in order to avoid injuries. Observe protection against cold!
•
Parts of the skin which have come into contact with liquid nitrogen or carbon dioxide snow must not be rubbed but covered with sterile surgical bandage!
Cleansing agents/chemicals •
Use only cleansing agents with a flash point above 65 °C!
•
Observe instructions for use in accordance with DIN safety data sheet of the regulations for dangerous substances!
•
Observe the specialist disposal of all cleansing agents and chemicals in accordance with the regulations for dangerous substances!
•
In case of accident, observe the accident leaflets including first-aid actions for dangerous substances in accordance with the regulations for dangerous substances!
2.
The non-observance of the safety instructions may cause danger to persons and failure of important functions of engine/system!
3.
California / USA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.
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Periodical schedule
A5.04.02
Heavy fuel M43/VM43
Intervall
Designation / Work to be carried out Remarks
Doc-Nr.
Daily inspection and monitoring procedures (if it is not automated)
-------------------------------------------------------------------------------------------------------------------------------General
Engine operating data Compare with acceptance test records: Speed, rating
A1.10
Temperature
Lubricating oil Engine inlet; Temperature rise at rated output see also A1.10
A1.06
Temperature
Cooling water Engine inlet; Temperature rise at rated output see also A1.10
A1.06
Temperature
Cooling water Upstream charge air cooler; downstream charge air cooler
A1.10
Temperature
Charge air Upstream charge air cooler; downstream charge air cooler
A1.10
Temperature
Exhaust gas After cylinder; downstream turbocharger
A1.10
Pressure
Lubricating oil At the main bearing or at the camshaft bearing see also A1.10
A1.05
Pressure
Cooling water Upstream engine see also A1.10
A1.05
Pressure
Fuel Upstream pumps
A1.05
Pressure
Charge air Upstream charge air cooler; downstream charge air cooler
A1.10
Pressure
Control air
A1.05
Pressure
Starting air
A1.05
Lube oil system
Lube oil circulation tank Check of the lube oil level
A3.05.08.00
Lube oil system
Lubricating oil duplex filter Maintenance/Cleaning at 50 % differential pressure
A5.05.08.04.01.01
Cooling water system
Expansion tank Check of the cooling water level
A3.05.09.00
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Periodical schedule
A5.04.02
Heavy fuel M43/VM43
Intervall
Designation / Work to be carried out Remarks
Doc-Nr.
Fuel system
Fuel duplex filter Maintenance/Cleaning at 50 % differential pressure
A5.05.07.12.01.08
Pressure air
Air bottles Drain
A3.06.10.00
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Periodical schedule
A5.04.02
Heavy fuel M43/VM43
Intervall
Designation / Work to be carried out Remarks
Doc-Nr.
First inspection and maintenance procedures Work to be carried out after the first commissioning or after major repairs.
-------------------------------------------------------------------------------------------------------------------------------24 h
Duplex fuel filter Maintenance/Cleaning Strainer
A5.05.07.12.01.08
24 h
Lubricating oil duplex filter Maintenance/Cleaning Cartridges
A5.05.08.04.01.01
150 h
Engine bolting and unions Inspection/Checking Tight fitand leaks
A5.05.03.07.01.00
150 h
Compressed air strainer Maintenance/cleaning
A5.05.05.09.06.nn
150 h
Exhaust gas turbocharger Function check see book C
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Periodical schedule
A5.04.02
Heavy fuel M43/VM43
Intervall
Designation / Work to be carried out Remarks
Doc-Nr.
Periodical maintenance procedures -------------------------------------------------------------------------------------------------------------------------------24 h
Compressed air strainer Maintenance/Cleaning
A5.05.05.09.06.nn
24 h
Exhaust gas turbocharger Maintenance/Cleaning see book C
A5.05.06.05.00.30
150 h
Valve rotor Inspection/Evaluate
A5.05.01.03.01.00
150 h
Cylinder head Inspection/Checking
A5.05.01.10.00.00
150 h
Exhaust gas turbocharger Maintenance/Cleaning see book C
A5.05.06.13.01.30
150 h
Prelubricating pump/Prelubrication Maintenance/Checking
A5.05.08.10.00.00
750 h
Control shaft bearings Maintenance/Checking
A5.05.05.01.02.00
750 h
Cooling water system Inspection/Corrosion inhibitors
A4.05.09.01
750 h
Stop piston Inspection/Checking
A5.05.10.03.01.00
750 h
Oil mist detector Inspection/Checking
A5.05.11.09.01.03
750 h
Turning device Maintenance/Disassembly and reassembly
A5.05.12.08.01.01
1,500 h
Governor Governor behaviour/governor control rod see book C
1,500 h
Valve clearance Inspection/Adjust
A5.05.01.01.01.00
1,500 h
Crankcase explosion safety valve Inspection/Checking
A5.05.03.01.01.02
1,500 h
Oil mist detector Inspection/Checking
A5.05.11.09.01.03
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Periodical schedule
A5.04.02
Heavy fuel M43/VM43
Intervall
Designation / Work to be carried out Remarks
Doc-Nr.
3.750 h
Starting valve Inspection/Checking
A5.05.01.09.01.00
3,750 h
Governor Oil change see book C
3,750 h
Monitors Checking of alarm and safety system see book C
3,750 h
Running gear/engine timing Inspection/Checking
A5.05.02.01.01.00
3,750 h
Timing gear train Inspection/Checking
A5.05.04.08.01.02
3,750 h
Deflector bolts Inspection/Replace of the deflector bolts of two injection pumps
A5.05.07.03.02.00
3,750 h
Turning device Maintenance/Disassembly and reassembly
A5.05.12.08.01.01
7,500 h
Anti-corrosion oil emulsion Change
A4.05.09.02
7,500 h
Inlet and exhaust valve cone Inspection/Disassembly and reassembly of one cylinder unit
A5.05.01.07.01.03
7,500 h
Piston rings and grooves Inspection/Checking of one piston
A5.05.02.07.01.01
7,500 h
Starting valve Maintenance/Disassembly and reassembly
A5.05.05.02.01.02
7,500 h
Control shaft Maintenance/Disassembly and reassembly
A5.05.05.08.01.00
7,500 h
Compressed air filter Maintenance/Cleaning
A5.05.05.09.06.nn
7,500 h
Exhaust gas line Inspection/Checking
A5.05.06.01.01.12
7,500 h
Injection pump Maintenance/Disassembly and reassembly of one pump
A5.05.07.03.01.03
7,500 h
Deflector bolts Inspection/Replace Replacement of all deflector bolts
A5.05.07.03.02.00
7,500 h
Fuel pressure damper Maintenance/Replace
A5.05.07.17.00.01
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Periodical schedule
A5.04.02
Heavy fuel M43/VM43
Intervall
Designation / Work to be carried out Remarks
Doc-Nr.
7,500 h
Injection valve Repair/Disassembly and reassembly
A5.05.07.09.01.30
7,500 h
RPM-switch Inspection/Adjust
A5.05.11.05.01.02
7,500 h
Lubricating oil/Cooling water thermostat Maintenance/Checking
A5.05.11.06.01.01
7,500 h
Oil mist detector Inspection/Checking
A5.05.11.09.01.03
12,000 h
Exhaust gas turbocharger Maintenance/Disassembly and reassembly
A5.05.06.14.01.00
15,000 h
Valve guide/Oil scraper ring Inspection/Replace
A5.05.01.05.01.01
15,000 h
Nozzle sleeve Maintenance/Disassembly and reassembly
A5.05.01.06.50.03
15,000 h
Inlet and exhaust valve cones Inspection/Disassembly and reassembly of all valve cones
A5.05.01.07.01.03
15,000 h
Starting valve Maintenance/Disassembly and reassembly
A5.05.01.09.02.03
15,000 h
Cylinder head Maintenance/Cleaning
A5.05.01.10.01.01
15,000 h
Big-end bearing Inspection/Disassembly of one big-end bearing
A5.05.02.04.01.30
15,000 h
Main bearings Inspection/Disassembly of 2 main bearings
A5.05.02.05.01.30
15,000 h
Cylinder liner Inspection/Measuring at one cylinder unit
A5.05.03.03.01.01
15,000 h
Camshaft bearing Inspection/Checking of one bearing
A5.05.04.01.01.00
15,000 h
Camshaft bearings Inspection/Disassembly and reassembly
A5.05.04.01.02.00
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AA000649
6/10
Periodical schedule
A5.04.02
Heavy fuel M43/VM43
Intervall
Designation / Work to be carried out Remarks
Doc-Nr.
15,000 h
Timing gear train Inspection/Checking
A5.05.04.08.01.02
15,000 h
Governor drive Inspection/Disassembly and reassembly
A5.05.04.08.03.02
15,000 h
Vibration damper on camshaft Repair/Disassembly and reassembly
A5.05.04.09.01.00
15,000 h
Exhaust gas turbocharger Maintenance/Cleaning resp. revision of turbocharger see book C
15,000 h
Injection pump Maintenance/Disassembly and reassembly of all pumps
A5.05.07.03.01.03
15,000 h
Oil pressure regulating valve Maintenance/adjust
A5.05.08.05.01.01
15,000 h
Turning device Maintenance/Disassembly and reassembly
A5.05.12.08.01.01
22,500 h
Pressure switch Inspection/Replace
A5.05.11.06.05.02
24,000 h
Exhaust gas turbocharger Maintenance/Disassembly and reassembly
A5.05.06.14.01.00
30,000 h
Valve rockers Maintenance/Disassembly and reassembly
A5.05.01.02.02.00
30,000 h
Relief Valve Maintenance/Replace
A5.05.01.06.70.01
30,000 h
Big-end bearing Inspection/Disassembly exchange all big-end bearings
A5.05.02.04.01.30
30,000 h
Main bearings Inspection/Disassembly exchange all bearings
A5.05.02.05.01.30
30,000 h
Main thrust bearings Inspection/Disassesmbly
A5.05.02.05.05.30
30,000 h
Piston rings and grooves Inspection/Checking of all pistons
A5.05.02.07.01.01
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AA000649
7/10
Periodical schedule
A5.04.02
Heavy fuel M43/VM43
Intervall
Designation / Work to be carried out Remarks
Doc-Nr.
30,000 h
Small-end bush Maintenance/Measuring
A5.05.02.09.01.01
30,000 h
Cylinder liner Inspection/Measuring at all cylinder units
A5.05.03.03.01.01
30,000 h
Cylinder Liner Maintenance/Disassembly
A5.05.03.04.01.00
30,000 h
Camshaft bearings Inspection/Checking at all bearings
A5.05.04.01.01.00
30,000 h
Camshaft bearings Inspection/Disassembly and reassembly
A5.05.04.01.02.00
30,000 h
Vibration damper Maintenance/Disassembly and reassembly
A5.05.12.04.01.00
30,000 h
Turning device Maintenance/Disassembly and reassembly
A5.05.12.08.01.01
36,000 h
Exhaust gas turbocharger Maintenance/Disassembly and reassembly
A5.05.06.14.01.00
45,000 h
Vibration damper Maintenance/Replace
A5.05.12.04.02.00
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AA000649
8/10
Periodical schedule
A5.04.02
Heavy fuel M43/VM43
Intervall
Designation / Work to be carried out Remarks
Doc-Nr.
Non-interval dependent maintenance procedures --------------------------------------------------------------------------------------------------------------------------------
en / 03.03.2009
Valve rocker brackets Maintenance/Disassembly and reassembly
A5.05.01.02.01.30
Valve rocker bush Inspection/Replace
A5.05.01.02.03.00
Media guiding system Maintenance/Disassembly and reassembly
A5.05.01.05.50.01
Cylinder head Maintenance/Disassembly
A5.05.01.06.01.30
Inlet and exhaust valve cones Repair/Checking
A5.05.01.08.01.00
Valve seat ring Repair/Checking
A5.05.01.08.02.00
Valve seat ring (inlet/outlet) Repair/Replace
A5.05.01.08.03.00
Cylinder head Repair/Reassembly
A5.05.01.11.01.30
Crank web deflection Inspection/Checking
A5.05.02.02.01.00
Bearing shells and bearing bushes Inspection/Evaluate
A5.05.02.03.03.01
Bearing shells Inspection/Evaluate
A5.05.02.03.07.01
Big-end bearings Inspection/Reassembly
A5.05.02.04.02.30
Hydraulic clamping element Maintenance/Replace
A5.05.02.04.51.00
Main bearings Maintenance/Reassembly
A5.05.02.05.02.30
Main thrust bearings Maintenance/Reassembly
A5.05.02.05.06.30
Pistons Maintenance/Disassembly
A5.05.02.06.01.30
Piston crown Maintenance/Replace
A5.05.02.06.02.04
Piston pin Inspection/Disassembly and reassembly
A5.05.02.08.01.00
AA000649
9/10
Periodical schedule
A5.04.02
Heavy fuel M43/VM43
Intervall
en / 03.03.2009
Designation / Work to be carried out Remarks
Doc-Nr.
Piston Maintenance/Reassembly
A5.05.02.10.01.30
Counter-balance Repair/Disassembly and reassembly
A5.05.02.11.00.00
Measures for emergency operation Repair/Disassembly and reassembly
A5.05.02.12.00.00
Cooling water distributor housing Maintenance/Disassembly and reassembly
A5.05.03.02.00.00
Cylinder liner Maintenance/Reassembly
A5.05.03.04.02.00
Camshaft Repair/Disassembly and reassembly
A5.05.04.04.01.08
Timing Gear Train Maintenance/Disassembly and reassembly
A5.05.04.08.02.02
Charge air cooler Maintenance/disassembly and reassembly
A5.05.06.04.02.30
Injection pump Repair/Disassembly and reassembly
A5.05.07.02.01.00
Pressure valve Maintenance/Disassembly and reassembly
A5.05.07.03.03.00
Injection pump Maintenance/Replace
A5.05.07.04.01.00
Fuel injector Maintenance/Disassembly and reassembly
A5.05.07.07.01.02
Fuel injector Maintenance/Adjust
A5.05.07.08.01.30
Duplex fuel filter Maintenance/Cleaning
A5.05.07.12.01.08
Fuel distributor/collection pipe Repair/Disassembly and reassembly
A5.05.07.15.01.30
Lubricating oil pump Maintenance/Disassembly and reassembly
A5.05.08.03.02.04
Lubricating oil duplex filter Maintenance/Cleaning
A5.05.08.04.01.01
Pressure switch Maintenance/Adjust
A5.05.11.06.06.02
Crankcase monitoring device Inspection/Checking
A5.05.11.09.01.03
AA000649
10/10
Valve clearance
A5.05. 01.01.01.00
Inspection / Adjust M43/VM43
1500
01
See also:
02.01.01.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Inspection: The valve clearance must be checked every 1,500 operating hours and adjusted if necessary.
Tools: Feeler gauge
W2 *
1.9075-003
* no picture
Note: Valve clearance may only be checked with the engine at operating temperature, i.e. 15 minutes after the engine has been stopped. Valve clearance (Fig. 1/S): Intake:
0.4 mm
Exhaust:
1.1 mm
The valve fitting position must be set correctly relative to the valve cone before adjusting valve clearance during regular maintenance or after work on the valve train.
Procedure: 1.
Set valve fitting.
1.1
Open indicator valves.
1.2
Engage the rotor.
1.3
Remove the cylinder head (valve) cover, do not damage the gaskets.
1.4
Turn the crankshaft until the cylinder to be set reaches ignition TDC.
en / 06.09.2006
IB004792
1/2
Valve clearance
A5.05. 01.01.01.00
Inspection / Adjust M43/VM43
1500
01
1.5
Release valve bridge of rocker arm (Fig. 1/1). Enlarge clearance „S“ and/or flap back rocker arm (1).
1.6
Release locknut (Fig. 2/3) and unsrew setting bolt (4) until a contact in „X” without clearance is reached.
1.7
At this position of the valve bridge screw in setting bolt (4) until contact at „Y” without any clearance is reached. Valve bridge must not be tited.
1.8
Hold tight setting bolt (4) and tighten locknut (3) with M = 250 Nm.
1.9
Check absence of clearance at „X“ and „Y“ with feeler gauge of 0.02 mm (W2). Afterwards adjust valve clearance „S“ as per instruction.
2.
Set valve clearance
2.1
Measure the clearance (Fig. 1/S) with the feeler gauge. Depress the push rod while measuring the clearance.
2.2
Correct the clearance “S“.
2.2.1
Loosen counternut (5).
2.2.2
Turn the valve adjusting screw (2) until the valve reaches the indicated clearance.
2.2.3
Retighten the counternut (5) M = 400 Nm to lock the adjusting screw into place.
2.2.4
Check the clearance again after tightening the counternut.
2.2.5
Remove the turning mechanism and close the indicator valves.
2.2.6
Install valve cover.
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IB004792
2/2
Valve Rocker Brackets
A5.05. 01.02.01.30
Maintenance / Disassembly and reassembly M43/VM43
01
See also:
01.01.01.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 0,20 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Store hydraulic device kit clamping cylinder high pressure hose high pressure hose
W1 W1.1 W1.2 W1.3
consisting of 1.9213 H 433420 A 433420 E
Auxiliary materials: Molykote Paste "G-Rapid Plus" ** ** or equivalent product
Attention: High pressure lines may not be bent below minimum bending radius r = 250 mm! Unit may only be operated with hydraulic oil. Protect the unit from corrosion during storage.
~
Attention! Do not place any body parts under equipment which is under pressure. Ensure that the engine cannot be started.
Procedure: 1.
Disassembly
1.1
Engage the rotor.
1.2
Open indicator valves.
1.3
Remove valve cover.
1.4
Turn piston to ignition TDC. Intake and exhaust valves are closed, rocker arms subject to no force.
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IB024440
1/4
Valve Rocker Brackets
A5.05. 01.02.01.30
Maintenance / Disassembly and reassembly M43/VM43
01
1.5
Remove the four rocker arm nuts with the hydraulic clamping unit.
1.5.1
Place the hydraulic clamping elements (W1.1) on the round nuts (1), unscrew threaded bush up to the limit stop and pull. Ensure that the slits are easily accessible. Loosen hydraulic clamping elements by 3 holes.
1.5.2
Connect the clamping elements with the high pressure pump (6) by means of the high pressure lines (W1.2, W1.3).
1.5.3
Close the valve on the high pressure pump and extend both rocker arm bracket bolts evenly and smoothly with a pressure of p = 2250 bar.
1.5.4
Loosen the round nuts with a pin. Turn the round nut back four holes.
1.5.5
Depressurize the clamping elements, dismantle the clamping device and remove the round nuts.
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IB024440
2/4
Valve Rocker Brackets
A5.05. 01.02.01.30
Maintenance / Disassembly and reassembly M43/VM43
01
Note: If the round nuts cannot be removed, the pressure on the nuts can be increased by ca. 50 bar more. If the round nuts are subject to higher pressure, the pin threading may stretch, which can cause the round nuts to lock into place. 1.5.6
Repeat dismantling procedure 1.5.1 to 1.5.5 for the upper round nuts (2).
1.6
Remove rocker arm bracket with intake and exhaust rocker arms.
2.
Assembly
2.1
Clean the contact surface for the rocker arm bracket.
2.2
Blow out the oil outlet with compressed air.
2.3
Place the rocker arm bracket on the cylinder over the studs and position. The bracket is fastened by means of studs.
2.4
Apply Molykote paste “G-Rapid Plus“ to the threads and contact surface for the nuts and tighten by hand.
2.5
Tighten the four rocker arm bracket bolts with the hydraulic clamping unit.
2.5.1
Place the hydraulic clamping elements (W1.1) on the round nuts (2) and tighten. Ensure that the slits are easily accessible.
2.5.2
Connect the clamping elements with the high pressure pump by means of the high pressure lines (W1.2, W1.3).
2.5.3
Close the valve on the high pressure pump and extend both rocker arm bracket bolts evenly and smoothly with a pressure of p = 2250 bar.
Attention: The pressure must remain constant when the pump is not being actuated to prevent incorrect tightening.
2.5.4
Tighten the round nut firmly with a pin. Check to ensure good action (no stiffness).
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IB024440
3/4
Valve Rocker Brackets
A5.05. 01.02.01.30
Maintenance / Disassembly and reassembly M43/VM43
2.5.5
01
Check to ensure that the round nut is seated properly.
• Reduce pressure by 50 bar. • The round nuts must be tight enough that they cannot be loosened with the pin. 2.5.6
Depressurize the clamping elements, dismantle the clamping unit.
2.5.7
Repeat installation procedure 2.5.1 to 2.5.6 for lower round nuts (1).
2.6
Set valve clearance (01.01.01.nn).
2.7
Diengage the rotor.
2.8
Install valve cover. (Check gasket!)
2.9
Close indicator valves.
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IB024440
4/4
Valve Rockers
A5.05. 01.02.02.00
Maintenance / Disassembly and reassembly M43/VM43
30000
See also:
01.02.01.nn, 01.02.03.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 0,20 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
01
---------------------------------------------------------------------------------------------------------------------------------Maintenance: Disassemble intake and exhaust rocker arms and check bearing clearance every
30,000 h
Note: The liners may only be lubricated with oil. Molykote paste may not be used for installing the bushings.
Procedure: 1.
Disassembly
1.1
Remove securing rings (Fig. 1/4) and thrust washers (5) from the rocker arm shaft (3).
1.2
Remove the intake valve rocker arm (1) and the exhaust valve rocker arm (2) from the rocker arm shaft (3).
Note: All additional maintenance work is identical for the intake and exhaust valve rocker arms. 2.
Clean all parts and check for damage. Blow out oil bores with compressed air and check to ensure that they are clear.
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IB004796
1/2
Valve Rockers
A5.05. 01.02.02.00
Maintenance / Disassembly and reassembly M43/VM43
3.
~ 4.
5.
30000
01
Check the bearing surfaces of the ball pin (Fig. 2/10) and the adjusting screw (12) for wear and damage. Replace parts as necessary. Cool ball pins to -195 °C with liquid nitrogen and slide into place.
Attention! Note and follow all safety instructions when handling liquid nitrogen. Measure the rocker arm bush (Fig. 2 /13) and shaft (Fig. 1/3) and replace the bush when the clearance meets or exceeds the wear limit (01.02.03.nn).
New clearance (mm)
Wear limit (mm)
0.056 - 0.208
0.30
Assembly
Note: Rocker arm shaft must be undamaged and may have no burrs or scratches. 5.1
Oil the contact surfaces of the intake (Fig. 1/1) and exhaust rocker arms (2) and the rocker arm shaft and slide the rocker arms onto the shaft carefully. Do not tilt the rocker arms.
5.2
Reinstall the rocker arm bracket and rocker arms on the cylinder cover (01.02.01.nn) and check the oil flow through the components.
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IB004796
2/2
Valve Rocker Bush
A5.05. 01.02.03.00
Inspection / Replace M43/VM43
See also:
01.02.01.nn, 01.02.02.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 0,40 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
01
-------------------------------------------------------------------------------------------------------------------------------Tools: Copper punch
W1 *
* no picture
Note: The liners may only be lubricated with oil. Molykote paste may not be used for installing the liners.
Procedure: 1.
Measure the rocker arm bush (1) and (01.02.02.nn).
2.
Replace.
2.1
Drive out the bush (1) with the proper copper punch (W1).
2.2
Oil the new bush lightly and press into rocker arm.
Attention: Note the position of the oil bores (2) and the separating joint (3) when pressing the new bush into place. The rokker arm must protrude past the liner (Z) s = ca. 0.2 mm on both sides. Be careful not to damage the plastic coated contact surface.
en / 05.06.2003
IB004798
1/1
Valve Rotor
A5.05. 01.03.01.00
Inspection / Evaluate M43/VM43
150
See also:
01.07.01.nn, 01.10.00.nn
Spare parts list:
B1.05.01.432107, B1.05.01.432225
Time requirement:
1 Pers./ 0,10 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
01
-------------------------------------------------------------------------------------------------------------------------------Inspection: of the valve rotor and the free-wheels every
150 h
Note: The valve rotational speed in relation to the engine speed must be measured and documented when the new or overhauled cylinder cover is taken into service in order to allow comparisons to be made over the course of subsequent inspections. The intake valves are equipped with valve rotors and the exhaust valves with vanes and a free-wheel.
Procedure: 1.
Open the valve cover and note the turning of the valves. The mark “X” on the valve spring plate (1) is provided for this purpose.
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IB004800
1/2
Valve Rotor
A5.05. 01.03.01.00
Inspection / Evaluate M43/VM43
2.
150
The valve rotor or free-wheel is functioning correctly when the valves rotate evenly in relation to the engine speed. The valve rotor and free-wheel must be lubricated with a few drops of oil-gas oil mixture (mixture ratio 1:1) if the rotational speed is noticeably slower than the speed indicated for new valves.
2.1
If the valve rotational speed slows to n ≤ 1 min-1 at the rated engine speed, the valve rotor or free-wheel must be replaced.
Note: The valve rotation speed can also be slowed by stiffness of the valve shaft in the valve guide. Solution: spray small amounts of gas-gas oil mixture on the valve shaft.
Attention: Use the gas-gas oil mixture sparingly! Excess use can dilute the engine oil!
en / 05.06.2003
IB004800
2/2
01
Valve guide/Oil scraper ring
A5.05. 01.05.01.01
Inspection / Replace M43/VM43
15000
See also:
01.01.01.nn, 01.02.01.nn, 01.06.01.nn, 01.07.01.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 0,20 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel
01
-------------------------------------------------------------------------------------------------------------------------------Inspection: of the valve guide clearance of the intake and exhaust valves after 15,000 h
Auxiliary materials: Molykote Paste “G-Rapid Plus” ** ** or equivalent product
Procedure: 1.
Replace the oil scraper rings (O-rings).
1.1
Disassemble valve cone, clean valve shaft carefully.
1.2
Remove O-ring (1) from groove with wire hook carefully.
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IB004804
1/2
Valve guide/Oil scraper ring
A5.05. 01.05.01.01
Inspection / Replace M43/VM43
15000
01
Attention: The O-ring meters the valve lubrication and may only be replaced with a new MaK replacement ring.
1.3
Clean the groove.
1.4
Oil the new O-ring lightly and place in groove carefully. The ring may not be twisted during installation!
2.
Measuring the valve guide clearance
2.1
Measure the outer diameter of the valve shaft in the guide area of the bush.
2.2
Measure the inner diameter of the guide across the engine block.
2.3
Exhaust Intake
3.
Normal clearance (mm)
Wear limit (mm)
0.22 - 0.29 0.15 - 0.22
0.4 0.4
Valve guide replacement
Note: The valve guides should be replaced by a certified MaK workshop within the scope of a cylinder cover overhaul if possible. The cylinder cover may be damaged when removing the old valve guides.
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IB004804
2/2
Media guiding system
A5.05. 01.05.50.01
Maintenance / Disassembly and reassembly M43
See also:
01.06.01.nn, 01.11.01.nn
Spare parts list:
B1.05.01.432144
Time requirement:
1 Pers./ 0,25 h
01
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Auxiliary material: Vaseline * * or a product of equal standard
Sequence of operations: 1.
Disassembly
~
Safety note: The system must be depressurized before disassembly!
1.1
Loosen the cheese head screws (fig. 2/18) and the connecting flanges (fig. 1/1, 2) together with the sleeves (9).
en / 24.03.2004
IB024333
1/4
Media guiding system
A5.05. 01.05.50.01
Maintenance / Disassembly and reassembly M43
01
1.2
Pull the sleeves (fig. 2/9) out of the connecting flanges (1, 2).
1.3
Check the O-rings (14). Replace faulty O-rings (14). Insert the O-rings in the grooves using vaseline and making sure that they are not twisted!
1.4
Remove hexagon screws (Fig. 1/21) and end flange (7).
1.5
Check gaskets (Fig. 2/13) of the connecting flanges (1, 2) as well as gaskets (13) of the end flange (7) on the last cylinder. Clean the sealing faces.
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IB024333
2/4
Media guiding system
A5.05. 01.05.50.01
Maintenance / Disassembly and reassembly M43
1.6
Remove the cheese head screws (Fig. 3/22) with connecting flange (8).
1.7
Pull the sleeves (10) out of the media block (6).
1.8
Check the O-rings (15). Replace faulty O-rings (15).
1.9
Remove lubricating oil pipe (4).
1.10
Remove hexagon screws (20, 23) with media block (6).
1.11
Clean all sealing faces.
en / 24.03.2004
IB024333
01
3/4
Media guiding system
A5.05. 01.05.50.01
Maintenance / Disassembly and reassembly M43
01
2.
Reassembly
2.1
Mount the connecting flanges (fig. 2/1 and 2) with inserted sleeves (9). Replace faulty gaskets (13) beforehand.
2.2
Mount the media block (fig. 3/6). Insert sleeves (10) with new O-rings (15).
2.3
Mount lubricating oil pipe (4).
2.4
Put the connecting flange (8) onto the sleeves (10) and mount it. Replace faulty gasket (13) beforehand.
2.5
Mount the blank flange (fig. 2/7). Replace faulty gaskets (13) beforehand.
Attention: Make sure that all gaskets (13) are centred properly by the dowel pins (19)!
3.
Check operation of the alarm probe for leakage fuel (fig. 3/20).
3.1
Dismantle the alarm probe, refit the connector and submerge the tip of the alarm probe in a medium. Acknowledge the alarm if an alarm is triggered. If an alarm is not triggered, replace the alarm probe and repeat the test.
3.2
Mount the alarm probe.
4.
Determine the defective fuel delivery pipe in the event of a "leakage fuel" alarm.
Note: Leakage fuel can result from -
a defective fuel delivery pipe or a faulty gasket between the fuel delivery pipe/injection pump or between the fuel delivery pipe/injection nozzle.
4.1
Acknowledge the alarm when a "leakage fuel" alarm is given and, beginning with cylinder 1, remove the screw (fig. 2/25) with gasket (24).
4.2
Check the bore in the connecting flange (1) for leakage fuel. If, for example, leakage fuel is discerned on cylinders 1, 2 and 3 but not on cylinder 4, then replace the fuel delivery pipe for cylinder 3 (07.02.01.nn).
4.3
Mount the screw (25) with a new gasket (24).
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IB024333
4/4
Cylinder Head
A5.05. 01.06.01.30
Maintenance / Disassembly M43
See also:
01.02.01.nn, 02.06.01.nn, 03.04.01.nn, 06.01.01.nn, 07.05.01.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
01
---------------------------------------------------------------------------------------------------------------------------------Tools: Store hydraulic device kit clamping cylinder high pressure hose high pressure hose test manometer cylinder head lifting gear ring screw cylinder bushing holder Hexagon screw
W1 W1.1 W1.2 W1.3 W1.4 W2 W3 W4 W5
consisting of 1.9213 P 433420 E 433420 A 433420 G 432005 A 439217 A 431011 A
Attention: Do not fall short of minimum bending radius r = 250 mm for high pressure hoses. Only use hydraulic oil as operating medium. Store devices protected against corrosion.
~
Safety notice: Avoid bringing body parts above the pressurised devices. Secure motor against involuntary starting.
Procedure: 1.
Open indicator valves, turn piston to ignition-TDC, remove cylinder head cover and pump chamber cover. Fit cylinder bushing holder (Fig. 1/W4).
2.
Drain cooling water: Disconnect connection pipe from reserve pump to cooling water manifold pipe. Inspection: Thermometer connection above the cooling water pump
Attention: When removing the last cylinder head on the opposite side of the clutch unscrew the manometer pipe (lubricating oil nozzle cooling) from the connecting flange.
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IB024287
1/4
Cylinder Head
A5.05. 01.06.01.30
Maintenance / Disassembly M43
3.
Disconnect and remove connecting flange of the media conduit for the cylinder head to be removed (01.05.50.nn).
4.
Remove rocker arm bracket (01.02.01.nn).
01
Note To prevent damage and ensure trouble-free assembly and disassembly, the complete rocker arm bracket must be removed! 5.
Remove injection pressure pipe (07.05.01.nn).
6.
Remove injection valve (07.07.01.nn).
7.
Remove covering cap between exhaust pipe and cylinder head.
8.
Screw hexagon screws (Fig. 2/W5) into cooling water blocks to support the exhaust pipe.
9.
Loosen clamp on exhaust pipe (06.01.01.nn).
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IB024287
2/4
Cylinder Head
A5.05. 01.06.01.30
Maintenance / Disassembly M43
01
10.
Loosen the six cylinder head screws using the hydraulic torque device.
10.1
Store hydraulic traction elements (Fig. 3/ W1.1) onto round nuts and tighten. Ensure good accessibility of the slots (3). Store hydraulic hydraulic traction elements by a 1 1/3 turn.
10.2
Store hydraulic traction elements via high pressure hoses (W1.2) to each other. Connect element 1 to pump. Fit test manometer (W1.4) onto element 6. Secure the coupling that is not connected by means of plug (8).
10.3
Close valve on high pressure pump and extend all 6 cylinder head screws simultaneously and continuously using a hydraulic pressure of p = 2250 bar -25 bar The pressure at the hydraulic pump must correspond to the pressure at the test manometer.
10.4
Loosen round nuts with pin. Turn round nuts back by at least 8 holes.
Note: If the round nuts cannot be loosend, the cylinder head screw can be pretensioned further with approx. 50 bar With further pressure increase there is a risk of the round nut becoming wedged due to an expansion of the bolt thread. 10.5
Relieve traction elements, remove hydraulic device and unscrew round nuts.
en / 13.02.2009
IB024287
3/4
Cylinder Head
A5.05. 01.06.01.30
Maintenance / Disassembly M43
11.
Screw ring screws (Fig. 4/W3) into cylinder head. Fit cylinder head lifting device (W2). Lift cylinder head with hoist. Watch for push rod bushing!
W2
W3
Attention: Risk of damage for conduit connection, cylinder head screws, push rods, fuel pressure pipe and charged air inlet connection.
12.
Lower cylinder head onto wooden surface (two beams, as nozzle protrudes).
en / 13.02.2009
IB024287
4/4
01
Nozzle sleeve
A5.05. 01.06.50.03
Maintenance / Disassembly and reassembly VM43
15000
See also:
01.06.01.nn, 07.07.01.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 0,50 h
01
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenace: Replacement of O-rings
every
15.000 h
Tools: wrench for nozzle sleeve torque wrench 200 - 500 Nm brass mandrel
W1 W2* W3*
432119 A 1.9454-500
* no illustration
Auxiliary material: Vaseline ** Adhesive and sealant “ Loctite 510 “** ** or a product of equal standard
Sequence of operations: 1.
Remove nozzle sleeve (1).
1.1
Place wrench (W1) so that nozzle sleeve (1) and wrench (W1) are engaged.
1.2
Mount the flange (3) (07.07.01.nn).
1.3
Attach torque wrench (W2) to wrench (W1) and unscrew nozzle sleeve until the threads of nozzle sleeve and cylinder head (2) are exposed.
en / 30.01.2008
IB024107
1/2
Nozzle sleeve
A5.05. 01.06.50.03
Maintenance / Disassembly and reassembly VM43
15000
01
Attention: The threads of the nozzle sleeve and the cylinder head may no longer mesh.
1.4
Remove flange (3).
1.5
Use a brass mandrel (W3) and carefully drive out the nozzle sleeve.
1.6
Remove the O-rings (4 and 5).
2.
Install nozzle sleeve (1).
2.1
Insert new O-ring (71 x 3,55) with Vaseline in the lower groove (5) without twisting.
2.2
Insert new O-ring (72,69 x 2,62) with Vaseline in the upper groove (4) without twisting.
Attention: The O-rings must be installed in the proper grooves (4 and 5)!
2.3
Coat “Loctite 510“ to the nozzle sleeve threads.
2.4
Slide the nozzle sleeve into the cylinder head.
2.5
Place the torque wrench on the nozzle sleeve wrench and tighten the nozzle sleeve to M =300 Nm
en / 30.01.2008
IB024107
2/2
Relief Valve
A5.05. 01.06.70.01
Maintenance / Replace M43/VM43
30000
See also:
01.06.01.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 0,20 h
01
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: Replacement of relief valve
every
30,000 h
Tools: Torque wrench 20 - 200 Nm
W1 *
1.9454-202
* no picture
Auxiliary Material: High-temperature thread paste “Dag 5420 A“ * * or a product of equal standard
Sequence of Operations: 1.
Unscrew hexagon nut (1).
2.
Remove cover (2).
en / 31.01.2008
IB023661
1/2
Relief Valve
A5.05. 01.06.70.01
Maintenance / Replace M43/VM43
30000
3.
Slacken relief valve (3) by means of a wrench and remove it.
4.
Lubricate the thread of the new relief valve with high-temperature thread paste “Dag 5420 A“ .
5.
Mount new relief valve (3) with new joint ring (4).
6.
Firmly tighten the relief valve by means of a wrench.
7.
Mount cover (2).
8.
Tighten hexagon nut (1) with a torque of
01
M = 50 Nm.
en / 31.01.2008
IB023661
2/2
Inlet and Exhaust Valve Cone
A5.05. 01.07.01.03
Inspection / Disassembly and reassembly M43/VM43
15000, 7500
See also:
01.02.01.nn, 01.05.01.nn, 01.06.01.nn, 01.08.01.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
01
---------------------------------------------------------------------------------------------------------------------------------Inspection: check the wear pattern of the intake and exhaust valve cone of the cylinder unit and check for deposits every
7,500 h
Maintenance: all intake and exhaust valve cones every
15,000 h
Tools: Valve spring compressor unit Pliers for circlips
W1 W2*
439222 D 1.9067-440
* no picture
Auxiliary materials: Molykote Paste “G-Rapid Plus“ ** ** or equivalent product
Note: The service life of a valve cone is dependent on the quality of the fuel used, the operating conditions under which the equipment is used and the grade of repaired valve cones/seat rings and varies from system to system. For this reason, the system operator must determine the maintenance intervals required for his equipment after inspecting the valve cones. Every time a valve cone is removed, the seat geometry must be checked and milled if necessary (01.08.01.nn, 01.08.02.nn).
en / 05.06.2003
IB023934
1/3
Inlet and Exhaust Valve Cone
A5.05. 01.07.01.03
Inspection / Disassembly and reassembly M43/VM43
15000, 7500
01
Sequence of operations: 1.
Disassembly
1.1
Disassemble the cylinder head (01.06.01.nn).
1.2
Disassemble the rocker arms (01.02.01.nn) and take off valve bridge.
1.3
Pull pin (10) out of spindle (11).
1.3.2
Sleeve (12) must rest above the split spindle end.
W1
10
Put the split spindle end onto valve cone stem so as to engage.
1.3.4
Press sleeve (12) above split spindle end and mount pin (10).
1.4
Remove circlip (5) by means of pliers (W2). Compress valve spring (3) by turning the stem of device (13) and take out clamping cone halves (4).
1.5
Relieve valve spring (3) by turning the stem of device (13) in the other direction.
~
11
Put the valve spring compressor unit (W1) onto valve spring retainer (2). To this end:
1.3.1
1.3.3
13
12 5 2
4
Attention! Spring force
1.6
Remove the valve spring compressor unit (W1). To this end:
1.6.1
Pull pin (10) out of spindle (11).
1.6.2
Sleeve (12) must rest above the split spindle end.
1.6.3
Pull the valve spring compressor unit off the valve cone stem.
1.7
Take valve spring retainer (2), valve spring (3) and valve rotator, freewheel or valve spring washer off the cylinder head.
3
en / 05.06.2003
IB023934
2/3
Inlet and Exhaust Valve Cone
A5.05. 01.07.01.03
Inspection / Disassembly and reassembly M43/VM43
1.8
15000, 7500
01
Pull the valve cone out of the cylinder head.
Note: Valve cones which display a large degree of wear in the clamping area and clamping piece haves with excessive burring must be replaced with new parts. All burrs must be removed from such valve cones before disassembly. Valve cone/valve seat repair (01.08.01.nn/01.08.02.nn). 2.
Assembly
2.1
Check valve guide clearance, replace O-ring (01.05.01.nn).
2.2
Oil the de-burred valve cone well before installation and insert valve cone with a twisting motion to prevent damage to the O-ring.
2.3
Installation is completed in the reverse order as disassembly.
2.4
After inserting clamping cone halves (4) and assembling circlip (5) by means of pliers (W2) slowly relieve valve spring (3). In doing so, make sure that the clamping cone halves are seated correctly.
en / 05.06.2003
IB023934
3/3
Inlet and Exhaust Valve Cones
A5.05. 01.08.01.00
Repair / Checking M43/VM43
See also:
01.07.01.nn, 01.08.02.nn
Spare parts list:
B1.05.01.432107
Time requirement:
0 Pers./ 0,00 h
Personnel qualification:
Chief engineer / skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
01
---------------------------------------------------------------------------------------------------------------------------------Tools: Valve seat grinding unit
W1
439224 A
Auxiliary materials: Diamond paste Dp 30/10 - 15 µm * Thinner F25 * * or equivalent product
Note: New, reworked or undamaged used inlet and exhaust valve cones must be ground in accordance with operation 4 before installation. It may also be necessary to rework the valve cones (according to operation 3):
• •
after longer operating time, the inspection reveals damaged sealing surfaces, deep graining, uneven wear pattern on the valve cone /seat.
Sequence of operations: 1.
Cleaning
1.
Clean the valve stem. Experience has shown that a thorough cleaning, such as an assessment of the valve cones requires, is only possible by blasting with material like glass beads. The stems may not be cleaned with sharp tools or cleaned with inorganic acids (hydrochloric acid, sulfuric acid, hydrofluoric acid, etc.) or by sandblasting.
2.
Inspection
2.1
Valves can be reused without being reworked when
•
the valve cone surface is bright and polished around the entire cone
•
the valve cone surface has no carbon deposits which may indicate blow-by
•
no cracks are found in the valve cone surface when checked with an illuminated magnifying glass (8 x magnification), or during a pulse spray test (Met L’Check) or a flux test.
en / 05.06.2003
IB004814
1/5
Inlet and Exhaust Valve Cones
A5.05. 01.08.01.00
Repair / Checking M43/VM43
•
•
there is HT corrosion as shown below, i. e. no deep craters over the entire area of the bottom side of the valve heads.
the straightness deviation does not exceed the following values (Fig. 1) Span “s“ = 495.6 mm = Contact point for measurement device
•
the radial deviation of the valve cone does not exceed the following values:
en / 05.06.2003
IB004814
2/5
01
Inlet and Exhaust Valve Cones
A5.05. 01.08.01.00
Repair / Checking M43/VM43
2.2
01
Valves may not be re-used for another interval when
• •
the valve cone surface is damaged (cracks, blow-by) there is burnout “s“ caused by high temperature corrosion on the underside of the valve head > 2.5 mm (Fig. 2)
• •
•
there is coarse graining on the undeside of the valve head (so-called cobblestone formation) there are corrosion pits and mechanical damages in the vicinity of the valve stem, the root of the stem and the valve head
the indicated reworking limits have been exceeded.
en / 05.06.2003
IB004814
3/5
Inlet and Exhaust Valve Cones
A5.05. 01.08.01.00
Repair / Checking M43/VM43
3.
01
Repair (reworking the sealing surface)
Note: The rework must be completed properly on precision spindle grinding machines. If such a machine is not available, the valve cone should be sent to a CAT workshop for regrinding. 3.1
Regrind the sealing surface in accordance with the indicated angle (Fig. 3). Do not rework the groove. Exhaust valve cone Inlet valve cone
= =
Fig. 3 Fig. 3a
3.2
Observe the instructions of the respective grinding machine manufacturer.
3.3
After grinding, measure the distance between the visible edge of the plating “X“ and outer edge of the seat surface. The valve cone must be replaced when the distance is smaller than the wear limit. (Fig. 3, Exhaust valve Fig. 3a, inlet valve).
3.4
Outer edge rounded with stone.
Attention: After the valve cone is reworked, the valve seat ring must also be reworked (01.08.02.nn).
4.
Maintenance (Check wear pattern/grinding)
4.1
Apply small dots of diamond paste Dp 30/ 10 - 15 µm to the seating new or reworked valve cone with a syringe and spread evenly. (Fig. 4). Next, spray the entire valve seat ring with a thinner which corresponds to the diamond paste (F25) to thin the paste and increase the grip.
en / 05.06.2003
IB004814
4/5
Inlet and Exhaust Valve Cones
A5.05. 01.08.01.00
Repair / Checking M43/VM43
4.2
Slide the oiled valve stem into the guide. Attach the rig (Fig. 5/W1) to the valve head and grind the cone and seat surface together briefly by turning the valve head with moderate pressure by hand. The contact surface (Fig. 6/a), which is visible after the grinding procedure, should not amount to more than 30 - 50 % of the seat width “b“ starting from the outside diameter.
4.3
If the contact surface does not appear to be in good order, do not regrind any more, but rework both sealing surfaces.
4.4
Components which have been ground together (valve cone and seat ring) must be kept together.
5.
Final inspection
5.1
Check that the reworking limit has not been exceeded.
5.2
Clean the valve cone / seat thoroughly and check the sealing surfaces with an illuminated magnifying glass (8 x magnification) for cracks in the plating and in the neighboring areas.
en / 05.06.2003
IB004814
5/5
01
Valve Seat Ring
A5.05. 01.08.02.00
Repair / Checking M43/VM43
See also:
01.07.01.nn, 01.08.01.nn
Spare parts list:
B1.05.01.432107
Time requirement:
0 Pers./ 0,00 h
Personnel qualification:
Chief engineer / skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
01
------------------------------------------------------------------------------------------------------------------------------Tools: Precision seat grinding machine Valve milling unit
W1 * W2
1.9224 M 439224 B
* no picture
Auxiliary materials: Illuminated magnifying glass (8x magnification) Diamond paste Dp 30/10 - 15 µm ** Thinner DIAPLASTOL ** ** or equivalent product
Note: If the sealing surface of the valve seat/valve cone has an uneven wear pattern or deep graining, both sealing surfaces must be reworked. Grind new or reworked valve seats as described in procedure 4. It may be necessary to rework the seats when:
• •
the engine has not been run for a long period of time, the inspection reveals damaged sealing surfaces, deep graining, uneven wear pattern on the valve seat /cone (Fig. 1 and 2).
en / 18.05.2006
IB004816
1/5
Valve Seat Ring
A5.05. 01.08.02.00
Repair / Checking M43/VM43
01
Procedure: 1.
Inspection The grade (hardness) of the valve seat is designed to allow the seat to adapt to the valve cone to a certain extent. Carbon deposits are therefore normal and pose no danger with adequate cooling (Fig. 3, 4 and 5).
en / 18.05.2006
IB004816
2/5
Valve Seat Ring
A5.05. 01.08.02.00
Repair / Checking M43/VM43
1.1
01
Valve rings can be reused without reworking when
• the seat surface is metallic and polished around the entire circumference • no carbon deposits which may indicate blow-through are visible or no wear is visible • no cracks are found when the seat surface is checked with an illuminated magnifying glass (8x magnification) or in a pulse spray test (Met L’Check) or flux test.
1.2
Valve seat rings may not be reused when
• there are cracks in the seat surface • the seat surface is burned through • the reworking limit has been exceeded. 2.
Cleaning Clean all deposits and soil from the seat surface.
3.
Repair (reworking the valve seat rings)
Note: The seat rings must be machined properly with an MaK precision-grinding machine (W1). Consult the special operating manual before beginning work. The seat rings can also be reworked with an MaK valve seat milling unit (Fig. 6/ W2). Avoid removing too much material, only the carbon deposits in the contact area should be removed. Do not use oil. 3.1
Mill valve seat
3.1.1
Clean the valve seat ring carefully in the contact area (3) of the centering disk (4) in order to ensure that the guide punch (5) is centered exactly. Remove the O-ring from the guide bush.
en / 18.05.2006
IB004816
3/5
Valve Seat Ring
A5.05. 01.08.02.00
Repair / Checking M43/VM43
3.1.2
01
Insert the centering disk (4) with the guide punch (5) and tighten with a star handle (6).
Attention: Handle the cutting head (Fig. 6/2) carefully, milling blades can be damaged easily by impact and hard or sudden contact can damage the valve seat surface.
3.1.3
Place the cutting head (2) on the greased guide punch, turn the knurled screw (1) in until there is resistance.
3.1.4
Mill the valve seat in a single motion by turning to the right, turn the rig as far as possible. The blades must cut noticeably. Adjust the cutting pressure depending on how the cut feels.
Attention: If the cutting pressure is too low or if the cut is made to rapidly, the milling unit may chatter.
3.1.5
Before ending the milling procedure, back out the knurled screw (1) slowly while turning the cutting head.
3.1.6
Maximum permissible dimension Ø (x) for reworking (Fig. 7): 148+0.2 a = no material may be removed
3.1.7
exhaust valve seat ring
= Fig. 7
intake valve seat ring
= Fig. 7a
Remove milling unit. Smooth the sharp edges with a fine emery cloth.
en / 18.05.2006
IB004816
4/5
Valve Seat Ring
A5.05. 01.08.02.00
Repair / Checking M43/VM43
01 4.
Contact surface check / grinding
4.1
Apply small dots of diamond paste DP 30/10 - 15 µm to the new or reworked vale shaft with a small syringe and spread evenly. Next, spray the entire seat ring surface with thinner (DIAPLASTOL). (01.08.01.nn).
4.2
Slide the oiled valve shaft into the guide bush. Attach the rig (W1) (01.08.01.nn) to the valve head and grind the cone and seat surface together briefly by turning the valve head back and forth with moderate pressure. The contact surface “a“, which is visible after the grinding procedure, should not amount to more than 30 - 50 % of the seat width “b“ around the entire edge of the entire circumference. (01.08.01.nn).
4.3
If the contact surface does not appear to be in good order, do not grind any more, both sealing surfaces must be reworked on a grinding machine.
4.4
Components (valve cone and seat ring) which have been ground together must be kept together.
5.
Final inspection
5.1
Check that the indicated reworking limit has not been exceeded.
5.2
Clean the valve cone / seat thoroughly and check the sealing surfaces with an illuminated magnifying glass (8 x magnification) for cracks in the plating and in the neighboring areas.
en / 18.05.2006
IB004816
5/5
Valve Seat Ring (Intake/Exhaust)
A5.05. 01.08.03.00
Repair / Replace M43/VM43
See also:
01.06.01.nn, 01.07.01.nn, 01.08.02.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 1,00 h
01
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
---------------------------------------------------------------------------------------------------------------------------------Tools: Press
W1
439222 C
Auxiliary materials: Diamond paste Dp 30/10 - 15 µm * Molykote Paste “G-Rapid“ * * or equivalent product
Procedure: 1.
Separate valve cones which can no longer be used at the shaft end (Fig. 1/1) and bezel the resulting gap (2) to prevent deformation. Turn the valve head to ca. 116 mm (inner diameter of seat ring).
2.
Place the valve cone in the valve seat ring and hold in the indicated position, connect the cone and seat ring around the entire circumference with a welded bead (electric welder). Grease the cylinder cover well outside of the seat ring area to prevent damage from flying sparks and slag.
3.
Drive the valve seat ring out onto the valve shaft by striking firmly, clean the bore by hand with 120 grit emery cloth, or with 260 serrated lock washer if the bore is extremely dirty.
en / 05.06.2003
IB004818
1/2
Valve Seat Ring (Intake/Exhaust)
A5.05. 01.08.03.00
Repair / Replace M43/VM43
01
4.
Install new seat ring.
4.1
Cool seat ring to at least -20 °C, heat cylinder head to 130 °C.
4.2
Tap the seat ring completely into the bore with the help of a hammer and valve cone (strike lightly). Apply a light coating of Molykote paste “G-Rapid“ to the threading and contact surface of the nut (Fig. 2/1). Tighten nut (1) to M = 150 Nm. Next, hold the seat ring in this position with a press (W1) until the cylinder head has cooled completely.
5.
Rework valve seat ring lightly with a valve seat grinding machine or valve seat milling unit. Grind the valve cone lightly with Diamond paste Dp 30/10 -15 µm and check the contact surface (01.08.02.nn).
6.
Install valve cone.
en / 05.06.2003
IB004818
2/2
Starting Valve Inspection / Checking
A5.05. 01.09.01.00
M43/VM43
3750
See also:
01.02.01.nn, 01.09.02.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 0,40 h
01
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Checking: Check starting valve of one cylinder for easy movement
all
3.750 h
For V-engines only on cyl. bank A
Attention: When working on the starter system, close the main valves on the pressure tanks, bleed the line and block the starting valve.
Procedure: 1.
Remove the rocker arm bracket (01.02.01.nn).
2.
Remove the cover (1) and O-ring (2) with the help of an M8 bolt.
3.
Push down piston (5) and spindle (9) approx. 7 mm using the handle of the hammer. The piston and spindle should move freely when doing so.
en / 27.10.2003
IB024089
1/2
Starting Valve Inspection / Checking
A5.05. 01.09.01.00
M43/VM43
4.
3750
01
Ensure that the piston (5) and spindle (9) return to the original position quickly and easily.
Note: Do not move spindle (9) by turning locknut (3). 5.
If the parts do not move freely, lubricate the piston (5) and guide in the cylinder head with engine oil.
6.
Fit cover (1) with new O-ring (3).
Note: If there is moisture, rust, dirt or other soiling between the cover (1) and piston (5), the treatment / dehumidification of the starting air should be checked.
en / 27.10.2003
IB024089
2/2
Starter Valve
A5.05. 01.09.02.03
Maintenance / Disassembly and reassembly M43/VM43
15000
See also:
01.06.01.nn, 01.11.01.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel
01
------------------------------------------------------------------------------------------------------------------------------Maintenance: Remove starter valve, disassemble and rework if necessary every
15,000 h
Tools: Insertion ring for starting valve piston Starting valve reseating tool
W1 * W2
439227 A 439224 C
* not shown
Auxiliary materials: Molykote Paste “G-Rapid“ ** ** or equivalent product
Attention: When working on the starter system, close the main valves on the pressure tanks, bleed the line and block the starting valve.
Procedure: 1.
Disassembly
1.1
Remove the rocker arm bracket (01.02.01.nn).
1.2
Lay the cylinder head on its side.
1.3
Remove the cover (1) and O-ring (2) with the help of an M8 bolt.
1.4
Remove circlip (12).
1.5
Loosen the hexagon nut (3) while holding the valve shaft (9) with a wrench.
1.6
Remove the clamping ring (4), piston (5), spring (6), spring plate (8) and valve shaft (9) with sleeve (7) from the cylinder head.
1.7
Clean all parts carefully with gas oil.
1.8
Check the piston (5), compression ring (10) and valve seat carefully. Smooth scored piston (5) carefully with emery cloth (240 grain or higher).
en / 11.02.2005
IB022699
1/3
Starter Valve
A5.05. 01.09.02.03
Maintenance / Disassembly and reassembly M43/VM43
15000
01
1.9
Rework starting valve seat with reseating tool (W2).
1.9.1
Carefully clean valve seat and guide of valve spindle.
1.9.2
Loosen adjusting screw (20) on reseating tool (W2). Lightly oil valve canon. Insert reseating tool in valve guide and fix with spanner (21).
1.9.3
Tighten adjusting screw (20) until a slight resistance is felt. Then tighten adjusting screw another 1/4 turn to set cutting pressure.
1.9.4
Turn reseating tool evenly and slowly without additional pressure. Repeat process until valve seat is clean.
1.9.5
Turn reseating tool evenly and slowly without additional pressure. Repeat process until valve seat is clean. To do so, apply a thin layer of try-out paste to valve spindle. Press valve spindle onto valve seat and turn through max. 90°°.
1.10
If the appearance of the bearing surface is not satisfactory, repeat steps 1.9.1 to 1.9.5. 21
20
en / 11.02.2005
IB022699
2/3
Starter Valve
A5.05. 01.09.02.03
Maintenance / Disassembly and reassembly M43/VM43
15000
01
2.
Assembly
2.1
Apply thin coat of Molykote paste “G-Rapid” to piston (5), distribute ring joints evenly around periphery. Insert piston using insertion ring (W1).
2.2
Installation is completed in the reverse order as disassembly. Replace O-ring (2). Make sure that the clamping ring (4) is installed correctly. Tighten the hexagon nut (3) until the hexagon nut (3) and valve shaft (9) cannot be moved separately (solid connection). Tighten the hexagon nut to M = 80 Nm.
2.3
Mount circlip (12).
2.4
Check the starter valve for leaks before starting the engine.
en / 11.02.2005
IB022699
3/3
Cylinder Head
A5.05. 01.10.00.00
Inspection / Checking M43/VM43
150
See also:
01.03.01.nn, 01.06.01.nn, 01.11.01.nn, 07.07.01.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 0,50 h
01
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
------------------------------------------------------------------------------------------------------------------------------Inspection: inspect the cylinder head every
150 h
Procedure: 1.
Check gasket between cylinder head, cylinder liner and coolant distributor housing for combustion gas leaks and check for coolant at the inspection bore (1). If leaks are found, remove the cylinder head (01.06.01.nn). Clean the sealing surfaces and inspect - replace O-rings and joint ring and tighten to the indicated torque (01.11.01.nn).
en / 05.06.2003
IB004824
1/2
Cylinder Head
A5.05. 01.10.00.00
Inspection / Checking M43/VM43
150
01
2.
Check the outside of the cylinder head for leaks.
2.1
If oil leaks are found, check the valve cover bolts to ensure that they are tight and check the rubber profile for damage.
2.2
If leaks are found at the media supply connecting flanges, check all bolts to ensure that they are tight. Replace gaskets as needed.
3.
Remove valve cover. Inspect the top of the cylinder head.
3.1
Check to ensure that the valves move identically. Irregularities can be seen most easily at low engine speeds.
3.2
Check the function of the valve rotor or free-wheel (01.03.01.nn).
3.3
Check valve springs for damage.
3.4
Check the oil supply to the valve rockers and rocker arm bearings.
en / 05.06.2003
IB004824
2/2
Cylinder Head
A5.05. 01.10.01.01
Maintenance / Cleaning M43/VM43
15000
See also:
01.02.01.nn, 01.06.01.nn, 01.07.01.nn, 01.09.02.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 1,00 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel
01
---------------------------------------------------------------------------------------------------------------------------------Note: The cylinder head may only be placed on the bench upright on a wood block.
Procedure: The following parts must be dismantled: Intake, exhaust, injector valve, starter valve and rocker arm bracket. 1.
Clean cylinder block with cold cleaning solution.
2.
Clean intake and outlet ports, underside of cylinder head (not the valve seats!) with a wire brush and scraper, all combustion deposits must be removed. Do not damage the gasket depression/ groove.
3.
Clean coolant intake and outlet ports.
4.
Inspect the underside of the cylinder head carefully for cracks at the valve fittings.
5.
Clean the sealing surface for the injector valve.
6.
Check the intake and outlet bores for media supply for blockage.
7.
Check function of leakage sensor for fuel leaks at the connection piece for media supply on the distributor plate (Cyl. 1).
en / 05.06.2003
IB004828
1/1
Cylinder Head
A5.05. 01.11.01.30
Repair / Reassembly M43
See also:
01.06.01.nn, 03.04.01.nn, 06.01.01.nn, 07.05.01.nn
Spare parts list:
B1.05.01.432107
Time requirement:
1 Pers./ 1,00 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
01
------------------------------------------------------------------------------------------------------------------------------Tools: See maintenance sheet 01.06.01.nn.
Ancillary materials: High temperature threading paste “Dag S-5080“ * Molykote paste “G-Rapid Plus“ * Vaseline * * or equivalent product
Attention: Do not fall below the minimum bend radius r =250 mm for the high pressure hoses. Only use hydraulic oil as operating medium.
~
Safety notice: Avoid bringing body parts above the pressurised devices.
en / 13.02.2009
IB024290
1/4
Cylinder Head
A5.05. 01.11.01.30
Repair / Reassembly M43
01
Procedure: 1.
Turn pistons to ignition TDC.
2.
Thoroughly clean sealing and bearing surfaces of cylinder head and cylinder bushing and check for damage. Insert new sealing ring (Fig. 1/1) into cylinder bushing collar. Check and clean sealing surface at exhaust pipe (06.01.01.nn).
3.
Replace the following O rings: Top O ring at cylinder bushing collar (2), at cylinder head (3), at the push rod bushing (4), at the cooling water conduit, at the starting air inlet, at the control air inlet and at the charger air inlet connection.
en / 13.02.2009
IB024290
2/4
Cylinder Head
A5.05. 01.11.01.30
Repair / Reassembly M43
01
Note: Insert all O rings with Vaseline or green lubricating sopa into the grooves without twisting. Align conduits for cooling water and starting air in cooling water manifold housing vertically and check for completeness. 4.
Carefully place cylinder head with cylinder head lifting device and hoist onto cooling water manifold housing. Ensure horizontal position of cylinder head on supporting surface.
5.
Align cylinder head. Fit clamp for exhaust pipe and hook in chain links (06.01.01.nn). Grease screw with high temperature threading paste “Dag S-5080“ and tighten by hand (no seal).
Attention: Before using the hydraulic device ensure that the cylinder head rests firmly on the cylinder bushing. This is achieved by manually tightening the round nuts and pin crosswise. Nonobservance may cause damage to the hydraulic device.
6.
Tighten the six cylinder head screws simultaneously using the hydraulic tightening device.
en / 13.02.2009
IB024290
3/4
Cylinder Head
A5.05. 01.11.01.30
Repair / Reassembly M43
6.1
Store hydraulic traction elements (Fig. 2/ W1.1) onto round nuts and tighten. Ensure good accessibility of the slots (3).
6.2
Store hydraulic traction elements via high pressure hoses (W1.2) to each other. Connect element 1 to pump. Fit test manometer (W1.4) onto element 6. Secure the coupling that is not connected by means of plug (8).
6.3
Close valve on high pressure pump and extend all 6 cylinder head screws simultaneously and continuously using a hydraulic pressure of p = 2250 bar -25 bar The pressure at the hydraulic pump must correspond to the pressure at the test manometer.
Attention: The pressure must remain constant with the pump not activated, otherwise the tightening is wrong.
6.4
Tighten round nuts with pin firmly. Ensure smooth movement.
6.5
Check the firm contact of the round nut.
• Reduce pressure by 50 bar. • It should no longer be possible to loosen the round nuts with the pin. 6.6
Relieve hydraulic traction element (W1.1) and remove.
7.
Tighten clamp for exhaust pipe. The clamp is held in position by a locking screw from below (06.01.01.nn).
8.
Remove hexagon screws (W5) (01.06.01.nn).
9.
Fit removed connecting flanges of the media conduit with new seals. Ensure proper fitting of dowel pins.
10.
Fit removed manometer pipes and fill with cooling water. Vent cooling water return line from turbo charger.
11.
Insert push rods into cylinder head.
12.
Fit rocker arm bracket (01.02.01.nn).
13.
Fit injection pressure pipe (07.05.01.nn).
14.
Adjust valve clearance (01.01.01.nn) and fit pump chamber cover.
15.
Check all connections for tightness after starting the motor.
en / 13.02.2009
IB024290
4/4
01
Running Gear / Engine Timing
A5.05. 02.01.01.00
Inspection / Checking M43/VM43
3750
See also:
03.01.01.nn, 04.08.01.nn, 01.01.01.nn
Spare parts list:
B1.05.03.431112
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
Chief engineer / skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
02
---------------------------------------------------------------------------------------------------------------------------------Note: The temperature check for the bearings must be carried out with the engine at operating temperature after switching off the circulation system lubrication. The remaining tasks are to be carried out after allowing a period of ventilation.
Sequence of operations: 1.
Open indicator valve and engage turning gear.
2.
Open crank case cover approx. 10 min. after shutting down the engine.
3.
Check crankshaft bearings and big end bearings for even and normal temperatures.
4.
Visually check screws and nuts.
5.
Check extent of soiling of the engine room (silt deposits, corrosion, bearing metal particles, detached paint).
6.
Check cylinder liner surface on engine side. Carry out lubrication oil flow check and check oil delivery at bearing points.
7.
Remove camshaft cover. Check screws of camshaft components and the lower valve mechanism for proper tightness.
7.1
Turn engine and check bearing surfaces of cams and rollers for scoring, pitting or other damage.
7.2
Check lubricating oil flow for camshaft bearing and valve mechanism.
8.
Check wheel mechanism (04.08.01.nn).
9.
Check oil tray and crank case for left-behind tools, cloths etc. Check seals of all crank case and sealing lids and refit cover.
en / 28.10.2003
IB020107
1/1
Crank Web Deflection
A5.05. 02.02.01.00
Inspection / Measuring M43
02
See also: Spare parts list:
B1.05.02.432520, B1.05.03.431110
Time requirement:
2 Pers./ 1,00 h
Personnel qualification: Chief engineer / skilled engine hand Operating medium:
Heavy fuel and distillate fuel
---------------------------------------------------------------------------------------------------------------------------------Inspection: Measurements must be made in the following cases: If there may be a foundation deformation, e.g.: • after sea damage to the ship • when the foundation appears to have settled • damage to the bearings or crankshaft • before and after docking the ship.
Tools: Crankshaft measuring unit
W1
1.9425-300
Note: Crank web deflection is the change in distance beween a web pair during one rotation of the crankshaft (Fig. 1). Depending on the location of the engine, the rigidness of the foundation and the ship, different values are given in comparison with loaded and unloaded condition of the ship as well as warm or cold engine. Measurements should therefore be carried out when the engine is warm, with normal loading and even keel; not in dock! Changes that suddenly appear or appear after a longer period under otherwise uniform conditions point to a deformation or subsiding of the foundation. It is therefore suggested to collect the measurement sheets extra so that the chronological allocation of the values and changes are visible. In the event of unpermissible changes, the installation must be realigned and the respective main bearings inspected.
a)Initial position b)Negative deflection c)Positive deflection
en / 24.04.2006
IB020114
1/4
Crank Web Deflection
A5.05. 02.02.01.00
Inspection / Measuring M43
02
Procedure: 1.
Turn the crankshaft journal to the exhaust side so that the dial gauge is spread apart as far as possible between the crankshaft webs and the connecting rod just passes the dial gauge (Fig. 2/1. Measurement point).
2.
Set the scale value 20 on the dial gauge: 1st measurement point (initial position).
3.
Turn the crankshaft so that the journal turns in the direction of the exhaust side and the dial gauge moves towards the control side.
4.
Watch the dial gauge and read the values for measurement points 2 - 5. If a value is read before or after a measurement point which is larger than the value at the measurement point, this value must be entered.
1
=
1st Measurement point
(Initial position)
2
=
2nd Measurement point
(Journal - exhaust side)
3
=
3rd Measurement point
(Journal - TDC)
4
=
4th Measurement point
(Journal - control side)
5
=
5th Measurement point
(Journal - BDC control side)
en / 24.04.2006
IB020114
2/4
Crank Web Deflection
A5.05. 02.02.01.00
Inspection / Measuring M43
02
Note: The web deflection is primarily used to measure and evaluate the engine when aligning it in relation to its shaft system. A large degree of web deflection places a greater load on the crankshaft and the main bearings, i.e. the permissible web deflection depends on the load which the engine is subjected to. (Engines which are subject to higher load allow less deflection as engines which are subject to lower loads.) The values indicated here may not be exceeded if permissible web deflection tolerance for the respective system cannot be obtained from MaK. Only web deflection values measured on an engine at operating temperature may be used for evaluation. The values measured on a cold engine are not necessarily indicative of the condition of the engine.
Web deflection values in mm:
RM43 Cylinder 1 or last cylinder with additional load (flywheel/coupling)
+ 0,07 / - 0,16 mm
All cylinders without external load
en / 24.04.2006
+ 0,07 / - 0,12 mm
IB020114
3/4
Crank Web Deflection
A5.05. 02.02.01.00
Inspection / Measuring M43
02
en / 24.04.2006
IB020114
4/4
Bearing Shells and Bearing Bushes
A5.05. 02.03.03.01
Inspection / Evaluate M43/VM43
See also:
02.03.07.nn, 02.04.01.nn, 02.05.01.nn, 02.09.01.nn
Spare parts list:
B1.05.02.432601, B1.05.03.431110
Time requirement:
0 Pers./ 0,00 h
Personnel qualification:
Chief engineer / skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
02
------------------------------------------------------------------------------------------------------------------------------Note: Oil contamination, foreign objects, water and faulty tools cause 85 % of all bearing damage. Dirt is the enemy of all bearings! In order to avoid unnecessarily shortening bearing life, note the following:
• • • •
Oil temperature and pressure requirements, see A1.05 and A1.06 Oil brand recommendations (viscosity class), see A4.05.08.nn Information on oil care, see A4.05.08.nn Oil change / additives, see A4.05.08.nn
Heavy start-stop operation (mixed friction) can cause the bearings to wear more rapidly so that the bearings must be replaced sooner.
Attention: When replacing bearings in the crankcase, note that all bearing shells must generally be replaced in pairs (upper and lower bearing shell)!
Note: Corrosion resistant two-component bearings are used for normal loads. These bearings consist of a protective steel shell and a running layer.
en / 25.08.2003
IB020119
1/2
Bearing Shells and Bearing Bushes
A5.05. 02.03.03.01
Inspection / Evaluate M43/VM43
02
The corrosion-resistant flash on the bearing (ca. 3 µm) is worn through after a short operating period. The bearing need only be replaced after -
heavy scoring, a clearance limit has been exceeded or in accordance with the applicable evaluation criteria (02.03.07.nn).
Attention: If a replacement criterion is found during an inspection, all bearings must be checked.
en / 25.08.2003
IB020119
2/2
Bearing Shells
A5.05. 02.03.07.01
Inspection / Evaluate M43/VM43
See also:
02.03.03.nn, 02.05.01.nn, 02.05.05.nn
Spare parts list:
B1.05.03.431110
Time requirement:
0 Pers./ 0,00 h
02
Personnel qualification: Chief engineer / skilled engine hand Operating medium:
Heavy fuel and distillate fuel
------------------------------------------------------------------------------------------------------------------------------Note: The following evaluation catalog contains different wear stages caused by mechanical wear and overloading the bearing shells. Evaluation catalog: Criteria for reinstallation Fig. 1 -The wear pattern is even across the entire width of the bearing surface. Any streaks caused by foreign bodies in the engine oil do not tend to have a significant influence on the operating safety of a sliding bearing. This bearing shell can be reused. Fig. 2 -The wear pattern is even across the entire width of the bearing surface. This bearing shell can be reused. Fig. 3 -The wear pattern is even across the entire width of the bearing surface. The scoring along the bearing surface is caused by fine solid particles in the engine oil. If these scores cannot be felt or the depth of these scores cannot be measured, the bearing shell can be reused. If the number, depth and length of such scoring has an adverse affect on the formation of the oil film, both bearing pairs must be replaced.
Achtung: When replacing bearings in the crankcase, note that all bearing shells must generally be replaced in pairs (upper and lower bearing shell)!
en / 05.06.2003
IB020121
1/4
Bearing Shells
A5.05. 02.03.07.01
Inspection / Evaluate M43/VM43
02
Criteria for replacement Fig. 4 -The wear pattern includes severe scoring and the aluminum alloy sliding layer is fretted. This bearing shell can not be used again, both bearing shells must be replaced. Find and eliminate the cause for the increased scoring. Fig. 5 -The wear pattern includes a large area of damage with varying degrees of fretting. This bearing shell can not be used again, both bearing shells must be replaced. Find and correct the cause of this damage. Check all other bearing shells. Fig. 6 -Bearing metal is missing in the loaded area of this bearing as a result of overloading. There may also be loose pieces of bearing metal in the affected area. This bearing shell can not be used again, both bearing shells must be replaced. The cause for the flaking must be determined and corrected. Check all other bearing shells.
en / 05.06.2003
IB020121
2/4
Bearing Shells
A5.05. 02.03.07.01
Inspection / Evaluate M43/VM43
02
en / 05.06.2003
IB020121
3/4
Bearing Shells
A5.05. 02.03.07.01
Inspection / Evaluate M43/VM43
02
en / 05.06.2003
IB020121
4/4
Big End Bearings
A5.05. 02.04.01.30
Inspection / Disassembly M43
30000, 15000
See also:
02.03.03.nn, 02.03.07.nn, 02.06.01.nn
Spare parts list:
B1.05.02.432601
Time requirement:
2 Pers./ 0,50 h
Personnel qualification:
Chief engineer / skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
02
---------------------------------------------------------------------------------------------------------------------------------Inspection: one big end bearing every exchange all big end bearings every
15,000 h 30,000 h
Tools: Hydraulic set consisting of High pressure pump High pressure line High pressure line Hydraulic clamping elements Pin
W1 W2 W3 W4 W5
433420 A 433420 E 1.9213 N
Big end bearing installation and disassembly set
W6
439228 A
Auxiliary materials: Molykote Paste “G-Rapid Plus“ * * or equivalent product
Attention: High pressure lines may not be bent below minimum bending radius r = 250 mm! The high pressure pump may only be operated with hydraulic oil. Protect hydraulic equipment from corrosion during storage.
~
Attention! Do not place any body parts under equipment which is under pressure! Ensure that the engine cannot be started.
en / 03.05.2004
IB024444
1/6
Big End Bearings
A5.05. 02.04.01.30
Inspection / Disassembly M43
30000, 15000
02
Procedure: 1.
Remove piston (02.06.01.nn).
2.
Turn the engine so that the connecting rod is horizontal. Both round nuts (2) must be accessible.
3.
Loosen the round nuts (2) with the hydraulic rig.
3.1
Place and tighten the hydraulic clamping elements (W4) over the round nuts (2). Ensure that the slits are easily accessible. Loosen hydraulic clamping elements by 1 turn.
3.2
Connect the hydraulic clamping elements (W4) to the high pressure pump (W1) by means of the high pressure lines (W2, W3).
4.
Close the valve (6) on the high pressure pump (W1) and apply force to both connecting rod bolts with a pressure of p = 2250 bar
5.
Loosen the round nuts (2) with a pin (W5). Turn the round nuts back 10 holes.
en / 03.05.2004
IB024444
2/6
Big End Bearings
A5.05. 02.04.01.30
Inspection / Disassembly M43
30000, 15000
02
Note: If the round nuts cannot be removed, the pressure on the nuts can be increased by p = 50 bar more. If the pressure is increased further, the connecting rod bolt threading may stretch, which can cause the round nuts to lock into place. 6.
Open valve of the high-pressure pump (W1), hydraulic jacks are relieved of tension.
7.
Wait until no pressure is left, dismount hydraulic devices (W4).
8.
Turn connecting rod (17) horizontally with the connecting rod shank division to the exhaust side.
9.
Fit mounting and dismounting device (W6) for big end bearing.
9.1
Mount guide rail holder (10) on both sides of the cylinder crankcase. 11
10
14
18
15 9.2
Suspend guide rail (11).
en / 03.05.2004
IB024444
3/6
Big End Bearings
A5.05. 02.04.01.30
Inspection / Disassembly M43
30000, 15000
9.3
02
Tighten hexagon nuts (12). 10
9.4
12
11
Mount guide rail extension (13) with carriage (14) on camshaft side. 13
18 3
15
19
en / 03.05.2004
IB024444
4/6
Big End Bearings
A5.05. 02.04.01.30
Inspection / Disassembly M43
30000, 15000
02
10.
Screw suspension (18) at big end bearing cap.
11.
Connect suspension (18) with carriage (14).
12.
Unscrew round nuts (2).
13.
Drive big end bearing cap (15) to the camshaft side out of the crankcase. Remove bearing shell (19). 13
19
15
14.
Fix big end bearing cap (15) at the crane and deposit on suitable support.
15.
Disassemble big-end bolts (3) and washers (4). Secure connecting rod (17) additionally with screw (20) at connecting rod holder.
en / 03.05.2004
IB024444
5/6
Big End Bearings
A5.05. 02.04.01.30
Inspection / Disassembly M43
30000, 15000
16.
Turn connecting rod (17) downward by 180°° so that the connecting rod shank division shows to the camshaft side.
17.
Mount suspension (16) for connecting rod (17) and connect with carriage.
18.
Dismount connecting rod holder at the counterweight (02.06.01.nn).
19.
Drive connecting rod (17) to the camshaft side out of the crankcase. Remove bearing shell (20). 16
20
17
20.
Sling suspension (16) with suspended connecting rod (17) at the crane. Dismount connection to the carriage (14).
21.
Deposit connecting rod (17) on suitable support.
22.
Evaluate the condition of the big end bearing shells (02.03.03.nn and 02.03.07.nn).
Note: If the bearings are scored, the neighboring bearings must also be checked.
en / 03.05.2004
IB024444
6/6
02
Big End Bearings
A5.05. 02.04.02.30
Inspection / Reassembly M43
See also:
02.04.01.nn, 02.03.03.nn, 02.03.07.nn
Spare parts list:
B1.05.02.432601
Time requirement:
2 Pers./ 0,50 h
Personnel qualification:
Chief engineer / skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
02
---------------------------------------------------------------------------------------------------------------------------------Tools: Tools W1 - W6 see 02.04.01.nn
Note: Bearing caps, bearing shells, connecting rod eyes and connecting rods are labeled according to the cylinder to which they belong and may not be switched around. New parts must be labeled accordingly.
Procedure: 1.
Bearing shell installation
1.1
Clean and oil crank journals.
1.2
Oil the inside and outside of the bearing shells.
Attention: The bearing shells are equipped with a positioning nose (Fig. 1/X) to allow them to be positioned properly in the connecting rod and big end bearing cap. The bearing shells must be installed with the positioning nose to the control side!
en / 03.05.2004
IB024448
1/8
Big End Bearings
A5.05. 02.04.02.30
Inspection / Reassembly M43
02
1.3
Mount suspension (16) at dismounted connecting rod.
1.4
Fasten suspension (16) with suspended connecting rod (17) at the crane and lift. Mount connection to the carriage (14). 16
20
17
1.5
Remove sling.
1.6
Push connecting rod (17) towards the crank pin up to approx. 20 mm.
1.7
Put upper bearing shell (without holes) on the crank pin and turn below the connecting rod by 180°.
1.8
Press connecting rod (17) carefully against bearing shell (20). The fixing lug of the bearing shell must be exactly positioned in the notch of the connecting rod.
en / 03.05.2004
IB024448
2/8
Big End Bearings
A5.05. 02.04.02.30
Inspection / Reassembly M43
02
1.9
Mount connecting rod holder at counterweight n (02.06.01.nn). Secure connecting additionally with screw (20) at connecting rod holder.
1.10
Dismount suspension (16).
1.11
Turn connecting rod (17) downward by 180°° so that the connecting rod shank division shows to the exhaust side.
1.12
Mount suspension (18) at big end bearing cap (15). 13
18 3
15
19
en / 03.05.2004
IB024448
3/8
Big End Bearings
A5.05. 02.04.02.30
Inspection / Reassembly M43
1.13
Fasten big end bearing cap (15) at crane and connect suspension (18) with carriage (14) at guide rail extension (13). 13
19
15
1.14
Remove sling.
1.15
Push big end bearing cap (15) towards the crank pin up to approx. 160 mm.
Attention: Pay attention to the appropriate bores (50 / connecting rod) and clamping pin (51 / big end bearing cap)!
en / 03.05.2004
IB024448
4/8
02
Big End Bearings
A5.05. 02.04.02.30
Inspection / Reassembly M43
1.16
Push big end bearing cap (15) forward towards the crank pin up to approx. 100 mm and insert, align and press lower bearing shell (19) into the big end bearing bore.
1.17
Push big end bearing cap (15) carefully against bearing shell (19) and bottom end of connecting rod. The lug of the bearing shell must be exactly positioned in the notch of the big end bearing cap (15). 10
12
11
Attention : Pay attention that the bearing shell halves on exhaust and camshaft side are axially aligned. Displacement of the bearing shell halves to each other in axial direction is not admissible.
en / 03.05.2004
IB024448
5/8
02
Big End Bearings
A5.05. 02.04.02.30
Inspection / Reassembly M43
02
1.18
Insert big-end bolts (3) with washer (4). Assemble washer (4) with chamfer pointing towards bottom end of connecting rod.
1.19
Install round nuts (5) and tighten by hand.
1.20
Remove installation / disassembly unit (W6).
1.21
Check bearing shell pairs for axial misalignment on the exhaust side. Align shells if necessary. 11
10
14
18
15
en / 03.05.2004
IB024448
6/8
Big End Bearings
A5.05. 02.04.02.30
Inspection / Reassembly M43
02
2.
Tighten the round nuts (5) with the hydraulic rig.
2.1
Turn the connecting rod with the connecting rod shank joint by about 15-30° downwards, see indicated position (Fig. 11). Both round nuts (5) must be easily accessible.
2.2
Place the hydraulic clamping element (W4) over the round nut (5) at camshaft side and screw onto big-end bearing bolt (6) so as to be finger tight. Make sure that the slits (8) are easily accessible.
2.3
Connect the hydraulic clamping element (W4) to the high-pressure pump (W1) by means of the high-pressure line (W2).
2.4
Close the valve of the high-pressure pump (W1) and extend the big-end bearing bolt at camshaft side steplessly, hydraulic pressure: p = 85 bar
2.5
Firmly tighten the round nut (5) at camshaft side with a pin (W5).
2.6
Open the valve of the high-pressure pump (W1), the clamping element is depressurized.
2.7
Wait until the pressure reduces completely.
2.8
Place the second clamping element (W4) over the round nut (5) at exhaust gas side and screw onto big-end bearing bolt (6) so as to be finger tight. Make sure that the slits (8) are easily accessible.
2.9
Connect the second hydraulic clamping element (W4) to the high-pressure pump (W1) by means of the high-pressure lines (W3).
2.10
Close the valve of the high-pressure pump (W1) and extend both big-end bearing bolts steplessly and simultaneously, hydraulic pressure: p = 2250 bar + 25 bar
Attention: The pressure must remain constant when the hydraulic pump is not actuated, otherwise they will be tightened incorrectly!
en / 03.05.2004
IB024448
7/8
Big End Bearings
A5.05. 02.04.02.30
Inspection / Reassembly M43
2.11
Visual check of angle of rotation 2.12
02
Firmly tighten the round nuts (5) with a pin (W5). While doing so the nuts must turn smoothly. 180°° ± 22°°
Check to ensure that the round nut is seated properly
• Reduce pressure by 50 bar • The round nuts must be tight enough so that they cannot be loosened with the pin any more.
2.13
Open the valve of the high-pressure pump (W1), the clamping elements are depressurized.
2.14
Wait until the pressure reduces completely.
3.
Mount the piston (02.10.01.nn).
en / 03.05.2004
IB024448
8/8
Hydraulic Jack
A5.05. 02.04.51.00
Maintenance / Replace M43/VM43
See also:
02.04.01.nn, 02.05.01.nn, 02.05.05.nn
Spare parts list:
B1.05.02.432601, B1.05.03.431110
Time requirement:
1 Pers./ 0,20 h
02
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: Exchange of all seals
Tools: Fork wrench Torque wrench 20 - 200 Nm
W1 * W2 *
436500 C 1.9454-202
* = no illustration
Auxiliary means: Molykote paste "G-Rapid Plus" * * or equivalent
Sequence of operations: 1.
Disassembly
1.1
Clamp hydraulic jack.
1.2
Loosen cover (1) using fork wrench (W1) and disassemble.
1.3
Remove cup spring pack (2).
1.4
Push piston (3) out.
1.5
Remove rubber rings (4 and 5) as well as joint rings (6 and 7).
2.
Assembly
2.1
Clean all parts and slightly coat them with Molykote paste "G-Rapid Plus".
en / 31.01.2008
IB024004
1/2
Hydraulic Jack
A5.05. 02.04.51.00
Maintenance / Replace M43/VM43
2.2
02
Insert new seals in consideration of the order: Order: At first rubber rings (4 and 5) and then joint rings (6 and 7).
Attention: Do not press joint rings in too much.
2.3
Press piston (3) into the cylinder.
Attention: Do not tilt the piston (3).
2.4
Mount cup spring pack (2).
2.5
Screw cover (1) on using fork wrench (W1) and tighten.
Note: Please note that the correct post-assembly position of the cup springs has to be strictly observed. 2.6
When the hose coupling has been disassembled mount threaded adapter (8) and high-pressure coupling nipple (9) and tighten with a torque wrench of M = 50 Nm.
en / 31.01.2008
IB024004
2/2
Main Bearings
A5.05. 02.05.01.30
Inspection / Disassembly M43
30000, 15000
02
See also:
02.03.03.nn, 02.03.07.nn
Spare parts list:
B1.05.03.431110
Time requirement:
2 Pers./ 2,00 h
Personnel qualification:
Chief engineer / skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
------------------------------------------------------------------------------------------------------------------------------Inspection: a) of two crankshaft bearings
every
Number of cylinders
bearing No.
6 7 8 9
5 and 7 5 and 7 6 and 8 7 and 9
b) exchange all crankshaft bearings
15,000 h
every
30,000 h
Tools: Hydraulic set consisting of High pressure pump High pressure line (3 x 1m) Pin Hydraulic tightening element (lateral uniform strength bolts) Hydraulic tightening element (crankshaft bearing bolts) Threaded sleeve for crankshaft bearing High pressure line
W1 W2 W3
433420 A
W4
1.9213 F
W5
1.9213 M 1.9203-108 433420 E
W6*
Installation / disassembly unit for crankshaft bearings, consisting of Rig W10 439214 A Carrier W11 439225 B * no picture
Attention: High pressure lines may not be bent below minimum bending radius r = 250 mm! The high pressure pump may only be operated with hydraulic oil. Protect hydraulic equipment from corrosion during storage.
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IB024452
1/9
Main Bearings
A5.05. 02.05.01.30
Inspection / Disassembly M43
30000, 15000
02
~
Attention! Do not place any body parts under equipment which is under pressure! Ensure that the engine cannot be started.
Attention: The neighboring bearings must be securely mounted during installation and for gap measurements.
Note: The bearing covers and bearing shells are numbered consecutively on the control side from the coupling forward according to their respective cylinder and may not be exchanged. New parts must be labeled accordingly. The crankshaft bearings must be removed, inspected and measured within the indicated intervals when: -
foundation deformations or web deflection changes occur after sea damage.
Procedure: 1.
Remove crankshaft bearings.
1.1
Open the corresponding crankcase cover on the control and exhaust side.
1.2
Turn the crankshaft to the position which removal can be completed most easily.
1.2.1
Turn one of the connecting rods next to the crankshaft bearing to be removed to 90° after crankshaft TDC or 90° before crankshaft TDC.
1.3
Loosen the round nuts (23) on the lateral uniform strength bolts with the hydraulic rig.
1.3.1
Remove the protective caps.
1.3.2
Place hydraulic clamping element (W4) over the round nut (23) and tighten. Ensure that the slits are easily accessible. Loosen hydraulic clamping element by 1 turn.
1.3.3
Connect the hydraulic clamping element (W4) to the high pressure pump (W1) by means of the high pressure line (W2). Secure the coupling that is not connected by means of plug.
1.3.4
Close the valve on the high pressure pump (W1) and apply force to uniform strength bolt with a pressure of p = 2250 bar
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IB024452
2/9
Main Bearings
A5.05. 02.05.01.30
Inspection / Disassembly M43
1.3.5
30000, 15000
02
Loosen the round nut with a pin. Turn the round nut back 10 holes.
Note: If the round nut cannot be loosened with the pin, the pressure on the uniform strength bolt can be increased to p = 50 bar more. If the pressure is increased further, the threading may stretch, which can cause the round nuts to lock into place! 1.3.6
Open the valve on the high pressure pump, the hydraulic clamping element is depressurized.
1.3.7
Wait until the pressure drops completely. Remove the hydraulic clamping element.
1.3.8
Repeat sequence of operations 1.3.2 - 1.3.7 on the opposite side.
1.3.9
Loosen the uniform strength bolts and screw out completely.
1.3.10
Loosen the round nuts on the lateral uniform strength bolts on the neighboring bearing(s) with the hydraulic rig (do not remove). ( if necesarry )
1.4
Insert rig.
1.4.1
Lift the rig (W10) into the crankcase collapsed and place in the guide rails of the oil pan. Insert carrier arm.
W10
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IB024452
3/9
Main Bearings
A5.05. 02.05.01.30
Inspection / Disassembly M43
30000, 15000
1.4.2
Connect the hydraulic cylinder of the rig (W10) to the high pressure pump (W1) by means of the high pressure line (W2).
14
W10
1.4.3
Bring the carrying arm into position and place the chute (10) between the crankcase and carrying arm.
W5
10
23
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IB024452
4/9
02
Main Bearings
A5.05. 02.05.01.30
Inspection / Disassembly M43
30000, 15000
02
1.4.4
Loosen the round nuts on the crankshaft bearing bolts with the hydraulic rig.
1.4.5
Place the hydraulic clamping element (W5) level on the plate above the chute (10). Remove the chute.
1.4.6
Raise the carrying arm. Place the hydraulic clamping element on the round nut (12) and tighten. Make sure that the slits (13) are easily accessible. Loosen hydraulic clamping elements by 1 turn.
12 13 W5
W10
1.4.7
Repeat the installation procedure on the opposite side.
1.4.8
Connect the hydraulic clamping elements (W5) to the high pressure pump (W1) by means of the high pressure lines (W2, W6).
1.4.9
Close the valve on the high pressure pump and subject both crankshaft bearing bolts to a pressure of p = 2250 bar
1.4.10
Loosen the round nuts (12) with a pin. Turn back the round nuts at least 8 holes.
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IB024452
5/9
Main Bearings
A5.05. 02.05.01.30
Inspection / Disassembly M43
30000, 15000
02
Note: If the round nuts cannot be loosened with the pin, the pressure on the uniform strength bolts can be increased to p = 50 bar more. If the pressure is increased further, the threading may stretch, which can cause the round nuts to lock into place! 1.5
Open the valve on the high pressure pump, the hydraulic clamping elements (W5) are depressurized.
1.5.1
Wait until the pressure reduces completely. Remove the hydraulic clamping elements. The hydraulic clamping elements (W5) are removed in the reverse order as assembly.
1.5.2
Remove the clamping element support disk (14) from the carrying arm. Place the spacer block (15) for the crankshaft bearing cover on the carrying arm.
15
W10
1.6
Measure gap, see procedure 2.
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IB024452
6/9
Main Bearings
A5.05. 02.05.01.30
Inspection / Disassembly M43
1.7
30000, 15000 Run the carrying arm of the rig (W10) to the crankshaft bearing cover. Bolt the bearing cover to the plate. Remove the round nuts.
W10
W2 1.8
Lower the carrying arm carefully to the lower stop with the main bearing cover and lower bearing shell.
1.9
Remove the lower bearing shell.
1.10
Place the carrier (W11) into the oil bore in the crankshaft until it stops.
1.11
Turn the upper bearing shell and remove.
Attention: Do not turn until the rig is lowered completely to the lower stop!
W11
8
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IB024452
7/9
02
Main Bearings
A5.05. 02.05.01.30
Inspection / Disassembly M43
30000, 15000
1.12
Inspect and evaluate the bearing shells, see 02.03.03.nn and 02.03.07.nn.
1.13
Check the wear and wall thickness with a micrometer in the main wear zone at the indicated measurement points (X).
02
Wear = Nominal size - current size 1.14
The bearing shells must be changed when the wear reaches > 0.05 mm. Nominal size = 8.820 - 0.025 mm
Attention: If measurements indicate that the bearing shells need to be replaced, the neighboring bearings must also be checked.
2.
Measure the gap.
2.1
Remove the uniform strength bolts for the respective main bearing on the exhaust and control side. (see procedure 1.4)
K
K
A
10
2.1.1
S
12
Loosen both round nuts (12) hydraulically as described in 1.5 and 1.6. Lower the rig.
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IB024452
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Main Bearings
A5.05. 02.05.01.30
Inspection / Disassembly M43
30000, 15000
2.1.2
Raise the bearing cap with the rig. Tighten the round nuts until the bearing shells barely touch.
2.1.3
Measure the gap “K“ between the crankcase and the bearing cover on the exhaust and control side and add both values. K = KA + KS
en / 04.05.2004
Gap “K“ mm
Operating limit mm
1.4 - 1.65
1.2
IB024452
9/9
02
Main Bearings
A5.05. 02.05.02.30
Maintenance / Reassembly M43
02
See also:
02.05.01.nn
Spare parts list:
B1.05.03.431110
Time requirement:
2 Pers./ 1,00 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
---------------------------------------------------------------------------------------------------------------------------------Tools: Tools W1 - W11 see maintenance sheet 02.05.01.nn Turning unit Torque wrench 20 - 200 Nm Reversible ratchet 1/2"
W12 W13 * W14 *
439225-001 1.9454-202 1.9459-033
* no picture
Auxiliary materials: Molykote Paste “G-Rapid Plus“ ** ** or equivalent product
Attention: High pressure lines may not be bent below minimum bending radius r = 250 mm! The high pressure pump may only be operated with hydraulic oil. Protect hydraulic equipment from corrosion during storage.
~
Attention! Do not place any body parts under equipment which is under pressure! Ensure that the engine cannot be started.
Note: The bearing covers and bearing shares are numbered consecutively on the control side from the coupling forward according to their respective cylinder and may not be exchanged. New parts must be labeled accordingly. Damaged main bearing bolts and round nuts must be replaced in sets.
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IB024459
1/6
Main Bearings
A5.05. 02.05.02.30
Maintenance / Reassembly M43
02
Procedure: 1.
Install bearing shells.
Note: The upper bearing shell is equipped with a lubrication groove and oil bore.
1.1
Oil the running surface of the upper bearing shell thoroughly, dry the back of the bearing and turn the bearing shell into the bearing as far as possible. Place the carrier (W11) into the oil bore until it stops.
Attention: Bearing shell designation on the opposite (control) side.
1.2
Insert turning mechanism (W12) into the bearing cover. Make sure that the unit seats properly at the side. Raise the rig (W10) carefully until it stops at the bearing shell. Lock the turning mechanism in place by hand with the round nuts (12). Lower the mechanism (W10) so that the bearing cap can be turned as needed.
12
W10
2
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IB024459
2/6
Main Bearings
A5.05. 02.05.02.30
Maintenance / Reassembly M43
1.3
Turn the upper bearing shell into place. Make sure that the bearing shell is centered. The positioning nose must slide into the guide groove in the bearing seat.
1.4
Raise the rig (W10), remove the round nuts (12). Lower the rig (W10) again and remove the carrier (W11) and the turning unit (W12).
1.5
Oil the running surface of the lower bearing shell, dry the back of the bearing and insert in main bearing cover. Raise the rig again.
Attention: The positioning nose on the lower shell is on the control side.
2.
Pre-install main bearing bolts.
2.1
Raise rig (W10) with the main bearing cover to the upper stop. Be careful not to damage the main bearing bolts.
2.2
Screw round nuts onto main bearing bolts evenly and tighten by hand with pin.
2.3
Remove bearing cap mounts on plate.
Note: Measure the gap “K“ after installing the bearing shells (see 02.05.01.nn). 2.4
Lower the rig (W10).
3.
Remove the lateral uniform strength bolts.
3.1
Apply Molykote to the uniform strength bolts, screw in the bolts and tighten to M = 200 Nm
3.2
Screw the round nuts (23) onto the uniform strength bolts and tighten by hand.
3.3
Place the hydraulic clamping elements (W4) over the round nuts (23) on the operating side and tighten by hand. Make sure that the slits (13) are easily accessible.
3.4
Connect the hydraulic clamping elements on the operating side to the high pressure pump (W1) by means of the high pressure line (W2). Secure the coupling that is not connected by means of plug.
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IB024459
3/6
02
Main Bearings
A5.05. 02.05.02.30
Maintenance / Reassembly M43
3.5
Close the valve on the high pressure pump and extend the uniform strength bolts with a pressure of p = 380 bar
Attention: The pressure must remain constant when the hydraulic pump is not being actuated to prevent the bolts from being tightened incorrectly!
3.6
Tighten the round nut (23) with a pin.
3.7
Open the valve on the high pressure pump (W1), the clamping elements (W4) are depressurized.
3.8
Remove hydraulic clamping elements (W4).
3.9
Connect the hydraulic clamping elements (W4) on the exhaust side with the high pressure pump (W1) by means of the high pressure line (W2). Secure the coupling that is not connected by means of plug.
3.10
Close the valve on the high pressure pump, extend the uniform strength bolts with a pressure of p = 2250 bar
Attention: The pressure must remain constant when the hydraulic pump is not being actuated to prevent the bolts from being tightened incorrectly!
3.11
Tighten the round nut (23) with a pin.
3.12
Check to ensure that the round nut is seated properly. • Reduce pressure by 50 bar. • The round nut must be tight enough that it cannot be loosened with a pin.
3.13
Open the valve on the high pressure pump (W1), the clamping elements (W4) are depressurized.
3.14
Wait until the pressure reduces completely. Remove the clamping elements (W4).
3.15
Repeat installation steps 3.8 to 3.14 on the operating side.
3.16
Tighten the round nuts (23) on the lateral uniform strength bolts on the neighboring bearing(s) with the hydraulic rig, see steps 3.2 to 3.13.
3.17
Screw the protective caps onto the uniform strength bolts.
4.
Tightening the main bearing bolts.
4.1
Run the carrying arm into position and place the chute (10) between the crankcase and carrying arm.
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IB024459
4/6
02
Main Bearings
A5.05. 02.05.02.30
Maintenance / Reassembly M43
02
13 W5 10
23
4
4.2
Place the hydraulic clamping element (W5) level on the plate above the chute. Remove the chute.
4.3
Raise the carrying arm. Place the hydraulic clamping element on the round nut (12) and tighten. Make sure that the slits (13) are easily accessible.
12
W5
13
W10
5
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IB024459
5/6
Main Bearings
A5.05. 02.05.02.30
Maintenance / Reassembly M43
02
4.4
Repeat the installation procedure on the opposite side.
4.5
Connect the hydraulic clamping elements (W5) to the high pressure pump (W1) by means of the high pressure lines (W2, W6).
4.6
Close the valve on the high pressure pump and extend both main bearing bolts with a pressure of p = 2250 bar
Attention: The pressure must remain constant when the hydraulic pump is not being actuated to prevent the bolts from being tightened incorrectly!
4.7
Tighten the round nuts (12) with a pin. Check to ensure good action (no stiffness).
4.8
Check to ensure that the round nut is seated properly.
• Reduce pressure by 50 bar. • The round nuts must be tight enough that they cannot be loosened with the pin. 4.9
Open the valve on the high pressure pump (W1), the clamping elements are depressurized.
4.10
Wait until the pressure reduces completely. Remove the hydraulic clamping elements (W5). The hydraulic clamping elements (W5) are removed in the reverse order as assembly.
4.11
Lower the rig until it reaches the lower stop.
4.12
Remove the rig (W10). The rig is dismantled in the reverse order as installation (see 02.05.01.nn).
4.13
Check engine oil flow.
4.14
Close the crankcase covers on the control and exhaust side and the covers under the gear drive.
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IB024459
6/6
Main Thrust Bearings
A5.05. 02.05.05.30
Inspection / Disassembly M43
30000
See also:
02.03.03.nn, 02.03.07.nn
Spare parts list:
B1.05.03.431110
Time requirement:
2 Pers./ 1,00 h
Personnel qualification:
Chief engineer / skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
02
---------------------------------------------------------------------------------------------------------------------------------Inspection: Main thrust bearings
every
30,000 h
Tools: Hydraulic set consisting of High pressure pump High pressure line Pin Hydraulic tightening element (lateral uniform strength bolts) Hydraulic tightening element (crankshaft bearing bolts) High pressure line
W1 W2 W3
433420 A
W4
1.9213 F
W5
1.9213 M
W6*
433420 E
Installation / disassembly unit for crankshaft bearings, consisting of Rig W10 439214 A Carrier W11 439225 B Lashing eye M20 W12 * no picture
Attention: High pressure lines may not be bent below minimum bending radius r = 250 mm! The high pressure pump may only be operated with hydraulic oil. Protect hydraulic equipment from corrosion during storage.
~
Attention! Do not place any body parts under equipment which is under pressure! Ensure that the engine cannot be started.
Note: The main thrust bearing consists of the first main bearing (coupling side) and four thrust washer segments which limit the axial clearance of the crankshaft. Both lower thrust washer segments are fixed in the main bearing cover with dowel pins and the two upper thrust washer segments are slid into grooves in the crankcase housing. The bearing covers and bearing shells of the main bearings are numbered on the control side and may not be exchanged. New parts must be labeled accordingly.
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IB024463
1/9
Main Thrust Bearings
A5.05. 02.05.05.30
Inspection / Disassembly M43
30000 The 1st main bearing must be removed, inspected and measured before the lapse of the indicated intervals when: -
foundation deformations or web deflection changes occur after sea damage.
Procedure: 1.
Measure axial clearance “s“.
1.1
Open the cover under the gear drive and the first coupling side crankcase cover on the control and exhaust sides.
1.2
Place a dial gauge on the flywheel with a magnetic retainer and place against crankcase.
1.3
Slide the crankshaft with a suitable hydraulic unit until it rests firmly against the thrust washer segments. Set the dial gauge to “zero“ and slide the crankshaft in the opposite direction, read the axial clearance “s“ on the dial gauge.
1.4
Axial clearance “s“: s = s1 + s2 New clearance mm
Wear limit mm
0.4 - 0-7
1.0
If the tolerance limit is exceeded, replace the thrust washer segments and bearing shells in pairs, see main thrust bearing removal procedure.
Attention: Label all thrust washer segments before removal for inspection and measurement to prevent them from being exchanged. Thrust washer segments must be reinstalled immediately after measurement and inspection!
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IB024463
2/9
02
Main Thrust Bearings
A5.05. 02.05.05.30
Inspection / Disassembly M43
30000
02
2.
Removing main thrust bearing.
2.1
Turn the piston of the 1st cylinder 90° after crankshaft TDC or 90° before crankshaft TDC.
2.2
Loosen the round nuts (23) on the lateral uniform strength bolts with the hydraulic rig.
2.2.1
Remove the protective caps.
2.2.2
Place hydraulic clamping element (W4) over the round nut (23) and tighten. Ensure that the slits are easily accessible. Loosen hydraulic clamping element by 1 turn.
2.2.3
Connect the hydraulic clamping element (W4) to the high pressure pump (W1) by means of the high pressure line (W2). Secure the coupling that is not connected by means of plug.
2.2.4
Close the valve on the high pressure pump (W1) and apply force to uniform strength bolt with a pressure of p = 2250 bar
2.2.5
Loosen the round nut with a pin. Turn the round nut back 10 holes.
Note: If the round nut cannot be loosened with the pin, the pressure on the uniform strength bolt can be increased to p = 50 bar more. If the pressure is increased further, the threading may stretch, which can cause the round nut to lock into place! 2.2.6
Open the valve on the high pressure pump, the hydraulic clamping element is depressurized.
2.2.7
Wait until the pressure reduces completely. Remove the hydraulic clamping element.
2.2.8
Repeat sequence of operations 2.2.2 - 2.2.7 on the opposite side.
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IB024463
3/9
Main Thrust Bearings
A5.05. 02.05.05.30
Inspection / Disassembly M43
30000
02
2.3
Insert rig.
2.3.1
Lift the rig (W10) into the crankcase collapsed and place in the guide rails of the oil pan. Insert carrier arm.
W10
3
2.3.2
Connect the hydraulic cylinder in the rig (W10) with the high pressure pump (W1) by means of the high pressure line (W2).
14
W10
4
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IB024463
4/9
Main Thrust Bearings
A5.05. 02.05.05.30
Inspection / Disassembly M43
2.3.3
30000 Bring the carrying arm into position and place the chute (10) between the crankcase and carrying arm.
W5 10
23
5
2.3.4
Loosen the round nuts on the crankshaft bearing bolts with the hydraulic rig.
2.3.5
Place the hydraulic clamping element (W5) level on the plate above the chute (10). Remove the chute.
2.3.6
Raise the carrying arm. Place the hydraulic clamping element on the round nut (12) and tighten. Make sure that the slits (13) are easily accessible.
12 13 W5
W10
6
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IB024463
5/9
02
Main Thrust Bearings
A5.05. 02.05.05.30
Inspection / Disassembly M43
30000
2.3.7
Connect the hydraulic clamping elements (W5) with the high pressure pump (W1) by means of the high pressure lines (W2, W6).
2.3.8
Close the valve on the high pressure pump and subject both crankshaft bearing bolts to a pressure of p = 2250 bar
2.3.9
Loosen the round nuts (12) with a pin. Turn the round nuts back 10 holes.
Note: If the round nuts cannot be loosened with the pin, the pressure on the uniform strength bolts can be increased to p = 50 bar more. If the pressure is increased further, the threading may stretch, which can cause the round nuts to lock into place! 2.4
Open the valve on the high pressure pump, the hydraulic clamping elements (W5) are depressurized.
2.5
Wait until the pressure drops completely. Remove the hydraulic clamping elements. The hydraulic clamping elements (W5) are removed in the reverse order as assembly.
2.6
Remove the clamping element support disk (14) from the carrying arm. Place the spacer block (15) for the crankshaft bearing cover on the carrying arm.
15
W10
7
2.7
Measure the gap, see step 3.
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IB024463
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02
Main Thrust Bearings
A5.05. 02.05.05.30
Inspection / Disassembly M43
2.8
30000 Run the carrying arm of the rig (W10) to the crankshaft bearing cover. Bolt the bearing cover to the plate. Remove the round nuts.
W10
W2 8
2.9
Lower the carrying arm with main bearing cover and bottom bearing shell carefully as far as possible.
2.10
Screw the lashing eyes (W12) into the bearing cover.
W12
9
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IB024463
7/9
02
Main Thrust Bearings
A5.05. 02.05.05.30
Inspection / Disassembly M43
30000
2.11
Secure the bearing cover to the hoists on both sides (exhaust gas side and camshaft side). Tension the slings evenly.
2.12
Separate the carrying arm of the device (W10) from the bearing cover.
2.13
Shift the device (W10) towards cyl. 1, so that there is sufficient clearance below the bearing cover.
2.14
Evenly lower the bearing cover by another 100 mm on both sides by means of the hoists.
2.15
Remove both lower thrust bearing segments (1) and replace them if there is a high degree of axial clearance, see step 1. Only remove the upper thrust washer segments if they need to be replaced.
2.16
Remove the lower bearing shell.
2.17
Place the carrier (W11) into the oil bore in the crankshaft until it stops.
2.18
Turn the upper bearing shell and remove.
Attention: Do not turn until the rig is lowered completely to the lower stop!
2.19
Inspect and evaluate the bearing shells, see 02.03..03.nn and 02.03..07.nn.
2.20
Check the wear and wall thickness in the main wear zone with a micrometer at the indicated measurement points (X). Wear = Nominal size - current size
2.21
The bearing shells must be changed when the wear reaches > 0.05 mm. Nominal size = 8.820 - 0.025 mm
Attention: If measurements indicate that the bearing shells need to be replaced, the neighboring bearings must also be checked.
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IB024463
8/9
02
Main Thrust Bearings
A5.05. 02.05.05.30
Inspection / Disassembly M43
30000
02
3.
Measure the gap.
3.1
Loosen both round nuts (12) hydraulically. Lower the rig (see step 2.3).
3.2
Raise the bearing cap with the rig. Tighten the round nuts until the bearing shells barely touch.
3.3
Measure the gap “K“ between the crankcase and main bearing cover on the exhaust and control side with a feeler gauge and add both values. K = KA + KS
en / 04.05.2004
Gap “K“ mm
Operating limit mm
1.4 - 1.65
1.2
IB024463
9/9
Main Thrust Bearings
A5.05. 02.05.06.30
Maintenance / Reassembly M43
02
See also:
02.05.05.nn
Spare parts list:
B1.05.03.431110
Time requirement:
2 Pers./ 1,00 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
---------------------------------------------------------------------------------------------------------------------------------Tools: Tools W1 - W12 see maintenance sheet 02.05.05.nn Turning unit
W12
439225-001
Auxiliary materials: Molykote Paste “G-Rapid Plus“ ** ** or equivalent product
Attention: High pressure lines may not be bent below minimum bending radius r = 250 mm! The high pressure pump may only be operated with hydraulic oil. Protect hydraulic equipment from corrosion during storage.
~
Attention! Do not place any body parts under equipment which is under pressure! Ensure that the engine cannot be started.
Note: The bearing covers and bearing shares are numbered consecutively on the control side from the coupling forward according to their respective cylinder and may not be exchanged. New parts must be labeled accordingly. Damaged main bearing bolts and round nuts must be replaced in sets.
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IB024467
1/7
Main Thrust Bearings
A5.05. 02.05.06.30
Maintenance / Reassembly M43
02
Procedure: 1.
Install bearing shells.
Note: The upper bearing shell is equipped with a lubrication groove and oil bore. Insert upper thrust washer segments if removed. 1.1
Oil the running surface of the upper bearing shell thoroughly, dry the back of the bearing and turn the bearing shell into the bearing as far as possible. Place the carrier (W11) into the oil bore until it stops.
Attention: Bearing shell designation on the opposite (control) side.
1.2
Insert turning mechanism (W12) into the bearing cover. Make sure that the unit seats properly at the side. Raise the rig (W10) carefully until it stops at the bearing shell. Lock the turning mechanism in place by hand with the round nuts (12). Lower the mechanism (W10) so that the bearing cap can be turned as needed.
12
W10
2
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IB024467
2/7
Main Thrust Bearings
A5.05. 02.05.06.30
Maintenance / Reassembly M43
1.3
Turn the upper bearing shell into place. Make sure that the bearing shell is centered. The positioning nose must slide into the guide groove in the bearing seat.
1.4
Raise the rig (W10), remove the round nuts (12). Lower the rig (W10) again and remove the carrier (W11) and the turning unit (W12).
1.5
Oil the running surface of the lower bearing shell, dry the back of the bearing and insert in main bearing cover. Raise the rig again.
Attention: The positioning nose on the lower shell is on the control side.
1.6
Place the lower thrust washer segments (1; only on main thrust bearings ) on the dowel pins (2) if removed.
2.
Pre-install main bearing bolts.
2.1
Raise rig (W10) with the main bearing cover to the upper stop. Be careful not to damage the main bearing bolts.
2.2
Screw round nuts onto main bearing bolts evenly and tighten by hand with pin.
2.3
Remove bearing cap mounts on plate.
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IB024467
3/7
02
Main Thrust Bearings
A5.05. 02.05.06.30
Maintenance / Reassembly M43
02
Note: Measure the gap “K“ after installing the bearing shells (see 02.05.01.nn). After replacing the bearing shells or the thrust washer segments the axial clearance must also be measured (see 02.05.01.nn). 2.4
Lower the rig (W10).
3.
Tighten the lateral round nuts of the adjacent bearing .
3.1
Screw the round nuts (23) of the adjacent bearing onto the uniform strength bolts and tighten by hand.
3.2
Place the hydraulic clamping elements (W4) over the round nuts (23) on the operating side and tighten by hand. Make sure that the slits (13) are easily accessible.
3.3
Connect the hydraulic clamping elements on the operating side to the high pressure pump (W1) by means of the high pressure line (W2). Secure the coupling that is not connected by means of plug.
3.4
Close the valve on the high pressure pump and extend the uniform strength bolts with a pressure of p = 380 bar
Attention: The pressure must remain constant when the hydraulic pump is not being actuated to prevent the bolts from being tightened incorrectly!
3.5
Tighten the round nut (23) with a pin.
3.6
Open the valve on the high pressure pump (W1), the clamping elements (W4) are depressurized.
3.7
Remove hydraulic clamping elements (W4).
3.8
Connect the hydraulic clamping elements (W4) on the exhaust side with the high pressure pump (W1) by means of the high pressure line (W2). Secure the coupling that is not connected by means of plug.
3.9
Close the valve on the high pressure pump, extend the uniform strength bolts with a pressure of p = 2250 bar
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IB024467
4/7
Main Thrust Bearings
A5.05. 02.05.06.30
Maintenance / Reassembly M43
02
Attention: The pressure must remain constant when the hydraulic pump is not being actuated to prevent the bolts from being tightened incorrectly!
3.10
Tighten the round nut (23) with a pin.
3.11
Check to ensure that the round nut is seated properly. • Reduce pressure by 50 bar. • The round nut must be tight enough that it cannot be loosened with a pin.
3.12
Open the valve on the high pressure pump (W1), the clamping elements (W4) are depressurized.
3.13
Wait until the pressure reduces completely. Remove the clamping elements (W4).
3.14
Repeat installation steps 3.8 to 3.13 on the operating side.
3.15
Screw the protective caps onto the uniform strength bolts.
4.
Tightening the main bearing bolts.
4.1
Run the carrying arm into position and place the chute (10) between the crankcase and carrying arm.
13 W5 10
23
5
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IB024467
5/7
Main Thrust Bearings
A5.05. 02.05.06.30
Maintenance / Reassembly M43
4.2
Place the hydraulic clamping element (W5) level on the plate above the chute. Remove the chute.
4.3
Raise the carrying arm. Place the hydraulic clamping element on the round nut (12) and tighten. Make sure that the slits (13) are easily accessible.
12
W5
13
W10
6
4.4
Repeat the installation procedure on the opposite side.
4.5
Connect the hydraulic clamping elements (W5) to the high pressure pump (W1) by means of the high pressure lines (W2, W6).
4.6
Close the valve on the high pressure pump and extend both main bearing bolts with a pressure of p = 2250 bar
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IB024467
6/7
02
Main Thrust Bearings
A5.05. 02.05.06.30
Maintenance / Reassembly M43
02
Attention: The pressure must remain constant when the hydraulic pump is not being actuated to prevent the bolts from being tightened incorrectly!
4.7
Tighten the round nuts (12) with a pin. Check to ensure good action (no stiffness).
4.8
Check to ensure that the round nut is seated properly.
• Reduce pressure by 50 bar. • The round nuts must be tight enough that they cannot be loosened with the pin. 4.9
Open the valve on the high pressure pump (W1), the clamping elements are depressurized.
4.10
Wait until the pressure reduces completely. Remove the hydraulic clamping elements (W5). The hydraulic clamping elements (W5) are removed in the reverse order as assembly.
4.11
Lower the rig until it reaches the lower stop.
4.12
Remove the rig (W10). The rig is dismantled in the reverse order as installation (see 02.05.01.nn).
4.13
Check engine oil flow.
4.14
Close the crankcase covers on the control and exhaust side and the covers under the gear drive.
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IB024467
7/7
Piston
A5.05. 02.06.01.30
Maintenance / Disassembly M43
See also:
01.06.01.nn, 02.07.01.nn, 03.04.01.nn
Spare parts list:
B1.05.02.432601
Time requirement:
2 Pers./ 0,30 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
02
------------------------------------------------------------------------------------------------------------------------------Tools: Piston lifting unit Hydraulic set consisting of High pressure pump High pressure line Hydraulic wrench consisting of Hydraulic wrench Sockets Spud Piston rod holder Cylinder liner retainer Disassembly unit for gauging ring
W1
432134 A
W3 W4
433420 A
W5 W6 W7 W8 W9 W10
435100 A 435102 A 435100 B 439228 B 439217 B 439216 B
Note: In order to prevent the cylinder liner from loosening during turning, the cylinder liner must be held in place with the cylinder liner retainer (Fig. Y/W9).
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IB024471
1/5
Piston
A5.05. 02.06.01.30
Maintenance / Disassembly M43
02
Procedure: 1.
Open the indicator valves, remove the crankcase cover for the respective cylinder on both sides.
2.
Turn crank journal ca. 20° to the control side from TDC.
3.
Remove cylinder head (01.06.01.nn).
4.
Place cylinder liner retainer (Fig. Y/W9) on coolant distributor housing (1). Tighten the round nut (5) by hand. Tighten the adjusting bolts (6) on the cylinder liner retainer against the cylinder liner (3) by hand.
5.
Clean carbon deposits from the area above TDC for 1st piston ring up to gauging ring. Do not damage the cylinder liner surface.
6.
Turn the upper piston edge up to just below the gauging ring (Fig. 2/4).
7.
Insert disassembly unit (W10) so that the recess is inside the gauging ring.
8.
Tighten the disassembly unit slightly by turning the spindle nut.
9.
Press out and remove the gauging ring by turning the engine to raise the piston.
10.
Remove disassembly unit.
11.
Rethread the threaded holes (Fig. Z/2; M16, 15 mm deep) in the piston crown.
12.
Bolt the piston lifting unit (W1) onto the piston crown.
13.
Connect the crane to the eye of the lifting unit, turn the piston to TDC together with the crane.
Attention: The crane and lifting eye must remain connected!
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IB024471
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Piston
A5.05. 02.06.01.30
Maintenance / Disassembly M43
02
14.
Split the connecting rod shank.
14.1
Insert a socket wrench with a square head (Fig. 3/W6) in the hydraulic wrench (W5). Mount the
support (Fig. 4/W7) on the hydraulic wrench.
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IB024471
3/5
Piston
A5.05. 02.06.01.30
Maintenance / Disassembly M43
02
Attention: In order to avoid damages to the hydraulic wrench (W5), adjust a maximum pressure of p = 425 bar on the high-pressure pump. Adjustment instructions see A6.05.90.10.nn . Note the direction of rotation, relocate the socket wrench with square head if necessary and turn the hydraulic wrench.
14.2
Connect the hydraulic wrench (W5) with the high pressure pump (W3) by means of the high pressure lines (W4). Secure the coupling that is not connected by means of plug.
14.3
Place hydraulic wrench with socket wrench (W6) on the uniform strength bolt (20). Prop the wrench on the connecting rod (22) or counterweight (30).
Attention: The engine may not be turned when the hydraulic wrench is connected.
~ 14.4
Safety note: During pressure build-up no parts of the body between support of the hydraulic wrench and connecting rod or balance weight. Close the valve on the high pressure pump (W3) and loosen the uniform strength bolts one after another with a pressure of p = 400 bar + 25 bar It may be necessary to move the cylinder of the wrench back and forth several times by releasing pressure [by opening the valve and closing the valve and pumping to build up pressure].
Attention: Hold the hydraulic wrench securely when reducing pressure. (The wrench may slip from the head of the bolt).
15.
Remove the uniform strength bolts (20) with the segments (21).
16.
Open the valve on the high pressure pump (W3). Wait until the pressure abates completely. Remove the hydraulic wrench (W5) with the socket wrench (W6).
17.
Mount the connecting rod holder (W8) on the counterweight to secure the connecting rod (22).
18.
Pull the piston carefully and place on a suitable surface.
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IB024471
4/5
Piston
A5.05. 02.06.01.30
Maintenance / Disassembly M43
02
Attention: Remove the big end if the piston will be stored for a longer period of time to prevent vibration damage in the cylinder liner area.
19.
Seal off the oil bore in the connecting rod shank split with a protective cap.
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IB024471
5/5
Piston Crown
A5.05. 02.06.02.04
Maintenance / Replace M43/VM43
See also:
02.06.01.nn, 02.07.01.nn, 02.08.01.nn
Spare parts list:
B1.05.02.432601
Time requirement:
2 Pers./ 0,70 h
02
Personnel qualification: Cat/MaK-specialist Operating medium:
Heavy fuel and distillate fuel
---------------------------------------------------------------------------------------------------------------------------------Tools: Piston lifting unit (piston crown) Piston lifting unit (big end) Torque wrench 20 - 200 Nm Torque wrench 200 - 500 Nm
W1 W2 W3 * W4 *
439223 A 439223 A 1.9454-202 1.9454-500
* no picture
Auxiliary materials: Molykote Paste “G-n plus” ** ** or equivalent product
Procedure: 1.
Turn the piston
1.1
Attach crane to piston lifting unit (Fig. 1/W1) , lift piston.
1.2
Mount second piston lifting unit (W2) on the big end (1) and attach second crane or sling.
1.3
Turn the piston carefully and place on suitable surface.
2.
Dismantling the piston crown
Note: The piston crown should only be replaced by the CAT Customer Service. 2.1
Connect piston lifting unit (W1) to crane, remove piston pin (2) (02.08.01.nn).
2.2
Measure piston pin bearing (3) (02.09.01.nn) and evaluate if necessary (02.03.03.nn).
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IB025184
1/4
Piston Crown
A5.05. 02.06.02.04
Maintenance / Replace M43/VM43
02
2.3
Loosen the hexagon nuts (Fig. 3/5) and remove with piston skirt (12).
2.4
Clean piston crown (8) and piston skirt (12). Make sure that the contact surfaces of piston parts and spacer sleeves (6) are clean.
Attention: Check the contact surfaces for friction marks / cold welding (Fig. 2/Z), if necessary consult the CAT Customer Service!
z
z
en / 19.11.2008
2
IB025184
2/4
Piston Crown
A5.05. 02.06.02.04
Maintenance / Replace M43/VM43
02
2.5
Clean and inspect the oil bores in the piston skirt (Fig. 3/12).
2.6
Piston assembly
2.7
Clean the contact surfaces of piston skirt (12) and piston crown (8) and check for unevenness. Carefully smooth out any raised spots with oil stone.
2.8
Clean bores for piston screws (7) and contact surfaces for spacer sleeves (6) in the piston skirt (12).
2.9
Screw piston screws (if removed) into piston crown and tighten to a torque of M = 40 Nm
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IB025184
3/4
Piston Crown
A5.05. 02.06.02.04
Maintenance / Replace M43/VM43
2.10
Insert new O-ring (13) untwisted into groove.
2.11
Put on piston skirt (12), fixation hole and spring dowel pin (11) must match.
2.12
Lubricate inside thread and bearing surfaces of the hexagon nuts (5) with Molykote paste.
2.13
Tighten piston screws (5) crosswise to a torque of
02
M = 170 Nm.
2.14
Loosen hexagon nuts again.
2.15
Retighten piston screws (7) in the piston crown, torque: M = 40 Nm
2.16
Tighten hexagon nuts (5) crosswise to a torque of M = 60 Nm and then continue tightening crosswise by 120°°.
2.17
Check: At a torque of
M = 115 Nm
the hexagon nuts must not turn any further! 2.18
Check by second person: Carry out a visual check to confirm if the hexagon nuts have been turned further by 2 hexagon corners. At a torque of M = 115 Nm the hexagon nuts must not turn any further in tightening direction!
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IB025184
4/4
Piston Rings and Grooves
A5.05. 02.07.01.01
Inspection / Checking M43/VM43
30000, 7500
See also:
02.06.01.nn
Spare parts list:
B1.05.02.432617
Time requirement:
1 Pers./ 0,50 h
02
Personnel qualification: Chief engineer / skilled engine hand Operating medium:
Heavy fuel
------------------------------------------------------------------------------------------------------------------------------Inspection: one piston and its rings
every
7,500 h
all pistons and piston rings
every
30,000 h
Piston ring pliers
W1
Maintenance:
Tools: 431001 A
Note: If the running surfaces of all cylinder liners have no scoring or polished areas and no other damage and all components of the piston being inspected are in perfect order, all piston rings loose in the grooves and if all parts have not been worn past the tolerance limits, the inspection of all pistons can be postponed to a later point in time if the mechanic decides to do so; the inspection cannot be postponed for more than 30,000 operating hours. During the inspection, special attention must be paid to the sharp-edgedness of the rings, ring tension or to any rings which may be stuck due to carbon deposits. Do not remove the graphite layer from the piston shaft. After installing new piston rings, the engine must be broken in in accordance with the break in procedure A3.10.01.nn!. Worked pistons with chromed 1st ring grooves may only be re-worked by MaK or MaK certified workshops.
Procedure: 1.
Piston inspection (7.500 h)
1.1
Open all crankcase covers.
1.2
Check the running surfaces of all cylinder liners (cylinder liner appearance) from the crankcase.
1.3
Remove the piston with the worst running surface (02.06.01.nn). If any piston rings are stuck or burnt, remove all additional pistons.
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IB020351
1/3
Piston Rings and Grooves
A5.05. 02.07.01.01
Inspection / Checking M43/VM43
30000, 7500
02
1.4
Piston rings may only be removed with the piston ring pliers (Fig. 1/W1) intended for this purpose. Record the position of the ring joints relative to the installation position of the piston in the measurement report.
1.5
Clean the piston rings.
1.6
Check wear in the chrome layer, especially at the gap and on the opposite side. If the chrome layer is worn away entirely or in sections, all rings for the respective piston must be replaced. If the chrome layer is worn on one of the rings, the rings on all pistons must be checked.
1.7
Clean the pistons, ring grooves and oil drain bores for the wiper ring.
1.8
Smooth light scoring and fretting with a fine emery cloth soaked in oil or a fine carborundum stone. Replace the piston if there is significant damage or scoring.
1.9
Measure the groove height hN (Fig. 2) in the forward groove area across and along the engine. If the wear limit has been exceeded, have the ring grooves reworked by MaK.
1.10
Measure the ring height hR (Fig. 2) at four opposing points.
hN1 = Nominal size hN2 = Wear
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IB020351
2/3
Piston Rings and Grooves
A5.05. 02.07.01.01
Inspection / Checking M43/VM43
1.11
30000, 7500
Calculate the clearance limit and check according to the table for standard piston equipment.
Groove
Piston ring height hR Nominal size mm
Groove height hN2 Wear limit mm
Wear limit hN2 - hR mm
1
10
10.8
0.9
2
10
10.5
0.6
3
10
10.3
0.4
1.12
Insert the rings in the grooves with the labeling up (Fig. 3/X) and with the ring gaps alternating to the front and back of the engine.
2.
Maintenance (30,000 h)
2.1
Remove all pistons (02.06.01.nn).
2.2
Check the running surface of the piston and clean the piston.
2.3
Remove the piston rings with the piston ring pliers (Fig. 1/W1). Record the position of the ring joints relative to the installation position of the piston in the measurement report.
2.4
Clean all rings and check the wear. If the chrome layer is worn away entirely or in sections, send the pistons to MaK for repair.
X
3
2.5
Measure the groove height hN as defined in 1.9.
2.6
Replace wiper ring and all compression rings.
2.6.1
Place the rings in the grooves with the labeling (Fig. 3/X) up and with the ring gaps alternating to the front and back of the engine.
2.7
Install all pistons (02.10.01.nn).
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IB020351
3/3
02
Piston Pin
A5.05. 02.08.01.00
Inspection / Disassembly and reassembly M43
02
See also:
02.06.01.nn, 02.09.01.nn
Spare parts list:
B1.05.02.432601
Time requirement:
2 Pers./ 1,00 h
Personnel qualification:
Chief engineer / skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
------------------------------------------------------------------------------------------------------------------------------Tools: Piston installation / disassembly unit Piston installation / disassembly unit Installation rig
W1 W2 W3
439223 A 439223 A 439220 C
Procedure: 1.
Turn the piston.
1.1
Connect crane to the piston installation unit (W1) and lift the piston.
1.2
Mount second installation unit (W2) on the connecting rod eye (1) and attach second crane or strap.
1.3
Turn the piston and place on suitable surface.
W2
X
1
X W3 3
6 2 4
5
W1
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IB020353
1/2
Piston Pin
A5.05. 02.08.01.00
Inspection / Disassembly and reassembly M43
02
2.
Disassembly
2.1
Mark the connecting rod eye (1), piston (2) and piston pin (3) for proper alignment during re-installation.
2.2
Lift the connecting rod eye slightly with the crane to relive pressure on the piston pin.
2.3
Remove the circlips (4).
2.4
Remove the piston pin (3) from the piston bore and piston pin bush without applying excessive force until the second oil bore is visible. Mount the rig (W3) and prop the piston with the crane.
Note: If the piston pin cannot be pressed out by hand, warm the piston to 80°C in an oil bath. The piston pin can usually be removed from and installed in the piston without warming. When working with new parts, the clearance may not be sufficient when the parts are cold. Full clearance is reached when the parts are at operating temperature. 2.5
Check the oil bores (6) in the connecting rod eye and check the piston pin bush to ensure that it is not stuck.
2.6
Check the piston pin surface for cracks and damage.
2.7
Measure the piston pin, piston pin bush and piston pin bore (02.09.01.nn).
3.
Assembly
3.1
Insert a circlip (4) into the piston pin bore.
3.2
Slide the connecting rod eye (1) into the piston until the piston pin bore and the piston pin bush are flush.
3.3
Oil the piston pin (3) and insert into the piston and piston pin bush without tilting; the pin must be installed in accordance with the markings. Remove the rig (W3). Slide the piston pin into position.
Note: If necessary, warm the piston to 80°C in an oil bath or freeze the piston pin. 3.4
Secure the piston pin with the second circlip.
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IB020353
2/2
Small End Bearing
A5.05. 02.09.01.01
Maintenance / Measuring M43/VM43
30000
See also:
02.03.03.nn
Spare parts list:
B1.05.02.432601
Time requirement:
2 Pers./ 1,00 h
02
Personnel qualification: Chief engineer / skilled engine hand Operating medium:
Heavy fuel
------------------------------------------------------------------------------------------------------------------------------Maintenance/Repair: Measure bearing clearance: Replace small end bearing:
every 30,000 h when replacement criteria met
Note: The exact installation of a small end bearing is generally impossible with the equipment normally found on board. This must be completed at the MaK plant or at an MaK certified workshop. The small end bearing in the offset connecting rod eye has an electroplated running surface, see 02.03.03.nn. The small end bearing is evaluated on the basis of the operating wear limits (see table). A small end bearing is only replaced when -
a wear limit has been reached or
-
the wear limit will more than likely be exceeded before the next overhaul.
Procedure: 1.
Measure the small end bearing
1.1
Clean the piston pin (Fig. 2/1), small end bearing (2) and piston bosses and measure dimensions A, B and C with a suitable measuring instrument such as an external and internal micrometer.
1.2
Determine the axial clearance [piston boss clearance (D) and bearing width (X)]. If the wear limit has been reached (see Fig. 1), the corresponding wearing parts must be replaced.
en / 29.07.2008
IB020357
1/3
Small End Bearing
A5.05. 02.09.01.01
Maintenance / Measuring M43/VM43
30000
02 Smallest clearance
Largest clearance
Operational clearance limit
Connecting rod eye Ø (A) Piston pin Ø (C)
0.06
0.092
0.12
Small end bushing Ø (B) Piston pin Ø (C)
0.2
0.302
0.31
Eye clearance (D) Bushing width (X)
0.7
1.2
1.5
1
2
D
A
B
U
V
X
U
V
1
C
Z
Z
2
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IB020357
2/3
Small End Bearing
A5.05. 02.09.01.01
Maintenance / Measuring M43/VM43
2.
30000
02
Removal of the small end bearing
Note: The following work should only be completed by MaK or by an MaK certified workshop. This work may only be completed on board in an emergency! 2.1
When removing the small end bearing, be sure to use as little force as possible. The small end bearing may not be pressed out, it must be released by carefully sawing or milling the indicated position (Fig. 3/Y).
Y
3
Achtung: Be extremely careful not to damage the surface of the small end bearing bore in the connecting rod eye! After removing the small end bearing, inspect the bore surface carefully for cracks, corrosion damage or other damage. Appropriate crack test material such as Magna-Flux and a magnifying glass must be used for this. Carefully remove any material deposits first. Connecting rod eyes with a damaged bore surface in the small end bearing bore may not be used without being reworked. The connecting rods can normally be re-worked by MaK.
3.
Small end bearing installation
3.1
Small end bushing to ca. -160°°C in C02 snow and warm connecting rod eye to ca. 80°C in a clean oil bath (note safety regulations!).
Achtung:
• •
Make sure that the small end bearing is installed correctly in the connecting rod eye! The lateral protrusion (Fig. 2/z) of the bushing must be the same on both sides!
3.2
Slide the bushing into the connecting rod eye.
3.3
After the parts have reached normal temperature, the dimensional accuracy and the position of the oil bores and oil grooves must be checked.
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IB020357
3/3
Piston
A5.05. 02.10.01.30
Maintenance / Reassembly M43
See also:
02.06.01.nn, 02.07.01.nn
Spare parts list:
B1.05.02.432601
Time requirement:
2 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
02
------------------------------------------------------------------------------------------------------------------------------Tools: Tools W1 - W9 see 02.06.01.nn Piston installation ring Piston installation guide (steel collar) Torque wrench 20 - 200 Nm Torque wrench 200 - 500 Nm
W12 W13 W14* W15*
439220 B 439220 A 1.9454-202 1.9454-500
* no picture
Auxiliary materials: Molykote Paste "G-Rapid Plus“ ** ** or equivalent product
Note: In order to prevent the cylinder liner from detaching during turning, the cylinder liner must be lokked securely with the cylinder liner retainer!(Fig. 2/W9) After installing a new piston, the engine must be broken in in accordance with the engine break-in instructions! (A3.10.01.nn)
Procedure: 1.
Insert all piston rings with the gap facing lengthwise respective to the engine; ring gaps must alternate to the front and back of the piston! Oil the piston rings and the outside of the piston well.
2.
Loosen the clamping bolts (Fig. 1/1) until the piston installation unit (W13) is open wide enough that it can be slid freely over the piston rings.
3.
Apply Molykote paste "G-Rapid Plus“ to the threads and contact surface of the clamping bolts (1).
3.1
Oil the ring area well.
W13 1
1
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IB024475
1/5
Piston
A5.05. 02.10.01.30
Maintenance / Reassembly M43
4.
Place the piston installation unit (Fig. 1/ W13) over the piston ring zone and tighten the clamping bolts (1).
W1
02
W12
Attention: When tightening the clamping bolts, make sure that the piston rings are not on the outer edge of the ring groove. Loosen any rings by tapping lightly on the piston installation unit.
5. 6.
7
5
Make sure that the rings are not stuck by turning the piston installation unit (W13).
Y Z
6
Attach the piston lifting unit (Fig. 2/W1) to the piston.
Attention: Place the crank journal in TDC.
Y
7.
Mount cylinder liner retainer (W9).
8.
Mount piston installation ring (W12).
9.
Attach piston to crane and lift. Oil cylinder liner and piston base well.
10.
Place the piston into the cylinder liner carefully; the piston must be inserted exactly in line with the cylinder axis.
Z
W9 W8 2
Attention: Remove the protective cap from the oil bore in the connecting rod.
11.
Lower the piston, being extremely careful that the cylinder does not catch in the cylinder liner.
12.
Place the piston insertion unit (Fig. 1/W13) flat on the piston installation ring (Fig. 2/W12) and place the piston carefully on the connecting rod (6) with the connecting rod eye. The connecting rod eye may not rest on the connecting rod with any force!
Note: Lower the piston carefully until the cylinder pins (Fig. 3/8) are run completely into the bores in the connecting rod eye (5).
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IB024475
2/5
Piston
A5.05. 02.10.01.30
Maintenance / Reassembly M43
02
13.
Install piston and connecting rod.
13.1
Apply Molykote to threads and contact surfaces of the uniform strength bolts (Fig. 3/ 20).
13.2
Place segments (21) on the connecting rod split and tighten uniform strength bolts hand tight with ring wrench.
13.3 13.4
5
Remove connecting rod holder (W8) (02.06.01.nn).
8
Tighten all uniform strength bolts (Fig. 4/ 20) to M = 50 Nm Mark the position of each of the uniform strength bolts with a chalk mark. Then tighten all uniform strength bolts to
6 3
M = 250 Nm
en / 30.01.2008
IB024475
3/5
Piston
A5.05. 02.10.01.30
Maintenance / Reassembly M43
13.5
02
Place socket wrench (Fig. 4/W6) with square head into the hydraulic wrench (W5). Mount support (W7) on hydraulic wrench.
Attention: In order to avoid damages to the hydraulic wrench (W5), adjust a maximum pressure of p = 425 bar on the high-pressure pump. Adjustment instructions see A6.05.90.10.nn . Note the direction of rotation, relocate the socket wrench with square head if necessary and turn the hydraulic wrench.
13.6
Connect the hydraulic wrench (W5) with the high pressure pump (W3) by means of the high pressure lines (W4). Secure the coupling that is not connected by means of plug.
13.7
Place hydraulic wrench with socket wrench (Fig. 4/W6) on the uniform strength bolt (20). Prop the wrench on the connecting rod (22) or counterweight (Fig. 5/30).
X 30
22 20 W5
W7
5
Attention: The engine may not be started when the hydraulic wrench is connected!
en / 30.01.2008
IB024475
4/5
Piston
A5.05. 02.10.01.30
Maintenance / Reassembly M43
02
~ 13.8
Safety note: During pressure build-up no parts of the body between support of the hydraulic wrench and connecting rod or balance weight. Close the valve on the high pressure pump (W3) and tighten all uniform strength bolts (20) on one side at a time with a pressure of p = 400 bar + 25 bar If necessary, move the cylinder in the hydraulic wrench back and forth several times by releasing the pressure [by opening the valve and closing the valve and pumping to build up pressure].
Attention: Hold the hydraulic wrench securely when reducing pressure. The wrench may slip from the head of the bolt.
13.9
Note the position of the uniform strength bolts (chalk mark), it must be at an angle of 55°° + 15°°
13.10
Open the valve on the high pressure pump (W3). Wait for the pressure to subside completely and remove the hydraulic wrench (W5), high pressure lines (W4) and high pressure pump (W3).
14.
Turn the piston to TDC together with the crane.
15.
Remove the piston insertion unit (Fig. 1/W13), piston installation ring (Fig. 2/W12) and piston lifting unit (W1).
16.
Clean the cylinder liner contact surface (3).
17.
Install new gauging ring.
18.
Install cylinder head (01.11.01.nn).
19.
Remove cylinder liner retainer (Fig. 2/W9), replace crankcase cover and close indicator valves.
en / 30.01.2008
IB024475
5/5
Balance weight
A5.05. 02.11.00.00
Repair / Disassembly and reassembly M43
See also:
02.12.00.nn
Spare parts list:
B1.05.02.432520
Time requirement:
2 Pers./ 0,50 h
02
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Hydraulic device set, consisting ofs High-pressure pump High-pressure hose Pin Hydraulic tightening element Sealing element
W1 W2 W3 W4 W9
Mounting and removal device for balance weights M52x3 hexagon nut (4x)
W7 W8 *
1.9204 D 433420 A 1.9213 G
* not illustrated
Auxiliary material: Molykote paste "G-Rapid Plus" ** ** or a product of equal standard
Attention: The smallest allowable bending radius for the high-pressure hoses is 250 mm. For the hydraulic device set use hydraulic oil only . Store the hydraulic device set protected against corrosion.
~
Safety note: Do not place any part of your body over hydraulic components under pressure! Secure the engine against unintentional starting!
en / 21.04.2004
IB022689
1/5
Balance weight
A5.05. 02.11.00.00
Repair / Disassembly and reassembly M43
02
Sequence of operations: 1.
Disassembly of balance weight.
1.1
Turn crankshaft to position according to (Fig. 3).
1.2
Mount the mounting and removal device for balance weights (Fig. 4/W7).
1.3
Attach the lugs (20) of device (W7) via shackles and slings to hoists. Pull the hoists so that the slings are slightly tensioned.
1.4
Loosen both round nuts (Fig. 3/1) of the studs (2) by means of the hydraulic device set.
1.5
Place hydraulic element (W4) over the round nut (1) and tighten it. Make sure the slits (Fig. 2/3) are easily accessible. Loosen the hydraulic element by 1 turn.
1.6
Connect the hydraulic element (Fig. 3/W4) via the high-pressure hose (W2) to the high-pressure pump (W1). Secure free hose coupling with sealing element (W9).
1.6.1
Close valve (10) of the high-pressure pump (W1) and stretch the stud steplessly with a pressure of p = 2050 bar
1.6.2
Note:
Loosen round nut (Fig. 2/1) with pin (W3). Turn back round nut at least 8 holes. If the round nut cannot be loosened with the pin, the stud can be preloaded higher with a pressure of p = 50 bar If the pressure is increased even more, there is a danger of the round nut becoming stuck due to stretching of the screw thread!
en / 21.04.2004
IB022689
2/5
Balance weight
A5.05. 02.11.00.00
Repair / Disassembly and reassembly M43
1.6.3
Open valve (Fig. 3/10) of the high-pressure pump (W1), the hydraulic element will be relieved.
1.6.4
Wait until the pressure has dropped completely, and then remove the hydraulic element (W4)
1.6.5
Loosen the second round nut (1), see sequence of operations 1.4.1 to 1.4.6.
1.6.6
Remove the round nuts completely.
1.7
Lower device (Fig. 4/W7) with the hoists slowly and evenly on both sides until the balance weight gets clear of the studs.
1.8
Move the balance weight slowly out of the crankcase and place it on a suitable base.
1.9
Remove the mounting and removal device for balance weights (W7).
1.10
Screw hexagon nuts (W8) onto the studs (Fig. 2/2) and lock with a second nut.
1.11
Loosen studs and screw out of the crankshaft.
2.
Reassembly of balance weight
2.1
Turn crankshaft to position according to (Fig. 3) .
2.2
Clean the contact surfaces on balance weight and crankshaft.
en / 21.04.2004
IB022689
3/5
02
Balance weight
A5.05. 02.11.00.00
Repair / Disassembly and reassembly M43
2.3
Apply a thin coat of Molykote paste to the studs (2) and insert in crankshaft.
2.4
Tighten the studs by means of locked hexagon nuts (W8) with a torque of
02
M = 400 Nm 2.5
Disassemble the hexagon nuts (W8).
2.6
Mount the mounting and removal device for balance weights (Fig. 4/W7). W7
20
4
2.7
Lower the device with balance weight slowly into the crankcase by means of hoists.
2.8
Tension the slings slowly and put balance weight on crankshaft via the studs.
2.9
Screw the round nuts (Fig. 3/1) onto the studs (2) so as to be fingertight.
3.
Tighten the round nuts (1) of the studs (2) with the hydraulic device set.
3.1
Place hydraulic element (W4) above the first round nut (1) and tighten it. Make sure the slits (Fig. 2/3) are easily accessible.
en / 21.04.2004
IB022689
4/5
Balance weight
A5.05. 02.11.00.00
Repair / Disassembly and reassembly M43
3.2
Connect the hydraulic element (Fig. 3/W4) via the high-pressure hose (W2) to the high-pressure pump (W1). Secure free hose coupling with sealing element (W9).
3.3
Close valve (10) of the high-pressure pump (W1) and stretch the first stud (2) steplessly with a pressure of p = 2050 bar + 25 bar
Attention: When the hydraulic pump is not actuated the pressure must remain constant, otherwise the tightening will be incorrect!
3.4
Firmly tighten round nut (1) with pin (Fig. 1/W3).
3.5
Open valve (10) of the high-pressure pump (W1), the hydraulic element will be relieved.
3.6
Wait until the pressure has dropped completely, and then remove the hydraulic element (W4).
3.7
Place hydraulic element (W4) onto the second round nut (1) according to sequence of operations 3.1 to 3.3.
3.8
Close valve (10) of the high-pressure pump (W1) and stretch the second stud (2) steplessly with a pressure of p = 2050 bar + 25 bar
3.9
Firmly tighten round nut (1) with pin (Fig. 2/W3).
3.10
Decrease hydraulic pressure by
p = 50 bar.
It must not be possible to loosen the round nut any more. 3.11
Relieve the hydraulic element according to sequence of operations 3.5 and 3.6.
en / 21.04.2004
IB022689
5/5
02
Measures for emergency operation
A5.05. 02.12.00.00
Repair / Disassembly and reassembly M43
See also:
01.06.01.nn, 01.11.01.nn, 02.04.01.nn, 02.06.01.nn
Spare parts list:
B1.05.13.431510
Time requirement:
2 Pers./ 4,00 h
02
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Retaining device for cam follower Plug for oil bore Lashing strap (2x)
W1 W2 W3
439235 A 439225 A 1.9461-790
Attention: In the case of resiliently mounted engines with one damaged running gear the following measures must be carried out before putting the engine into service for emergency operation!
Sequence of operations
1.
Locking of the resilient mounting.
1.1
Disassemble nuts and washers (Fig. 1/20, 21 and 22).
1.2
Disassemble spring dowel pin (23).
1.3
Screw down locking ring (24) so that it abuts against pipe (25). To this end an auxiliary bore Ø 14 for a tool is provided in the locking ring.
1.4
Apply a thin coat of oil to the foundation bolts. Place washer (22) onto side stopper (26) and together with nut (21) tighten with a torque of M = 3000 Nm As an alternative with M = 150 Nm + 60 ° torque angle
2.
Disassemble cylinder head (01.06.01.nn).
en / 21.11.2000
IB022678
1/5
Measures for emergency operation
A5.05. 02.12.00.00
Repair / Disassembly and reassembly M43
02
en / 21.11.2000
R
=
Shown in locked condition (running gear damage)
S
=
Shown under normal operation
IB022678
2/5
Measures for emergency operation
A5.05. 02.12.00.00
Repair / Disassembly and reassembly M43
3.
02
Disassemble the push-rods for inlet and exhaust valve. Put up the cam followers for inlet and exhaust valve and secure by means of lashing straps (Fig. 2/W3).
W3
4.
Insert retaining device for cam follower (Fig. 3/W1) of the injection pump drive into the engine block.
4.1
Screw in the hexagon head screw (2) until there is clearance S between the cam follower and the injection cam S = 1,0 - 2,0 mm After lifting up the cam follower lock the hexagon head screw (2) with a hexagon nut (3).
5.
Draw piston (02.06.01.nn).
5.1
Disassemble cylinder liner retainer.
6.
Disassemble big-end bearing and big-end bearing cap as well as connecting rod (02.04.01.nn).
6.1
Place connecting rod onto a suitable base.
6.2
Disassemble one balance weight of the damaged running gear (02.11.00.nn).
en / 21.11.2000
2
IB022678
3/5
Measures for emergency operation
A5.05. 02.12.00.00
Repair / Disassembly and reassembly M43
7.
7.1
Obturate the oil bore in the crank pin of the damaged running gear by means of plug (Fig. 4/W2). Make sure the gaskets (11) and stuffing cones (12) are positioned correctly.
02
13 12 11
Tighten prevailing torque type nut (13) by hand.
11 12 4
Y
8.
Disassemble the control air pipe (Fig. 5/30) of the corresponding injection pump. Obturate connection (31) on pump and connection (32) on the pipe with plug and swivel nut.
9.
Mount cylinder head (01.11.01.nn).
10.
Mount crankcase cover on camshaft and exhaust side.
11.
Start the engine under emergency operation (A3.12.02.nn). Continuously check the foundation bolts (Fig. 1/27) for tight fit during emergency operation. Retighten if necessary.
en / 21.11.2000
IB022678
4/5
Measures for emergency operation
A5.05. 02.12.00.00
Repair / Disassembly and reassembly M43
02
12.
Repairing a damaged engine.
12.1
Disassemble cylinder head, plug in the crank pin (Fig. 4/10), retaining device for cam follower of the injection pump drive (Fig. 3/10) and the lashing straps (W3) used for the cam followers for inlet and exhaust valve. Mount control air pipe (Fig. 5/30).
12.2
Deactivating the locking of the resilient mounting.
12.3
Exchange / repair any damaged parts.
12.4
Mount connecting rod, connecting rod bearing with bearing cap (02.04.02.nn), piston (02.10.01.nn), balance weight (02.11.00.nn), push rods for inlet and exhaust valve and cylinder head (01.11.01.nn).
12.5
Mount crankcase cover on camshaft and exhaust side.
12.6
Put the engine into service (A3.05.00.nn).
en / 21.11.2000
IB022678
5/5
Explosion relief valve
A5.05. 03.01.01.02
Inspection / Checking M43
1500
See also:
02.01.01.nn
Spare parts list:
B1.05.03.431633
Time requirement:
1 Pers./ 1,00 h
03
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Check: Ease of movement of the explosion relief valve every
1,500 h
Tools: Torque wrench 20 - 200 Nm
W1
1.9454-202
Auxiliary materials: Molykote Paste "G Rapid Plus“ * Sealing compound "Dirko No. 610.020" * * or equivalent product
Note: Removal of the explosion relief valve (5) is only required if the specified spring tension is not provided any more, in the event of abnormal oil contamination or if any leaks should be identified during operation.
Procedure: 1.
Check the relief valve from the inside of the crankcase door (1) for ease of movement by actuating the valve by hand. For this purpose dismantle the crankcase door (1) or the explosion relief valve (5).
2.
Disassembly
2.1
Unscrew and remove screws (8) from crankcase door (1).
2.2
Remove explosion relief valve (5) completely from the crankcase cover (1).
3.
Assembly
3.1
Coat the threads of screws (8) slightly with Molykote Paste "G-Rapid Plus".
3.2
Clean the sealing face on the crankcase door (1) and lubricate with sealing compound "Dirko No. 610.020".
3.3
Put the explosion relief valve (5) in place on the crankcase door (1).
en / 18.11.2008
IB026117
1/2
Explosion relief valve
A5.05. 03.01.01.02
Inspection / Checking M43
3.4
1500
03
Tighten screws (8) to a torque of M = 25 Nm.
3.5
After assembly check the explosion relief valve for proper operation by actuating it by hand.
3.6
When mounting the explosion relief valve on the crankcase door care has to be taken to ensure proper sealing between seat and crankcase door.
en / 18.11.2008
IB026117
2/2
Coolant Distributor Housing
A5.05. 03.02.00.00
Maintenance / Disassembly and reassembly M43
See also:
01.06.01.nn, 02.06.01.nn, 03.03.01.nn, 03.04.01.nn, 03.04.02.nn
Spare parts list:
B1.05.03.431110
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
03
---------------------------------------------------------------------------------------------------------------------------------Maintenance: Replace O-rings
Tools: Eye bolts M16 Cylinder liner retainer * no picture
W1 W2*
439217 A
Auxiliary materials: Vaseline ** ** or equivalent product
Procedure: 1.
Remove coolant distributor housing.
1.1
Remove mounting bolts (Fig. 2/1) on the coolant block.
en / 28.07.1999
IB020182
1/3
Coolant Distributor Housing
A5.05. 03.02.00.00
Maintenance / Disassembly and reassembly M43
1.2
Loosen the sleeves (2) from the starting air channel and slide into opposite distributor housing.
1.3
Remove the distributor housing mounting bolts (3). Screw the eye bolts (Fig. 3/W1) into the coolant distributor housing (6) and lift housing with crane.
Attention: The lower cylinder liner retainer must be installed (01.06.01.nn).
1.4
Replace O-ring (4) on the charge air passage and O-ring (5) on the valve lifter passage in the coolant distributor housing (6).
Note: All O-rings must be inserted into the groove with Vaseline or green lubricant paste without twisting.
en / 28.07.1999
IB020182
2/3
03
Coolant Distributor Housing
A5.05. 03.02.00.00
Maintenance / Disassembly and reassembly M43
03
2.
Install coolant distributor housing.
2.1
Set coolant distributor housing (6) into place on the crankcase with a crane. Replace coolant block gasket (Fig. 2/7).
2.2
Tighten coolant distributor housing mounting bolts (3).
2.3
Slide sleeves (2) for starting air channel into place and secure.
2.4
Apply a light coat of Molykote to the coolant block mounting bolts (1), slide into place and tighten to M = 100 Nm Then tighten the bolts to M = 260 Nm
2.5
Remove eye bolts (Fig. 3/W1).
2.6
Remove cylinder liner retainer (W2).
en / 28.07.1999
IB020182
3/3
Cylinder Liner
A5.05. 03.03.01.01
Inspection / Measuring M43/VM43
30000, 15000
03
See also:
02.06.01.nn, 03.04.01.nn
Spare parts list:
B1.05.03.431110, B1.05.03.431611
Time requirement:
1 Pers./ 0,20 h
Personnel qualification:
Chief engineer
Operating medium:
Heavy fuel
---------------------------------------------------------------------------------------------------------------------------------Inspection: -
of one cylinder liner
every
15,000 h
-
of all cylinder liners
every
30,000 h
-
of the cylinder liner each time a piston is removed, before the removal and installation of a cylinder liner.
W1 1
Tools: Cylinder liner gauge rail W1 Fine gauge inside micrometer W2 *, ** * no picture ** or equivalent measuring instrument
439218-001 1.9419 G
Procedure: 1.
Check cylinder liner. 2
Note: Unusual forms of wear may be found in cylinder liners depending on the respective total operating time and operating conditions; this wear must be measured and evaluated. (See Fig. 3) 1.1
Remove gauging ring and remove piston.
1.2
Clean the inside of the cylinder liner, cover the crankcase well.
1.3
Measure the cylinder liner with the fine gauge inside micrometer (W2) at the points indicated by the gauge rail (Fig. 1/ W1) and table (Fig. 2) along, across and 2 x diagonal to the engine axis.
3
1
1.4 Measurement point
Wear value Along engine axis
across engine axis
diagonal
diagonal
1 2 Refe3 rence value
en / 25.08.2003
IB020186
1/2
Cylinder Liner
A5.05. 03.03.01.01
Inspection / Measuring M43/VM43
30000, 15000
1.5
Enter the values measured into the table (Fig. 2) and calculate the wear values (d1 - reference value d3, etc.), see also measurement sheet in folder “Forms for Maintenance Reports”.
1.6
When the wear limit has been reached, normally at the point at which the top piston ring reverses direction (TDC, 1st ring) or other threshold values in the table (Fig. 3 and Fig. 4)have been met, replace the cylinder liner. The cylinder liners can only be reworked by Caterpillar/MaK . Cylinder liner wear chart Evaluation criteria
Wear limit (mm)
Explanation
Nominal Ø (new))
*
Limit value for conically honed cylinder liners
430,0 + 0,063
**
Radius r ≥ 3 mm
Max. out-or-round
0,30
*** in circumferencial direction
Wear 4
0,75 0,90 *
TDC. 1st Ring
Gusset 1
Height Depth **
13,00 0,05
wedge-shaped indentation across the entire circumference, beginning from the TDC of 1st. piston ring.
Canyon 5
max. number Length total width
3 13,00 6,00
Individual deep blow-through ducts in the area of the first piston ring (TDC).
Scores 3
Number Length Depth
3 250,00 0,05
Vertical and linear scores.
Pocket
Number Length Width *** Depth **
3 120,00 40,00 0,03
Irregular indentations.
2
2
3
4 5
***1
4
en / 25.08.2003
IB020186
2/2
03
Cylinder Liner
A5.05. 03.04.01.00
Maintenance / Disassembly M43
30000
03
See also:
02.06.01.nn, 03.03.01.nn
Spare parts list:
B1.05.03.431110, B1.05.03.431611
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
------------------------------------------------------------------------------------------------------------------------------Maintenance: Remove cylinder liner, replace O-ring
every
Cylinder liner rig Cylinder liner retainer
W1 W2
30,000 h
Tools: 439216 A 439217 A
Attention: The cylinder liner sealing surface must be protected from damage!
Procedure 1.
Remove cylinder liner.
1.1
Remove piston (02.06.01.nn). Remove cylinder liner retainer (W2).
1.2
Measure wear (03.03.01.nn).
1.3
Insert rig (W1) with threaded rod and swivel cross arm (1) into the cylinder liner.
1.4
Fasten clamping plate (2) and swivel cross arm (1) securely with the nut (3).
Attention: Make sure that the swivel cross arm (1) rests on the cylinder liner correctly.
1.5
Attach lifting unit to eye bolt (4) and pull cylinder liner out along cylinder axis and place on suitable surface.
1.6
Remove the O-ring (13) in the coolant distributor housing (14).
en / 28.07.1999
IB020188
1/2
Cylinder Liner
A5.05. 03.04.01.00
Maintenance / Disassembly M43
30000
1.7
Clean the sealing surface and O-ring groove thoroughly and check for damage.
1.8
Clean coolant area on the cylinder liner collar thoroughly.
1.9
Clean cylinder liner collar seat, upper and lower fitting bore in crankcase thoroughly.
en / 28.07.1999
IB020188
03
2/2
Cylinder Liner
A5.05. 03.04.02.00
Maintenance / Reassembly M43
See also:
03.03.01.nn, 03.04.01.nn
Spare parts list:
B1.05.03.431110, B1.05.03.431611
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
03
------------------------------------------------------------------------------------------------------------------------------Tools: Cylinder liner rig
W1
Auxiliary materials: -
Liquid beef suet or green potassium soap
Note: Take complete measurements after installing a new cylinder liner. After installing a new cylinder liner, the engine must be broken in in accordance with the break-in procedures A3.10.01.nn!
Procedure: 1.
Clean the inside of the coolant distributor housing (Fig. 1/1).
2.
Place new O-ring (4) into the groove in the coolant distributor housing.
Attention: Place O-ring in the groove with fluid beef suet or green potassium soap without twisting!
3.
Clean the cylinder liner contact surfaces (2) on the crankcase (3).
en / 28.07.1999
IB020192
1/2
Cylinder Liner
A5.05. 03.04.02.00
Maintenance / Reassembly M43
03
4.
Connect hoisting unit to the eye bolt on the rig (Fig. 1/W1) and lower the cylinder liner into the crankcase (3).
5.
Mount rig onto the cylinder liner to be installed in accordance with steps 1.3 and 1.4 of the disassembly instructions (03.04.01.nn).
Note: Insert the cylinder liner so that the mark (5) (Fig. 2/X, top view cylinder liner collar) faces the coupling side in the direction of the engine axis. The mark (6) on the coolant distributor housing is intended to ease alignment.
Attention: The cylinder liner must slide into the crankcase fitting bores (Fig. 1/3) by means of its own weight!
6.
Remove the rig (W1) from the cylinder liner and install piston (02.10.01.nn).
en / 28.07.1999
IB020192
2/2
Engine Fasteners and Connections
A5.05. 03.07.01.00
Inspection / Checking M43/VM43
See also:
150
03
02.02.01.nn, 06.01.01.nn
Spare parts list: Time requirement:
1 Pers./ 2,00 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
---------------------------------------------------------------------------------------------------------------------------------Inspection: all engine fasteners and connections for tightness and leaks.
Note: The preventative inspection must be completed once to find leaks or loose bolted connections resulting from "settling“ connecting elements or seals which could lead to subsequent damage. After starting up a new system (150 h) or after large scale repairs, the engine connecting elements must be checked to ensure that they are tight and that there are no leaks.
Procedure: 1.
Check the tightness and seal of the engine connecting flange, filter, control unit and the line connections of the following systems:
• Coolant • Engine oil • Fuel • Starting air • exhaust gas • Pneumatic control 2.
Check the compensators for leaks and check the exhaust line (06.01.01.nn) behind the exhaust turbocharger to ensure that it is suspended properly.
3.
Check the brackets and connecting pieces of the charge air line for tightness and leaks.
4.
Tighten the mounting bolts in the bearing blocks of the fuel pump regulating rod and check the safety unit on the connection joints.
5.
Check the control and monitoring equipment to ensure secure fit. Cables and impulse lines may not chafe.
6.
Check foundation bolts and fitted pieces by tapping. Check web deflection after tightening loose foundation bolts (02.02.01.nn). Obtain tightening values from MaK customer service.
7.
Check elastic bearing elements for damage.
en / 25.08.2003
IB020232
1/1
Camshaft Bearing
A5.05. 04.01.01.00
Inspection / Checking M43
30000, 15000
04
See also:
02.01.01.nn, 04.01.02.nn
Spare parts list:
B1.05.04.433120
Time requirement:
1 Pers./ 0,20 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
---------------------------------------------------------------------------------------------------------------------------------Inspection: -
of the clearance of one camshaft bearing
-
of the clearance of all camshaft bearings
15,000 h every
30,000 h
Note: Camshaft bearings are subject to no load alternation. The bearings are only loaded at the lower bearing area; the load here is relatively high. Light edging is not unusual.
Procedure: 1.
Check camshaft bearing clearance
1.1
Remove the corresponding sight hole cover on the control side of the camshaft cover.
1.2
Check camshaft bearing /bearing journal clearance. New clearance mm
Wear limit mm
0.26 - 0.32
0.5
Note: When the wear limit has been reached, replace camshaft bearing (MaK customer service) and check the bearing clearance of all camshaft bearings. Check the bearing journal running surfaces of the corresponding camshaft bearing.
en / 28.07.1999
IB020303
1/1
Camshaft Bearing
A5.05. 04.01.02.00
Inspection / Disassembly and reassembly M43
30000, 15000
See also:
02.03.03.nn, 04.04.01.nn
Spare parts list:
B1.05.04.433120, B1.05.04.433140
Time requirement:
1 Pers./ 0,20 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
04
---------------------------------------------------------------------------------------------------------------------------------Inspection: -
Check the running surface of one camshaft bearing and corresponding camshaft section after the 1st cylinder
every
15,000 h
Check the running surface of all camshaft bearings and corresponding camshaft sections after the 1st cylinder
every
30,000 h
Tools: see 04.04.01.nn
Note: Camshaft bearings are subject to no load alternation. The bearings are only loaded at the lower bearing area; the load here is relatively high. Light edging is not unusual.
Procedure:
Attention: The camshaft bearing between the camshaft gear and the 1st cylinder may only be dismantled and installed by MaK customer service!
1.
Check the running surface of one camshaft bearing and the corresponding camshaft section after the 1st cylinder.
1.1
Remove all rocker arms from the corresponding cylinder and the rocker arms of all cylinders located to the right of the cylinder to be checked to relieve the load on the camshaft (01.02.02.nn). Remove pushrods.
1.2
Remove the injection pump of the cylinder to be checked and all cylinders located to the right of the cylinder to be checked (07.03.01.nn).
1.3
Raise and secure the rocker arms of the cylinder to be checked and all cylinders to the right of the cylinder to be checked (04.04.01.nn).
en / 09.10.2006
IB020282
1/5
Camshaft Bearing
A5.05. 04.01.02.00
Inspection / Disassembly and reassembly M43
1.4
30000, 15000 Loosen the hex head bolts (Fig.1/1) on the left flange of the camshaft section (3). Turn the camshaft to access and remove all bolts which are inaccessible. Remove all hex head bolts. Replace two opposing hex head bolts with longer bolts (W2). Set measure “s“ s = 68 ± 0.5 mm
Z Y
3
13
Y
Z 1 5
4 W2
s
1
en / 09.10.2006
IB020282
2/5
04
Camshaft Bearing
A5.05. 04.01.02.00
Inspection / Disassembly and reassembly M43
30000, 15000
04
Note: When removing the hex head bolts, make sure that the injector cam faces up vertically (TDC) after turning the engine for the last time.
Attention: The camshaft may only be turned when the connecting bolts are loosened when -
the rocker arms of the camshaft section to be replaced and all rocker arms to the right of the section to be replaced have been removed and
- the camshaft section is pulled out far enough, that the straight pin (5) and the recess are no longer engaged!
1.5
Remove retaining bolt (Fig. 2/11).
1.6
Drive the camshaft bearing (4) out to the right with a suitable wood block and rubber mallet. Fill the bearing shell with cardboard.
2
12 10
1 1.7
Place cardboard or similar material around the camshaft bearing journal.
1.8
Slide the camshaft to the right until it stops (distance “s“) with a strip of wood. Distance s = 68 ± 0.5 mm
1.9
11
4
Remove bolts (Fig. 1/W1).
Attention: Apply no excessive or sudden force when sliding! Do not damage the bearings or bearing journals. 2
Note: To check the last camshaft bearing, remove the oscillation damper (Fig. 2/10) (04.09.01.nn) and slide to the right as far as possible!
en / 09.10.2006
IB020282
3/5
Camshaft Bearing
A5.05. 04.01.02.00
Inspection / Disassembly and reassembly M43
1.10
30000, 15000
04
Check crankshaft bearing. Replace (04.04.01.nn) if: - the wear pattern is bad (running surface, lower bearing area, scoring).
1.11
Check the camshaft bearing for scuffing on the back of the bearing and replace if necessary (04.04.01.nn).
1.12
Check the running surfaces of the bearing journals of all available crankshaft sections for scoring.
1.13
Replace defective camshaft sections and check the corresponding bearings (04.04.01.nn).
1.14
Install camshaft (04.04.01.nn).
1.15
Install bearing and align with positioning bore.
1.16
Install retaining bolt (Fig. 2/11). Tighten bolt to M = 130 Nm
Note: Install the oscillation damper after checking the last camshaft bearing (04.09.01.nn)! 2.
Check the running surface of all camshaft bearings and camshaft sections after the 1st cylinder.
2.1
Release and raise all rocker arms (04.04.01.nn).
2.2
Loosen the hex head bolts (Fig.1/1) on the left flange of the camshaft section (3) of the 1st cylinder. Turn the camshaft to access and remove all bolts which are inaccessible. Remove all hex head bolts. Replace two opposing hex head bolts with longer bolts (W1). Set measure “s“.
2.3
Remove the retaining bolts (Fig. 2/11) on the camshaft bearings one after the other.
2.4
Drive out the camshaft bearings (4) to the right with a suitable wood block and rubber mallet. Fill the bearing shell with cardboard.
en / 09.10.2006
IB020282
4/5
Camshaft Bearing
A5.05. 04.01.02.00
Inspection / Disassembly and reassembly M43
30000, 15000
04
2.5
Slide the camshaft to the side (1.4 to 1.7).
2.6
Prop up the oscillation damper and the camshaft section above the 1st cylinder.
2.7
Check the running surfaces of the bearing journals of all camshaft sections for scoring.
2.8
Replace defective camshaft sections (04.04.01.nn).
2.9
Install camshaft (04.04.01.nn).
2.10
Install retaining bolt (11). Tighten bolt to M = 130 Nm
2.11
Disengage the rotor.
2.12
Install rocker arms and complete all remaining work (04.04.01.nn).
en / 09.10.2006
IB020282
5/5
Bottom part for Valve Mechanism
A5.05. 04.02.00.30
Maintenance / Disassembly and reassembly M43
See also:
01.01.01.nn, 01.02.01.nn, 07.02.01.nn
Spare parts list:
B1.05.04.433502
Time requirement:
2 Pers./ 2,00 h
04
Personnel qualification: skilled engine hand / Assistant engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Mounting and removal device for lower valve drive consisting of: Support, compl. Guide rail, compl. Bracket with hexagon bolt Carriage Arm, compl. (3x) Support (only on cyl.1) Screw Tubular hexagon box wrench Torque wrench 200-500 Nm
W1
432135 A
W1.1 W1.2 W1.3 W1.4 W1.5 W1.6 W1.7 W1.8 * W2 *
1.9454-500
* no picture
Auxiliary materials: Molykote Paste "G Rapid Plus" ** Vaseline ** ** or equivalent product
Procedure:
1.
Disassembly:
1.1
Engage barring device.
1.2
Disassemble corresponding rocker arm bracket (01.02.01.nn).
1.3
Mark and disassemble push-rods (7). Push-rods may not be interchanged.
1.4
Disassemble corresponding camshaft cover.
1.5
Disassemble corresponding injection pump (07.02.01.nn)
1.6
Disassemble injection pump drive.
1.7
Loosen circlips (8) of oil pipes (9) and shift towards the centre of the pipe.
en / 30.09.2008
IB024513
1/7
Bottom part for Valve Mechanism
A5.05. 04.02.00.30
Maintenance / Disassembly and reassembly M43
04
1.8
Remove oil pipes (9).
1.9
Remove clamping screw (10) and both lower fastening screws (11).
12
12
10
11
11
1.10
Bring into position support (W1.1) and firmly mount to cam follower bracket.
1.11
Bring into position arms (W1.5) and tension them by means of tubular hexagon box wrench (W1.8).
W1.5
W1.1
12
9
en / 30.09.2008
12
IB024513
2/7
Bottom part for Valve Mechanism
A5.05. 04.02.00.30
Maintenance / Disassembly and reassembly M43
1.12
In case of disassembly and assembly at cylinder 1 mount support (W1.6). Here the camshaft cover is bigger.
W1.6
1.13
Mount guide rail (W1.2). Firmly tighten the nuts only after having aligned all parts of the device.
W1.4
W1.2
1.14
Put on carriage (W1.4). By means of setscrew (15) adjust height if necessary so that the screw
en / 30.09.2008
IB024513
3/7
04
Bottom part for Valve Mechanism
A5.05. 04.02.00.30
Maintenance / Disassembly and reassembly M43
04
holes coincide.
W1.7
W1.2
9 9 W1.4
15
1.15
Screw together carriage (W1.4) and support (W1.1). Use screws (W1.7).
1.16
Remover upper fastening screws (12) of the cam follower bracket.
1.17
Bring into position bracket with hoist (W1.3).
Attention: Before that, roll out valve drive a bit on carriage (W1.4). Pay attention to spacer sheets (13). Spacer sheets (13) are adjusted to each valve unit individually and must not be interchanged upon reassembly. In order to have sufficient clearance, lower inlet and exhaust cam follower a bit by adjusting the arms (W1.5) with tubular hexagon box wrench (W1.8).
en / 30.09.2008
IB024513
4/7
Bottom part for Valve Mechanism
A5.05. 04.02.00.30
Maintenance / Disassembly and reassembly M43
1.18
Engage hoist in support (W1.1) and tension it.
1.19
Roll out valve drive completely on the carriage.
04
W1.3 W1.5
W1.1
Attention: Rope of the hoist must be evenly coiled, otherwise there is a risk of injury.
1.20
Separate support (W1.1) from carriage (W1.4) by removing screws (W1.7).
1.21
Disassemble carriage (W1.4).
1.22
Disassemble guide rail (W1.2).
1.23
Lower complete valve drive with hoist and deposit on a suitable base support.
1.24
Remove support (W1.1).
en / 30.09.2008
IB024513
5/7
Bottom part for Valve Mechanism
A5.05. 04.02.00.30
Maintenance / Disassembly and reassembly M43
04
2.
Assembly:
2.1
Bring into position support (W1.1) and firmly mount to cam follower bracket.
2.2
Bring into position arms (W1.5) and tension them by means of tubular hexagon box wrench (W1.8).
2.3
Raise complete valve drive with hoist up to limit stop.
2.4
Mount guide rail (W1.2).
2.5
Mount carriage (W1.4).
2.6
Deposit valve drive on carriage (W1.4).
2.7
Separate connection to hoist.
2.8
Screw together carriage (W1.4) and support (W1.1). Use screws (W1.7).
2.9
Carefully roll valve drive into camshaft casing.
2.10
Make sure there is sufficient clearance for inlet and exhaust cam followers. Possible correction by adjusting the arms (W1.5).
2.11
Insert spacer sheets (13).
Attention: Spacer sheets (13) are adjusted to each valve unit individually and may not be interchanged upon reassembly.
2.12
Insert the two upper fastening screws (12) of the valve drive with extension sleeves (14) and slightly tighten.
2.13
Lower cam follower and disassemble arms (W1.5).
2.14
Separate carriage (W1.4) and support (W1.1).
2.15
Disassemble carriage.
2.16
Disassemble guide rail (W1.2).
2.17
Disassemble bracket with hoist (W1.3).
en / 30.09.2008
IB024513
6/7
Bottom part for Valve Mechanism
A5.05. 04.02.00.30
Maintenance / Disassembly and reassembly M43
04
2.18
Remove support (W1.1).
2.19
Lubricate threads and contact faces of screws (10, 11, 12) with Molykote Paste "G Rapid Plus".
2.20
Insert the two lower fastening screws (11) with extension sleeves (14) and slightly tighten them.
2.21
Tighten fastening screws (11, 12) "crosswise" gradually until a torque of M = 455 Nm is reached.
2.22
Assemble clamping screw (10) and tighten to a torque of M = 455 Nm.
Alternative tightening instructions for screws (10,11,12): Lubricate threads and contact faces of screws (10, 11, 12) with Molykote Paste "G Rapid Plus" and tighten screws in two steps as follows: Step 1: Preload screws to M = 270 Nm. Step 2: Mark screws and continue turning by a torque angle of α = 30°° by means of box wrench SW 35 (spanner size) (30° ≤ 1/2 hexagon) 455 Nm = 270 Nm + 30°° 2.23
Slightly lubricate new O-rings (16) with Vaseline and insert into the oil pipe grooves untwisted.
2.24
Insert oil pipes (9) into the cam follower shaft and assemble circlips (8).
2.25
Insert push-rods according to their marking.
2.26
Assembly injection pump drive.
2.27
Assemble injection pump (07.02.01.nn) .
2.28
Assemble push-rods (7).
2.29
Assemble rocker arm bracket (01.02.01.nn).
2.30
Check valve clearance (01.01.01.nn) .
2.31
Assemble valve cover.
2.32
Start prelubrication pump and check oil pipes (9) for leaks.
2.33
Assemble camshaft cover.
en / 30.09.2008
IB024513
7/7
Camshaft
A5.05. 04.04.01.08
Repair / Disassembly and reassembly M43
See also:
01.01.01.nn, 01.02.01.nn, 04.01.01.nn, 04.01.02.nn, 07.02.01.nn
Spare parts list:
B1.05.04.433120
Time requirement:
1 Pers./ 3,00 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
04
---------------------------------------------------------------------------------------------------------------------------------Tools: Sling Hex bolts Torque wrench 20 - 200 Nm Torque wrench 200 - 500 Nm Insert Reversible ratchet
W1 * W2 * W3 * W4 * W5 * W6 *
439230 A 1.9454-202 1.9454-500 1.9424-030 1.9459-033
* no picture
Auxiliary materials: Molykote Paste “G-Rapid Plus” ** ** or equivalent product
Procedure: Attention: The camshaft may only be turned after the bolted connection is loosened when the rocker arms of the camshaft section to be replaced and all rocker arms to the right of the section to be replaced have been removed or raised and secured and the straight pin (Fig. 1/5) has been removed from the bearing journal (13) or the left camshaft section is removed!
1.
Disassembly
1.1
Open the indicator valves and remove the camshaft cover with housing covers and gaskets on the control side.
1.2
Remove all rocker arms for the corresponding cylinder and the rocker arms of all cylinders located to the right of the camshaft section to be removed to relieve the load on the camshaft.
en / 31.01.2008
IB025492
1/8
Camshaft
A5.05. 04.04.01.08
Repair / Disassembly and reassembly M43
1.3
Remove the injection pump of the corresponding cylinder and for all cylinders to the right of the cylinder being checked (07.03.01.nn).
1.4
Remove the lifters and the camshaft section for the corresponding cylinder and all camshaft sections to the right of the camshaft section being removed. Raise and secure the rokker arms for the intake and exhaust valves as well as for the injection pump drives for the corresponding cylinder and all cylinders to the right of this cylinder.
Z Y
3
13
Y
Z 1 5
4 W2
s
1
en / 31.01.2008
IB025492
2/8
04
Camshaft
A5.05. 04.04.01.08
Repair / Disassembly and reassembly M43
1.5
When removing the last camshaft section:
1.5.1
Remove the oscillation damper (Fig. 2/10) (04.09.01.nn) and slide to the right as far as possible.
1.5.2
Remove the intermediate piece (12).
1.6
Place the sling (Fig. 3/W1) around the camshaft section (3) between the exhaust cam and injector cam and connect to the lifting unit through the injection pump bore in the crankcase.
1.7
Tighten the sling (W1) with the lifting unit.
1.8
Remove the retaining bolt (11).
1
12
04 10
11
4
2
W1
3
en / 31.01.2008
IB025492
3
11
3/8
Camshaft
A5.05. 04.04.01.08
Repair / Disassembly and reassembly M43
1.9
Drive the right camshaft bearing (Fig. 1/4) out of the camshaft section with a suitable wood block and rubber mallet. Fill the camshaft bearing (4) with cardboard.
1.10
Loosen the hex head bolts (Fig. 1/1) on both camshaft section (3) flanges. Turn the engine to make access any inaccessible hex head bolts and remove all bolts from the left flange. Replace two opposing hex head bolts with longer bolts (W2). Set measure “s“. s = 68 ± 0.5 mm Remove all hex head bolts on the right flange of the camshaft section.
1.11
Place cardboard or similar material around the camshaft bearing journal.
1.12
Slide the camshaft to the right until it stops (distance “s“) with a strip of wood. Secure the remaining sections. Distance s = 68 ± 0.5 mm
3
3
a
b
3
c 4
en / 31.01.2008
IB025492
4/8
04
Camshaft
A5.05. 04.04.01.08
Repair / Disassembly and reassembly M43
04
Attention: Apply no excessive or sudden force when sliding! Do not damage the bearings or bearing journals.
1.13
Secure the right end of the camshaft with wooden wedges.
Attention: Do not tilt the camshaft sections too much! Be very careful!
1.14
Fill the camshaft trough with cardboard or a similar material.
1.15
Pull the camshaft section (Fig. 4/3) out of the bearing block to the left while lowering the lifting unit. Swing the camshaft section 90° and lift from the camshaft trough. Note the weight of the section (ca. 200 kg).
1.16
Remove camshaft bearing (4) and inspect (04.01.02.nn), replace if necessary.
2.
Assembly
2.1
Press the straight pin (Fig. 5/5) into the flange until it stops in accordance with the numbering (see table) on the camshaft section flange. Camshaft section for cylinder
Insert straight pin for code
1 2 3 4 5 6 7 8
4 7 2 5 4 3 6 1
7
1
2
6
5
3 4 5
3 5
en / 31.01.2008
IB025492
5/8
Camshaft
A5.05. 04.04.01.08
Repair / Disassembly and reassembly M43
2.2
Oil the inside and outside of the camshaft bearing (Fig. 1/4) thoroughly and place on intake cam of the right camshaft section.
2.3
Place camshaft section (3) facing the coupling side in the corresponding camshaft trough on cardboard or similar material.
2.4
Place the sling (Fig. 3/W1) around the camshaft section between the exhaust cam and the injection pump cam and connect to lifting unit through the injection pump bore in the crankcase.
2.5
Raise the lifting unit slowly and slide the camshaft section bearing journal into the bearing bore in the crankcase carefully.
Attention: Do not tilt the camshaft sections too much! Be very careful!
2.6
Align the camshaft section with the straight pin towards the bore in the bearing journal or in the bearing flange built into the left end of the camshaft section.
2.7
Attach the camshaft section to the right camshaft section flange by tightening two opposing hex head bolts (Fig. 1/1) hand tight.
2.8
Slide the camshaft section carefully to the left with a wood strip until the straight pin (5) and the recess in the camshaft section engage securely. When sliding the camshaft section to the left, the free-hanging camshaft section must be supported.
Attention: Apply no excessive or sudden force when sliding! The camshaft gear may not be slid by the camshaft section!
2.9
Apply Molykote to all hex head bolts (1).
2.10
Place the hex head bolts in the left camshaft section flange (as many as possible) and gradually tighten at least three bolts to M = 420 Nm crosswise. Bolt the bores which cannot be reached at this time later!
2.11
Align the retaining bore in the camshaft bearing with the bore for the retaining bolt (11) in the crankcase. The notch in the bearing shell must be at the top.
en / 31.01.2008
IB025492
6/8
04
Camshaft
A5.05. 04.04.01.08
Repair / Disassembly and reassembly M43
2.12
Drive the camshaft bearing (4) into place evenly with a suitable wood block and rubber mallet. Do not tip the bearing. The bearing shell must face the retaining bore.
2.13
Apply Molykote to the retaining bolt (11) and install. Tighten the bolt to M = 130 Nm
2.14
Lower the lifting unit and remove the sling (Fig. 1/W1).
2.15
Screw the remaining hex head bolts into the right and left camshaft section flanges by hand. (Turn the engine if necessary). Tighten the bolts (1) gradually crosswise to M = 420 Nm
2.16
After installing the last camshaft section:
2.16.1
Place the intermediate piece (Fig. 2/12) on the camshaft section (3) securely. The recess must be placed into the camshaft section completely.
2.16.2
Insert the hex head bolts (1) into the connection between the camshaft section and the intermediate piece. Tighten the bolts hand tight. Then tighten the bolts gradually crosswise to M = 420 Nm
Alternative Tightening Instruction for Bolts (1): Apply Molykote Paste "G-Rapid Plus" to threads and contact surfaces of the bolts (1) and tighten them in two steps as follows: Step 1: Preload screws with a torque of M = 176 Nm. Step 2: Mark the screws and continue turning by a torque angle of α = 30°° by means of a single-end box wrench SW (spanner size) 30 (30° ≈ 1/2 hexagon) 420 Nm = 176 Nm + 30°°
en / 31.01.2008
IB025492
7/8
04
Camshaft
A5.05. 04.04.01.08
Repair / Disassembly and reassembly M43
04 2.16.3
Install the oscillation damper (10 ) (04.09.01.nn).
2.17
Install valve actuators and the injection pump drives.
2.18
Install the lifters.
2.19
Install the rocker arms and check valve clearance (01.01.01.nn).
2.20
Install injection pump (07.02.01.nn).
2.21
Check oil flow through camshaft.
2.22
Mount housing cover.
2.23
Close indicator valves.
2.24
Remove turning unit (12.08.01.nn).
en / 31.01.2008
IB025492
8/8
Timing Gear Train
A5.05. 04.08.01.02
Inspection / Checking M43
15000, 3750
04
See also:
02.01.01.nn
Spare parts list:
B1.05.04.435140
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
------------------------------------------------------------------------------------------------------------------------------Inspection: of the tooth profiles and oil nozzle
every
3,750 h
the axial clearance of the step gear
every
15,000 h
W1 *
1.9075-003
Tools: Dial gauge with bracket Feeler gauge * no picture
Auxiliary materials: Molykote Paste “G-Rapid“ ** ** or equivalent product
Procedure:
1.
Checking the tooth profiles and oil nozzles.
1.1
Remove the timing cover from the control and exhaust side.
en / 25.03.2004
IB024301
1/3
Timing Gear Train
A5.05. 04.08.01.02
Inspection / Checking M43
15000, 3750
04
1.2
Check the tooth profiles on the camshaft gear (Fig. 1/2), step gear (1) and crankshaft gear (3) for pitting, misaligned running, loose metal, etc.
1.3
Measure the tooth clearance between the step gear and the camshaft gear (2) and between the step gear and the crankshaft gear (3). Nominal values
1.4
x = 0.23 - 0.40 mm z = 0.23 - 0.41 mm
Check the function and seat of the oil nozzles (4 and 5).
en / 25.03.2004
IB024301
2/3
Timing Gear Train
A5.05. 04.08.01.02
Inspection / Checking M43
2.
15000, 3750
04
Measure the axial clearance of the step gear (Fig. 2/s) with a feeler gauge or dial gauge. Nominal value
s = 0.6 - 1.1 mm
If damage is found on the teeth or if one of the permissible nominal values (tooth or axial clearance) is exceeded, MaK customer service must be informed. 2.1
Check the gaskets and install the timing gear cover on the exhaust and control side.
en / 25.03.2004
IB024301
3/3
Timing Gear Train
A5.05. 04.08.02.02
Maintenance / Disassembly and reassembly M43
04
See also:
02.01.01.nn
Spare parts list:
B1.05.04.435140
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench 20 - 200 Nm Reversible ratchet 1/2" Feeler gauge
W1 * W2 * W3 *
1.9454-202 1.9459-033 1.9075-003
* no picture
Auxiliary materials: Molykote Paste “G-Rapid” ** ** or equivalent product
en / 31.01.2008
IB024305
1/3
Timing Gear Train
A5.05. 04.08.02.02
Maintenance / Disassembly and reassembly M43
04
Note: The work specified in the following can only be carried out when the flywheel is removed.
Procedure: 1.
Replace the O-ring (Fig. 2/6) on the step gear shaft (2).
1.1
Loosen the hex head bolts (7 and 8) and remove with sleeves (5) and locking plates (3 and 4).
1.2
Remove the crankcase cover for the 1st cylinder.
1.3
Press the step gear shaft (2) out of the gear housing towards the coupling only far enough that the O-ring (6) is accessible.
1.4
Replace the O-ring (6) and slide the gear shaft back into place.
en / 31.01.2008
IB024305
2/3
Timing Gear Train
A5.05. 04.08.02.02
Maintenance / Disassembly and reassembly M43
04
Attention: Do not damage the O-ring (6).
1.5
Apply Molykote to the contact surfaces and threads of the hex head bolts (7 and 8).
1.6
Mount hex head bolts (7) and hex head bolts (8) with sleeves (5) and locking plates (3 and 4) and tighten hand tight.
1.7
Tighten hex head bolts (7 and 8) to M = 190 Nm
en / 31.01.2008
IB024305
3/3
Governor Drive
A5.05. 04.08.03.02
Inspection / Disassembly and reassembly M43
15000
04
See also: Spare parts list:
B1.05.03.431110, B1.05.04.434111
Time requirement:
1 Pers./ 2,00 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Inspection: -
contact pattern at hypoid gear pair contact pattern at intermediate wheel channel toothing of governor drive shaft end play of cam shaft toothed wheel
every
15,000 h
Tools: Torque wrench 20 - 200 Nm Reversible ratchet 1/2"
W1* W2*
1.9454-202 1.9459-033
* not shown
Ancillary materials: Molykote Paste “G-Rapid Plus“ ** Sealant “Dirko 610.020“ ** ** or equivalent product
Procedure: 1.
Disassembly
1.1
Detach governor floater linkages from governor (Fig. 1/10) This is achieved by:
1.1.1
Locking stop lever in stop position.
1.1.2
Removing locking nut (1) with distance bushing (4), bolt (6) and washer (2).
1.1.3
Removing spring link (7).
1.2
Removing hexagonal screws (11) and lifting governor (10).
en / 13.02.2009
IB023455
1/4
Governor Drive
A5.05. 04.08.03.02
Inspection / Disassembly and reassembly M43
15000
1.3
Removing hexagonal screws (Fig. 2/20) with resilient sleeves (21).
1.4
Lightly attach governor drive housing (23) with sling to hoist and carefully lift out of cylinder crank housing.
04
Attention: Risk of damage to lubricating oil passage sleeve (30) and O-ring (31).
1.5
Deposit governor drive housing (23) onto suitable surface.
1.6
Clean bearing surfaces on engine block.
en / 13.02.2009
IB023455
2/4
Governor Drive
A5.05. 04.08.03.02
Inspection / Disassembly and reassembly M43
15000
1.7
Check tooth profiles of hypoid gears (Fig. 3/40, 41) for pitting, off-track running or blow-outs. Check intermediate wheel (42).
1.8
Check channel toothing of governor drive shaft (43) and governor (Fig. 1/10) for wear, clean if necessary.
1.9
Check all oil lubrication holes for lubricating the governor drive gear and the hypoid gears for proper flow.
en / 13.02.2009
IB023455
04
3/4
Governor Drive
A5.05. 04.08.03.02
Inspection / Disassembly and reassembly M43
15000
04
2.
Assembly
2.1
Provide lubricating oil passage sleeve (Fig. 2/30) with new O-rings (31).
2.2
Place governor drive housing (23) carefully onto engine block by means of a crane. During this operation absolutely pay attention to lubricating oil passage sleeve (30) and dowel pins (Fig. 3/ 32).
2.3
Insert screws (Fig. 2/20) with resilient sleeves (21).
2.4
Tighten screws (20) crosswise.
2.5
Brush bearing surface of governor with “Dirko 610.020“. Put governor (Fig. 1/10) onto bearing surface of governor drive (Fig. 2/23).
Note: The channel toothing of the governor shaft must slide easily into the channel toothing of the governor drive shaft (Fig. 3/43). 2.6
Insert screws (Fig. 1/11) and tighten firmly.
2.7
Fit governor floater linkages in reverse order to removal. If necessary, carry out readjustment of governor (also see governor adjustment, Book C).
en / 13.02.2009
IB023455
4/4
Vibration Damper on Camshaft
A5.05. 04.09.01.00
Repair / Disassembly and reassembly M43
15000
04
See also: Spare parts list:
B1.05.03.431112, B1.05.04.433140
Time requirement:
1 Pers./ 1,00 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench 20 - 200 Nm
W1*
1.9454-202
* not available as figure
Auxiliary material:
1
Molykote paste "G-Rapid Plus" **
2
** or a product of equivalent standard
Note: After 15,000 operating hours the vibration damper must be exchanged against a new one.
~
Safety note!
3
4
5
Attention, there is a risk of injury! Never open a vibration damper
Sequence of operations: 1.
Disassembly
1.1
Remove lateral and face casing covers.
1.2
Release screws (2) and remove together with extension sleeves (3).
1.3
Lift the vibration damper (1) off the intermediate piece (4). Remove distance ring (5).
2.
Reassembly
2.1
Clean contact face of damper (1) and intermediate piece (4) (fat free).
2.2
Lubricate the thread of screw (2) with Molykote-Paste "G-Rapid".
en / 31.01.2008
IB020809
1/2
Vibration Damper on Camshaft
A5.05. 04.09.01.00
Repair / Disassembly and reassembly M43
15000
04
2.3
Mount distance ring (5)..
2.4
Push new damper (1) onto intermediate piece (4) and screw in screws (2) with extension sleeves.
2.5
Tighten screws (2) with a torque of M = 130 Nm
2.6
Mount lateral and face casing covers.
en / 31.01.2008
IB020809
2/2
Control Shaft Bearings
A5.05. 05.01.02.00
Maintenance / Checking M43/VM43
750
05
See also:
05.08.01.nn
Spare parts list:
B1.05.04.434110, B1.05.05.434210, B1.05.05.434523
Time requirement:
1 Pers./ 0,20 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
---------------------------------------------------------------------------------------------------------------------------------Maintenance: Oil control shaft
every
750 h
Auxiliary materials: Multi-purpose grease as per A4.05.08.nn
Procedure: 1.
Remove the control shaft, injection pump and operator stand covers.
2.
Check the control shaft and shaft to emergency stop lever in the operating console and oil lightly at the bearing surfaces.
Attention: After cleaning with solvents, a light coat of oil must be applied to all glossy metal parts to protect them from rust and corrosion! Special attention must be paid to ensure that all bearing surfaces affected by the cleaning procedure are oiled carefully!
3.
Grease the following bearings with multi-purpose grease: •
Jointed heads on the connecting rod between the shaft in the operating console and the control shaft.
•
Jointed heads on the spring member between the control shaft and the control unit.
Remove all grease which exits the bearing carefully. 4.
Oil all movable bearings on the jointed lever between the control shaft and injection pump lightly.
5.
Reinstall cover.
en / 12.06.2008
IB020299
1/1
Starting Valve
A5.05. 05.02.01.02
Maintenance / Disassembly and reassembly M43
7500
See also:
A3.05.nn
Spare parts list:
B1.05.05.1.4906
Time requirement:
1 Pers./ 1,20 h
05
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: of the starting valve
every
7.500 h
Tools: Fork wrench
W1*
0.9105 A
* not available as figure
Auxiliary material: Molykote paste “ G-Rapid “ ** ** or a product of equal standard
~
Safety note: Danger of accident! Be careful during disassembly! Position (Fig. 2/17) is under spring tension.
Note: All pneumatic elements are lubricated with a special grease (see A4.05.08.nn; multi-purpose grease) which ensures sufficient lubrication for several years. In the event of a repair only this grease may be used. If other lubricants are used, the function of the components cannot be guaranteed.
en / 30.11.1999
IB020586
1/4
Starting Valve
A5.05. 05.02.01.02
Maintenance / Disassembly and reassembly M43
7500
05
Sequence of operations: 1.
Close the main shut-off valve on the air receiver.
1.1
Vent the air pipes on the engine.
1.2
Disassemble all pipework and cable connections from the starting valve.
Disassembly: 2.
Unscrew the screws (Fig. 1/1) and disassemble the starting valve from the engine.
1
1
en / 30.11.1999
IB020586
2/4
Starting Valve
A5.05. 05.02.01.02
Maintenance / Disassembly and reassembly M43
7500
3.
Disassemble the protective cover (Fig. 2/2).
3.1
Disassemble the silencer (3) and remove the solenoid (4).
3.2
Disassemble the armature (5) by slackening the screw connection (6). Pay attention to the spring (7).
3.3
Slacken the screw connection (8) and pull out the emergency actuation knob (9). Pay attention to the spring (10).
3.4
Disassemble screw connection (11) and nut (12).
3.5
Disassemble piston (13) by means of the fork wrench (W1).
05
Note: When disassembling nut (12) and piston (13) secure the spindle (14) against being dragged along. To this end put a wrench through the air duct (15) on the key face of the spindle (14) and counterhold it. 3.6
Unscrew the hexagon socket screws (16) and disassemble flange (17). Pay attention to the spring (18).
3.7
Remove the spindle (14) completely from the casing.
4.
Clean the casing by means of gas oil. Check the sliding surfaces for rust formation, if necessary carefully rework with polishing cloth.
en / 30.11.1999
IB020586
3/4
Starting Valve
A5.05. 05.02.01.02
Maintenance / Disassembly and reassembly M43
7500
05
Reassembly: 5.
Renew all O-rings, piston guide ring (19) and other sealing rings. Grease the sliding surfaces slightly.
5.1
Insert a new, completely assembled spindle (14).
5.2
Assemble all valve parts in inverse disassembly order.
5.3
Assemble the emergency actuation knob (9) with a new spring (10) and a new O-ring (20).
Note: Daub the threads of all fixing screws slightly with Molykote paste "G-Rapid". 5.4
Put the finish assembled valve onto the engine. Firmly tighten the screws (Fig. 1/1)..
5.5
Mount all pipe and cable connections.
5.6
Mount the protective cover (Fig. 2/2).
6.
Open the main shut-off valve on the air receiver.
7.
Carry out a functional and leakage test with starting air.
en / 30.11.1999
IB020586
4/4
Control Rod
A5.05. 05.08.01.00
Maintenance / Disassembly and reassembly M43
7500
05
See also:
05.01.02.nn
Spare parts list:
B1.05.05.434210
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
------------------------------------------------------------------------------------------------------------------------------Maintenance: Replace the bushings
every
7,500 h
Procedure: 6 8 1.
Remove bushings (1).
1.1
Disassemble the connection between the injection pump control rod (Fig. 1/7) and jointed lever (8) on the control shaft.
1.2
Remove the bracket (6) from the jointed lever.
1.3
Remove the bushings (Fig. 2/1) from the bracket (6).
2.
Install bushings (1).
7
X
Note: As a matter of principle, new nuts (2) are to be used after each loosening operation [turning back of the nuts (2)] 2.1
Place new bushings (1) into the bracket (6).
2.2
Connect the bracket (6) to the jointed shaft by installing the pin (3), the washers (4 and 5) and a new nut (2).
2.3
Tighten the nut (2) with a torque of M = 40 Nm
en / 06.08.2008
IB020301
1
1/2
Control Rod
A5.05. 05.08.01.00
Maintenance / Disassembly and reassembly M43
7500
2.4
Connect the bracket (6) to the injection pump control rod by installing the pin (3), the washers (4 and 5) and a new nut (2).
2.5
Tighten the nut (2) with a torque of M = 40 Nm
Attention: Check the linkage for ease of movement by pressing against the jointet lever. If the linkage is sluggisch, readjust the injection pump and / or the linkage on the control shaft.
X 4
1
6
6
2
1
5
3
8
2
en / 06.08.2008
IB020301
2/2
05
Compressed-Air Filter
A5.05. 05.09.06.00
Maintenance / Cleaning M20/M25/M32/M43/M453C/M552C/M601C
24, 7500
05
See also: Spare parts list:
B1.05.05.1.4900
Time requirement:
1 Pers./ 0,20 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance/cleaning: Drain compressed-air filter:
every
24 h
Disassemble and clean compressed-air filter:
initially
150 h
Disassemble and clean compressed-air filter:
every
7,500 h
Auxiliary material: Nitro-Solvents * * or a product of equal standard
~
Safety note: Close feed air lines and depressurize air system before every disassembly!
Note: It is to be checked to what extent following units/systems (emergency stop) in the circuit are affected in their functioning by the execution of the disassembly and cleaning measures!
en / 30.05.2000
IB021438
1/2
Compressed-Air Filter
A5.05. 05.09.06.00
Maintenance / Cleaning M20/M25/M32/M43/M453C/M552C/M601C
24, 7500
05
Sequence of operations: 1.
Drain compressed-air filte
1.1
Loosen drain plug (7) and empty filter completely.
1.2
Close drain plug.
2.
Disassemble compressed-air filter and clean
2
2.1
Loosen drain plug (7) and drain filter completely.
3
2.2
1
4
Close compressed-air feed line and secure.
5
2.3
Relieve compressed-air filter via drain plug.
2.4
Loosen housing cap (5) and remove, check O-ring (1) and replace if necessary.
2.5
Loosen Phillips screw (4), remove with guide (3) and filter element (2).
2.6
Remove locking ring (8), unscrew drain plug and check O-ring (6), replace if necessary.
2.7
Clean all disassembled parts and check for reuse.
2.8
Assemble compressed-air filter in reverse sequence. Open shut-off valve in the compressed-air supply line.
2.9
Close drain plug after a short while.
en / 30.05.2000
6 8
IB021438
7
2/2
Compressed-Air Filter
A5.05. 05.09.06.01
Maintenance / Cleaning M20/M25/M32/M43
24, 7500
See also:
C5.05.05.45.23.nn
Spare parts list:
B1.05.05.9.4523
Time requirement:
1 Pers./ 0,20 h
05
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance/cleaning: Drain compressed-air filter:
every
24 h
Disassemble and clean compressed-air filter:
initially
150 h
Disassemble and clean compressed-air filter:
every
7,500 h
Maintenance and trouble shooting: refer to manual C C5.05.05.45.23.nn
en / 23.03.2007
IB024847
1/1
Exhaust Line
A5.05. 06.01.01.12
Inspection / Checking M43
7500
06
See also: Spare parts list:
B1.05.06.437210
Time requirement:
2 Pers./ 3,00 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
------------------------------------------------------------------------------------------------------------------------------Inspection: The exhaust line must be checked for leaks every 7,500 operating hours.
Auxiliary materials: High temperature thread paste "B & W Rivolta G.W.F“ * * or equivalent product
Note: The exhaust line after the exhaust turbine must also be checked within the scope of this inspection. If there are significant oscillations and noised in the exhaust turbine, the flange connection for the exhaust line after the turbine must be loosened and the pipe checked for distortion. In order to prevent damage to the compensators, they may not be subjected to bending or radial force during removal or installation. Bolting the compensators into place during installation results in a slight degree of tension (stretching; ca. 3-5 mm) in the axial direction. All bolts must be installed with high temperature thread paste "B & W Rivolta G.W.F“ to prevent them from burning into place.
Procedure: 1.
~ 2.
Remove the exhaust line shroud.
Safety notice! Be careful, not exhaust line may cause burns! Before commencing work on the exhaust line, check the temperature of the line and allow it to cool! Check all bolted connections to make sure that they are tight.
en / 28.04.2004
IB024377
1/3
Exhaust Line
A5.05. 06.01.01.12
Inspection / Checking M43
3.
7500
06
Carbon, which can especially be found at flange connections and compensators, is a sign of leaks.
Note: If leaks are not caused by cracks in the lines or loose bolted connections, new gaskets must be installed, see 4.8. 4.
Replace any defective exhaust lines as follows:
4.1
Loosen and remove adjacent compensators (4). Compensators may not be subjected to bending or radial forces!
4.2
Loosen the hex head bolts (1) far enough that the upper sections of the clamps (3) are still connected but can be slid easily.
4.3
Slide the upper sections of the clamps aside, remove the chain links (2) from the lower clamp section on both sides.
4.4
Lift both upper clamp sections simultaneously, replace defective exhaust line.
4.5
Prepare fitted pieces (x or y) for the installation of the new exhaust line. Fitted piece length e
en / 28.04.2004
x = 130 mm Y = 195 mm
IB024377
2/3
Exhaust Line
A5.05. 06.01.01.12
Inspection / Checking M43
7500
4.6
Bolt fitted piece or pieces to new exhaust line.
4.7
Mount exhaust gas pipe with new seal (5) and clamp tops.
4.8
Remove fitted piece or pieces, install compensator(s) and bolt securely into place. - Note the indicated direction of flow when installing the compensators (4), see arrow on the flange. Compensators may not be subjected to bending or radial forces! - Insert bolts from the compensator side!
4.9
Tighten screws (6) with a torque of
06
M = 130 Nm. 4.10
Tighten screws (7) with a torque of M = 260 Nm.
5.
Replace any compensators with cracks in the bellows, see 4.8.
6.
Install shroud.
en / 28.04.2004
IB024377
3/3
Charge Air Cooler
A5.05. 06.04.02.30
Maintenance / Disassembly and reassembly M43
06
See also: Spare parts list:
B1.05.06.437250, B1.05.09.438330
Time requirement:
2 Pers./ 1,00 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
------------------------------------------------------------------------------------------------------------------------------Maintenance: The charge air cooler must be removed and cleaned on the air side when the differential pressure before/after the cooler exceeds 1.5 times the test bench value (see acceptance brake certificate A1.10).
Auxiliary materials: Cleaning agent as recommended by the manufacturer, such as:
• Vecom GmbH, Hamburg * • Drew Ameroid GmbH, Hamburg * • UNITOR chemicals * Molykote Paste "G-Rapid Plus“ * * or equivalent product
Procedure: 1.
Disassembly
1.1
Loosen the bleeder bolts, or for engines with continual bleeding, ensure that the corresponding cock valves are open, remove the drain bolts (Fig. 1/5) and drain water from charge air cooler.
1.2
Remove the coolant feed and return lines(4) from the charge air cooler.
en / 17.04.2008
IB024499
1/3
Charge Air Cooler
A5.05. 06.04.02.30
Maintenance / Disassembly and reassembly M43
06
1.3
Remove hexagon screws (Fig. 2/28) with washers (37).
1.4
Pull the charge air cooler (9) out of the housing (3) on exhaust gas side, suspend with hoist and lower into suitable container for cleaning.
1.5
Clean the charge air cooler in accordance with the manufacturer's instructions (see Book C).
1.6
Inspect the housing, drain all condensation by opening the drain line.
~
Attention! Follow the instructions contained in the handbook for the cleaning agent used, protect skin from contact with cleaning agents, wear rubber gloves, safety goggles and respiratory protection if necessary! Ensure adequate ventilation!
en / 17.04.2008
IB024499
2/3
Charge Air Cooler
A5.05. 06.04.02.30
Maintenance / Disassembly and reassembly M43
06
2.
Assembly
2.1
Install charge air cooler in the reverse order as disassembly.
2.2
Insert new O-ring (8) into O-ring sheet (9).
2.3
Slide charge air cooler (2) into the housing (3) carefully.
Note: Apply a light coat of Molykote paste “G-Rapid Plus” to the contact surfaces and threads of all bolts. 2.4
Insert hexagon screws (28) with washers (37).
2.5
Tighten hexagon screws (28) one after the other to a torque of M = 130 Nm.
2.6
Attach coolant supply and return lines (4) to the charge air cooler.
2.7
Tighten drain bolts (5) and fill engine completely with coolant.
2.8
Tighten bleeder bolts or the corresponding cock valves tightly.
en / 17.04.2008
IB024499
3/3
Exhaust gas turbocharger
A5.05. 06.05.00.30
Maintenance / Cleaning M43
24
See also:
A5.05.06.13.01.nn, A3.06.06.nn
Spare parts list:
B1.05.06.437259 nn
Time requirement:
1 Pers./ 0,40 h
06
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: Compressor cleaning
RM43C
every
24 h
Prerequisites: - The compressor stage must be cleaned with the engine at operating temperature and under full load (at least 85 % load ), if possible, i.e., at high turbocharger rpm. - Clean pipes from the intake air system and downstream from each turbocharger.
Note: Deposits and dirt particles may clog the nozzles, negatively impacting the washing results.
Operation of the air-side washing device:
Basic position -
Washing water container (2) :
EMPTY
-
Cap (1)
closed
:
Washing procedure: 1.
Remove cap (1) from water container (2).
1.1
Fill water container (2) with clean water.
1.2
Return cap (1) to its position and tighten.
Attention: A water container that has not been closed or closed incorrectly may cause injury of the operator.
en / 22.11.2007
IB024495
1/3
Exhaust gas turbocharger
A5.05. 06.05.00.30
Maintenance / Cleaning M43
24
06
1 3
2
2.
Push valve handle (3) against the spring and hold for approx. 10 seconds until the entire water volume has been injected.
Note: After cleaning the air side, the engine should be run under load for at least 5 minutes. When the compressor impeller was contaminated, the success of a cleaning can be told by the charge air pressure after the turbocharger.
Cleaning parameters for ABB TPL 76-C33 turboloader are as follows : Turbocharger rpm:
Full load – speed (at least 85 % )
hydrostatic pressure:
none
diaphragm :
yes
water injection time :
10 seconds
water volume :
1.0 liters
en / 22.11.2007
IB024495
2/3
Exhaust gas turbocharger
A5.05. 06.05.00.30
Maintenance / Cleaning M43
24
06
Attention: Because of the increased risk of corrosion, only clear water (drinking water) - never salt water - may be used for cleaning. This water should not contain any coolant treatments or other chemicals which may form deposits in the air ducts.
Attention: The injection tube must never be connected directly to city water, to a different or larger metering device or a larger water container than those provided by Caterpillar Engines.
Attention: Avoid getting uncontrolled amounts of water into the turbocharger or the engine. This can cause personal injury and major damage.
Additional details on the exhaust turbocharger may be found in the maintenance instructions in book C or in the operator’s manual from the turbocharger manufacturer. Instructions for emergency engine operation with a defective turbocharger see User Manual A3.12.01.nn.
en / 22.11.2007
IB024495
3/3
Exhaust gas turbocharger
A5.05. 06.13.01.30
Maintenance / Cleaning M43
150
See also:
A5.05.06.05.00.nn, A3.06.06.nn
Spare parts list:
B1.05.06.437259 nn
Time requirement:
1 Pers./ 0,40 h
06
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: Turbine cleaning
RM43C
every
150 h
Prerequisites: - wet cleaning wet cleaning of the turbine and the nozzle ring requires low exhaust temperatures and low engine load*.
Note The cleaning effect during turbine washing is caused by the mechanical impact of the water droplets as well as by the water solubility of the deposits.
Attention: Please note that these cleaning instructions apply only to the engines listed on cover A0 and thus, only the “low load washing“ cleaning type:
“WASHING OF TURBINE AND NOZZLE RING AT LOW EXHAUST GAS TEMPERATURE OR AT LOW ENGINE LOAD *“ may be used.
* Definition of low engine load: Low engine load means either that the engine - is running either, at zero pitch and rated speed - or, on the grid at rated speed and a max. of 20 % load - or, disengaged at rated speed.
en / 27.11.2008
IB024491
1/4
Exhaust gas turbocharger
A5.05. 06.13.01.30
Maintenance / Cleaning M43
150
06
Requirements for water and air feeds for washing turbine and nozzle ring: Note: Water flow is controlled by a diaphragm (2) upstream from control valve (1).
These are the cleaning parameters for ABB TPL 76-C33 turbocharger:
injection time:
< 430 ° C = a min. of 10 minutes
water pressure before control valve :
2.0 bar ± 0.2 bar
volume flow:
0.43 to 0.50 Liter/sec
needle valve opening diameter
no needle valve
diaphragm:
yes
pressure after pressure reducer:
1.0 bar
temperature before turbine intake:
Quality requirements for water for washing turbine and nozzle ring: Clear freshwater (drinking water) without cleaners or solvents is to be used. The wash water used should have minimal mineral and salt content.
Notes on the cleaning procedure: During cleaning, the water should be drained from the gas outlet casing. The water flow must be controllable, and the water drain line must regularly be checked for deposits. The exhaust gas temperature after the turbocharger will decrease considerably during cleaning (down to between 50° and 100°C).
Attention: At rated speed and zero load, washing water must flow from the drain line (7); if the washing water does not drain, continue to decrease the speed until water drains; if still no water will drain from the line, the washing device, including all its lines, must be checked.
en / 27.11.2008
IB024491
2/4
Exhaust gas turbocharger
A5.05. 06.13.01.30
Maintenance / Cleaning M43
150
06
Cleaning procedure Note
After start of engine or reduction of engine load. The exhaust gas temperature before the turbine may not exceed 430 °C. Lower values will yield improved washing results.
Sequence: 1.
Wait for 10 to 15 minutes until after the exhaust gas temperature has stabilized and is below 430 °C.
2.
Control valve (1) on the control panel is locked in the “Operation (air)“position.
3.
Shut-off valve (4) is closed.
4.
Connecting the water supply to shut-off valve (4) before pressure meter (5). Check if the water supply is ensured.
Note: Before washing check the basic function of the drain (funnel duct) (3). To this end, open drain valve (3) for a short time and then close it again. In doing so, a distinct flow of exhaust gas must be noticeable.
Attention: The emerging exhaut gas may cause burns, therefore never check the drain with unprotected body parts.
6
1
3 7
1
2 5 4
en / 27.11.2008
IB024491
3/4
Exhaust gas turbocharger
A5.05. 06.13.01.30
Maintenance / Cleaning M43
5.
150
06
Open drain valve (3).
Note Along the funnel duct at drain valve (3), the operator may see the results of the cleaning from the cleanliness of the draining water. 6.
Open shut-off valve (4); pressure meter (5) should indicate a pressure of p = 2,0 ± 0, 2 bar .
7.
Pull up on control valve (1) on the control panel and hold for 10 minutes.
8.
Check if exhaust gas temperature after turbocharger decreases.
9.
Closing shut-off valve (4).
10.
Return control valve (1) on the control panel to its “Operation (air)“position.
Attention: After washing, the water supply must be disconnected completely; i.e., including shut-off valve (4) pressure meter (5) from the fitting on control valve (1).
11.
After approx. 5 minutes, close drain valve (3), completing this cleaning procedure.
12.
Disconnect the water supply completely, including shut-off valve (4) and pressure meter (5) from the fitting on control valve (1).
13.
If necessary, the cleaning procedure may be repeated.
14.
If the engine will not be operated for an extended period of time, the drying air may be turned off at valve (6) on the control panel in order to save pressurized air.
Attention: Avoid getting uncontrolled amounts of water into the turbocharger or the engine. This can cause personal injury and major damage. In order to prevent corrosion on the inside surfaces of the housing, the engine must be run at the same load stage for ten more minutes. Due to increased corrosion risk from wash water residues in the exhaust system, we recommend not performing the washing procedure before longer engine standstill periods.
For additional instructions, see User Manual A3.06.06.nn.
en / 27.11.2008
IB024491
4/4
Turbocharger
A5.05. 06.14.01.00
Maintenance / Disassembly and reassembly M43/VM43
12000, 24000, 36000
06
See also:
C5.05.06.10.2n.nn
Spare parts list:
B1.05.06.43725n, B1.05.06.437259
Time requirement:
2 Pers./ 9,00 h
Personnel qualification: Cat/MaK-specialist Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: Exhaust gas turbocharger: Dismount, clean and check every Exchange the nozzle ring and the diffuser after Exchange the axial and radial bearing after
12.000 h 24.000 h 36.000 h
Note: Caterpillar points out that this maintenance sheet has only been configurated for the purpose of maintenance planning. As to any other information regarding service, maintenance, and trouble-shooting please look into the documentation of the manufacturer. Book C contains the operating and maintenance instructions for the
ABB Exhaust Gas Turbocharger Types TPL 71/73/76/77
The manufacturer recommends to carry out the maintenance measures when reaching the above-mentioned operating periods.
Attention:
Please observe the particular safety and assembly instructions in "Book C" of the manufacturer's documentation!
en / 31.10.2007
IB024902
1/1
Injection Pump
A5.05. 07.02.01.00
Repair / Disassembly and reassembly M43
See also:
05.08.01.nn, 07.03.01.nn, 07.05.01.nn, 07.15.01.nn
Spare parts list:
B1.05.04.433580, B1.05.07.438510, B1.05.07.438540, B1.05.08.438480
Time requirement:
1 Pers./ 1,00 h
07
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Lifting device for injection pump Torque wrench Socket , width across flats 41 Socket wrench for indicator valve
W1 W2 * W3 * W5 *
439235 B 435100 A 435102 B 1.9100-060
* not available as figure
Auxiliary material: Molykote paste "G-Rapid Plus" ** ** or a product of equal standard
Sequence of operations: 1.
Disassembly
1.1
Open the indicator valves.
1.2
Remove corresponding camshaft casing cover on camshaft side.
1.3
Remove the high-pressure injection pipe (07.05.01.nn) .
1.4
Mount the injection pump lifting device (Fig. 1/W1). To this end use the threaded holes for fastening the high-pressure pipe.
1.5
Turn the engine so that the cam follower (2) of the corresponding injection pump drive is on the base circle of the fuel cam (1).
en / 16.02.2009
IB020380
1/6
Injection Pump
A5.05. 07.02.01.00
Repair / Disassembly and reassembly M43
1.6
Close the shut-off valves.
1.7
Drain the fuel distributing/collecting line on the fuel duplex filter.
1.8
Remove the lubricating oil leakage line (Fig. 2/10), fuel leakage line (Fig. 3/20, 21) and control air pipes (Fig. 4/30, 31) of the corresponding injection pump.
07
Note: To remove the two outer injection pumps (cylinder 1 and last cylinder) leave the corresponding flange in place. Remove lubricating oil leakage line, fuel leakage line, and control air line. Unscrew the screws of the fuel filter lines (admission and return). 1.9
Remove the fuel distributing/collecting line (07.15.01.nn).
en / 16.02.2009
IB020380
2/6
Injection Pump
A5.05. 07.02.01.00
Repair / Disassembly and reassembly M43
07
1.10
Disassemble the connection (Fig. 5/40) between injection pump control rack (41) and control shaft.
en / 16.02.2009
IB020380
3/6
Injection Pump
A5.05. 07.02.01.00
Repair / Disassembly and reassembly M43
1.11
~
07
Push the control rack (41) as far as possible into the injection pump.
Safety note: Attention! The spring tension of the injection pump drive acts against the injection pump. For removal the cam follower (Fig. 1/2) of the injection pump drive must be on the base circle of the fuel cam (1), if necessary turn the engine.
Attention: In order to avoid damages to the hydraulic wrench (W2), adjust a maximum pressure of p = 500 bar on the high-pressure pump. Adjustment instructions see A6.05.90.10.nn .
1.12
Put on the torque wrench (W2) and evenly slacken the nuts (5). Hydraulic pressure
p = 500 bar
1.13
Attach the injection pump (6) with lifting device (W1) to a crane and lift from the engine block.
1.14
Remove the sleeve (Fig. 5/50) with O-rings (51).
en / 16.02.2009
IB020380
4/6
Injection Pump
A5.05. 07.02.01.00
Repair / Disassembly and reassembly M43
07
Attention: The cylinder-specific spacer plates (7) are secured with round head grooved pins and must not be removed.
2.
Assembly
2.1
Clean the contact surfaces of the injection pump (Fig. 1/6) and the spacer plates (7).
2.2
Clean the contact surfaces of the pressure spring (3) and the pushrod (8) on the tappet body and the bottom spring plate of the injection pump respectively.
Note: For assembly of the injection pump the cam follower (2) of the injection pump drive must be on the base circle of the fuel cam (1), if necessary turn the engine. When mounting the injection pump make sure the control air transition sleeve is correctly positioned in the cooling collar. 2.3
Mount sleeve (Fig. 6/50) with new O-rings (51).
2.4
Renew O-ring (Fig. 1/4) and put the injection pump over the fastening screws. Insert pushrod (8) and pressure spring (3) into the receptacle provided on the injection pump.
~
Safety note: Attention! The spring tension of the injection pump drive acts against the injection pump.
2.5
Lubricate thread and contact surfaces of the nuts (5) with Molykote paste and tighten the injection pump by even, alternate tightening of the nuts. Upon assembly, align the injection pump with respect to the hinged lever (Fig. 5/42).
2.6
Put on the torque wrench (W2) and tighten the nuts (Fig. 1/5) one after the other with a hydraulic pressure of p = 500 bar
( 740 Nm )
2.7
Screw together hinged lever (Fig. 5/42) and control rack (41) of the injection pump (05.08.01.nn). Before assembly check hinged lever and control shaft (43) for ease of movement.
2.8
Mount lubricating oil leakage line (Fig. 2/10), fuel leakage line (Fig. 3/20, 21) and control air pipes (Fig. 4/30, 31).
2.9
Mount the high-pressure injection pipe (07.05.01.nn).
2.10
Mount the fuel distributing/collecting line (07.15.01.nn).
2.11
Mount the screws of the fuel filter lines (admission and return).
en / 16.02.2009
IB020380
5/6
Injection Pump
A5.05. 07.02.01.00
Repair / Disassembly and reassembly M43
2.12
Check the control air pipe (Fig. 4/30) for the stop piston for leakage by means of compressed air.
2.13
Check stop piston / emergency stop device for correct function (10.03.01.nn).
2.14
Mount the camshaft casing cover on camshaft side.
2.15
Open the shut-off valves.
2.16
Fill the fuel system by means of the stand-by pump and have it circulate the fuel for about 10 minutes to vent the system.
2.17
Close the indicator valves.
en / 16.02.2009
IB020380
6/6
07
Injection Pump
A5.05. 07.03.01.03
Maintenance / Disassembly and reassembly M43/VM43
15000, 7500
See also:
07.02.01.nn, 07.03.02.nn
Spare parts list:
B1.05.07.433597
Time requirement:
2 Pers./ 2,00 h
07
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel
-------------------------------------------------------------------------------------------------------------------------------Inspection: a) of one injection pump b) of all injection pumps
every every
Pressure pipe Nozzle testing device Torque wrench 20 - 200 Nm Torque wrench 200 - 500 Nm 2 x cheese head screw M16x150 DIN 912 Adapter for injection pump
W1 * W2 * W3 * W4 * W5 * W6 *
7,500 h 15,000 h
Tools: 1.9470-051 1.9470 H 1.9454-202 1.9454-500 432147 A
* no picture
Auxiliary materials: Molykote Paste "G-Rapid Plus“ ** ** or equivalent product
Note: All components in the injection pump are manufactured to high tolerances in special workshops. This is the only way to ensure proper function. When overhauling a pump, it is important to make sure that the individual pump components such as control sleeve, control rod, etc. are kept with the proper housing. Exchanging or replacing parts can have a significant effect on the fuel flow and may require that the pump is recalibrated on a test bench. Pump elements and pressure valves may only be replaced in complete sets! When replacing complete pump elements or pressure valves, the fuel feed volume is not changed. In order to keep repair costs as low as possible, all elements needing to be overhauled should be sent as a complete set in a manner which prevents them from being exchanged. Protect lapped surfaces, do not touch them. If there is a significant decline in cylinder output, the pressure valve must be checked and replaced if necessary.
en / 29.01.2009
IB022649
1/6
Injection Pump
A5.05. 07.03.01.03
Maintenance / Disassembly and reassembly M43/VM43
15000, 7500
07
Procedure: 1.
Check the pressure valve
1.1
Place the injection pump next to the injector testing unit (W2) with the help of a crane.
1.2
Mount adapter (W6) on valve support (Fig. 1/20) and connect to testing unit (W2) via pressure pipe (W1). The cap screws (33) must be tight!
1.3
Pump to raise pressure to opening pressure pO and see if the pressure valve maintains the set pressure pO = 120 + 5 bar / - 15 bar (new value pO = 120 +/-5 bar) If the pressure valve opens before the the lower opening pressure limit, replace the valve.
en / 29.01.2009
IB022649
2/6
Injection Pump
A5.05. 07.03.01.03
Maintenance / Disassembly and reassembly M43/VM43
2.
Disassembly
2.1
Clean the outside of the injection pump.
2.2
Remove deflector bolts (Fig. 1/6).
2.3
Check defector bolts for cavitation in the deflector surface, replace deflector bolts if necessary (07.03.02.nn).
2.4
Clamp the injection pump with the valve support (20) down.
~
15000, 7500
07
Attention! Caution! The spring tension of the pump spring (9) presses against the lower pump housing section (4)!
2.5
Release and dismantle two opposite screws (Fig. 3/36)
2.6
Replace by longer screws (W5). (Assembly aid).
2.7
Slowly dismantle the remaining screws (36).
2.8
Slowly dismantle the assembly aid screws (W5).
2.9
Carefully lift the bottom pump housing (4) by means of a crane, until the slotted disk (26) of the pump spring (9) is clear.
Note: Take care that the tappet body (2) is also lifted up. 2.10
Take the slotted disk (26) sideways out of the foot of the pump plunger (50).
en / 29.01.2009
IB022649
3/6
Injection Pump
A5.05. 07.03.01.03
Maintenance / Disassembly and reassembly M43/VM43
15000, 7500
07
2.11
Remove the pump spring and check for corrosion.
2.11.1
Remove the control sleeve (5) with spring plate (7).
2.11.2
Check the toothing in the control housing for damage.
2.11.3
Loosen guide bolt (11), remove control rod (Fig. 2/10) and check control rod toothing for damage.
2.12
Remove stop piston (15):
2.12.1
Loosen cap screws (44), remove stop (16) and cap screws.
2.12.2
Remove stop piston and control rod spring (Fig. 2/18).
2.13
Place the injection pump in the clamp with the vale support (Fig. 1/20) up.
2.14
Loosen and remove the cap screws (33) - inner screw hole circle - cross-wise.
2.15
Loosen and remove the cap screws (33) - outer screw hole circle - cross-wise and lift the valve support (20) carefully. Be careful with the pressure valve (22).
2.16
Drive the pump element (1) out of the housing with a suitable wooden dowel.
2.17
Clean all parts with gas oil and a stiff brush and blow out with compressed air.
2.18
Replace all O-rings and gaskets.
2.19
Remove the pressure piece (24) completely with the cap screws (27), slotted disks (26) and spacer plate to replace gaskets (31) and (32).
2.20
Reinstall the complete pressure piece after replacing the gaskets.
Note Insert the O-rings into the grooves with Vaseline without twisting, do not pull the rings over sharp edges. Check all injection pump parts for damage and wear. In particular, check for the following wear: Pump piston
Grooving on the running surface, metering edge wear (cavitation or erosion). Blackening or spots on the piston indicate water in the fuel.
Piston guide
Grooving in the running surface; damage in the pump element sealing surface. Cavitation in the feed bore.
Deflector bolts
Cavitation in the deflection surfaces.
en / 29.01.2009
IB022649
4/6
Injection Pump
A5.05. 07.03.01.03
Maintenance / Disassembly and reassembly M43/VM43
15000, 7500
Tappet
Grooving in the running surface, worn out pressure bar bed.
Pressure valve
Damaged sealing surfaces, worn out seat, worn pressure valve spring.
Stop piston
Worn control rod spring (18), grooving in the stop piston (15).
Lower spring plate
Grooving / damage in the contact surface.
3.
Assembly
3.1
The pump is assembled in the reverse order as disassembly.
07
Attention: As is the case with all injection pump parts, the sealing surfaces cannot and may not be reworked on board! During the assembly absolutely make sure that the pump plunger (50) is in correct position with respect to the guide in the control sleeve (5). When installing the injection pump, make sure that the control rod is positioned exactly in relation to the control sleeve and that the markings on the control sleeve and pump piston match up! A tooth is milled into the control sleeve in order to allow the control sleeve to be positioned in relation to the control rod. The control rod is equipped with a double tooth. The control rod double tooth must mesh with the tooth gap in the control sleeve!
3.1.1
3.1.2
Coat the thread and contact faces of all screws with Molykote-Paste „G-Rapid Plus“ and tighten to the respective torque: Deflector bolts (Fig. 1/6)
M
= 200 Nm
Cheese head screws (27)
M
=
45 Nm
Cheese head screws (35)
M
=
60 Nm
Choke screws (Fig. 2/14 and 17)
M
=
60 Nm
Tighten cheese head screws (Fig. 4/33) - outer hole circle - according to the sequence (1, 7, 4, 10, 2, 8, 15, 11, 3, 9, 12) and cheese head screws (33) - inner hole circle - according to the sequence (13, 16, 14, 17, 15, 18) in three steps. 1. Step according to the sequence by applying M
=
2. Step according to the sequence by applying M
= 120 Nm
3. Step according to the sequence by applying M
= 190 Nm
en / 29.01.2009
IB022649
60 Nm
5/6
Injection Pump
A5.05. 07.03.01.03
Maintenance / Disassembly and reassembly M43/VM43
3.1.3
3.1.4
15000, 7500
07
Tighten cheese head screws (Fig. 4/36) according to the sequence (19, 21, 22, 20) in three steps. 1. Step according to the sequence by applying M
=
40 Nm
2. Step according to the sequence by applying M
=
80 Nm
3. Step according to the sequence by applying M
= 120 Nm
Check the action of the control rod (Fig. 2/10); must be smooth.
en / 29.01.2009
IB022649
6/6
Deflector Bolts
A5.05. 07.03.02.00
Inspection / Replace M43/VM43
3750, 7500
See also:
07.03.01.nn
Spare parts list:
B1.05.07.433597
Time requirement:
1 Pers./ 0,50 h
07
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Inspection: Alternate inspection of the deflector bolts of two injection pumps Replacement of all deflector bolts
every after
3.750 h 7.500 h
Tools: Caliper gauge Torque wrench 20 - 200 Nm
W1* W2*
1.9454-202
* no picture
Sequence of operations: 1.
Remove deflector bolts.
1.1
Check deflector bolts (6) for cavitation (Y) of the deflection surfaces (X).
1.2
Maximum permissible wear value s = 4 mm.
6
X
en / 31.01.2008
IB024554
Y
1/2
Deflector Bolts
A5.05. 07.03.02.00
Inspection / Replace M43/VM43
3750, 7500
1.3
To check this use the depth gauge of the caliper gauge.
1.4
When the above wear value is reached, replace deflector bolts (6) with new ones.
2.
Mount deflector bolts.
2.1
Lightly lubricate thread and contact faces of the deflector bolts with engine lubricating oil.
2.2
Tighten new deflector bolts (6) by hand.
2.3
After that, tighten deflector bolts to a torque of
07
M = 200 Nm.
en / 31.01.2008
IB024554
2/2
Pressure Valve
A5.05. 07.03.03.00
Maintenance / Disassembly and reassembly M43/VM43
See also:
07.05.01.nn
Spare parts list:
B1.05.07.433597
Time requirement:
1 Pers./ 0,50 h
07
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench
20 - 200 Nm
W4 *
1.9454-202
* no picture
Note: When the engine is operated on heavy fuel it is necessary, prior to carrying out any work on the injection system, to run the engine for at least 0.5 hours on distillate fuel to thoroughly flush the entire injection system. In case of overhaul work care has to be taken to ensure that the individual components of an injection pump remain assigned to the respective casing. Only exchange complete pressure valves! When complete pressure valves are exchanged delivery quantity will not be changed! In case of a significant drop in cylinder output check the pressure valve and, if necessary, exchange it completely!
Procedure: 1.
Disassembly
1.1
Close shut-off valves of the fuel line.
1.2
Empty the fuel distributing and collecting pipe on the fuel duplex filter.
1.3
Remove the fuel injector delivery pipe of the corresponding injection pump (07.05.01.nn).
en / 31.01.2008
IB024603
1/2
Pressure Valve
A5.05. 07.03.03.00
Maintenance / Disassembly and reassembly M43/VM43
07
1.4
Remove cheese head srews (1 und 2)..
1.5
Remove valve support (3). Pay attention to dowel pins (5).
1.6
Remove pressure valve (4).
2.
Assembly
2.1
Insert new pressure valve (4) into valve support (3).
2.2
Replace O-ring (6).
2.3
Put valve support (3) onto injection pump. Pay attention to dowel pins (5).
2.4
Lubricate threads and contact faces of cheese head screws (1 und 2) with engine lubricating oil.
2.5
Tighten cheese head screws (1) crosswise to a torque of M = 190 Nm.
2.6
Tighten cheese head screws (2) crosswise to a torque of M = 190 Nm.
2.7
Replace O-ring (7).
2.8
Mount fuel injector delivery pipe (07.05.01.nn).
2.9
Open shut-off valves of the fuel line.
en / 31.01.2008
IB024603
2/2
Injection Pump
A5.05. 07.04.01.00
Maintenance / Replace M43/VM43
See also:
07.02.01.nn
Spare parts list:
B1.05.07.433597
Time requirement:
0 Pers./ 0,00 h
07
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
--------------------------------------------------------------------------------------------------------------------------------
Attention: After mounting a new injection pump it has to be made sure that the pump is preheated with circulating heavy fuel for at least 20 minutes. After start the engine has to be operated for at least 10 minutes at no load. In case that the engine will be switched over from HFO to MDO, it has to be made sure that the max. permissible MDO temperature of 70°° C is not exceeded. The viscosity during HFO operation has to be within 12 - 13 cst.
en / 25.08.2003
IB023228
1/1
High-Pressure Injection Pipe
A5.05. 07.05.01.00
Maintenance / Disassembly and reassembly M43/VM43
07
See also:
07.07.01.nn, 07.08.01.nn
Spare parts list:
B1.05.01.432107, B1.05.07.432260, B1.05.07.438526
Time requirement:
1 Pers./ 0,50 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench 20 - 200 Nm Torque wrench 200 - 500 Nm Open jawed spanner for torque wrench
W1 * W2 * W3 *
1.9454-202 1.9454-500 1.9106 A
* not available as figure
Auxiliary material: Molykote-Paste “G-Rapid Plus“ ** ** or a product of equal standard
Note: In the event of heavy fuel operation the engine is to be operated on distillate fuel for at least 0.5 h before carrying out any work on the injection system in order to thoroughly flush the entire injection system.
Sequence of operations: 1.
Disassembly
1.1
Valve cover is removed.
en / 31.01.2008
IB020575
1/4
High-Pressure Injection Pipe
Maintenance / Disassembly and reassembly
A5.05. 07.05.01.00
M43/VM43
07
1.2
Disassemble the fillister head screws (Fig. 2/1) with cover (3) and O-ring (2).
1.3
Loosen the clamping screw (4) (about 5 turns).
1.4
Loosen the pressure screw (6) and disassemble it.
1.5
Take the transverse thrust piece (15) out of the receptacle (14).
1.6
Screw the cap screw (8) out of the cylinder head/injection nozzle holder (20).
1.7
Take the complete radial thrust piece (13) with cap screw (8) out of the cylinder head through the receptacle (14).
1.8
Disassemble the spring ring (10) from the cylinder head and take out the sleeve (12).
1.9
Remove the fillister head screws (16) and carefully draw the receptacle (14) off the injection pump connection (17).
en / 31.01.2008
IB020575
2/4
High-Pressure Injection Pipe
Maintenance / Disassembly and reassembly
A5.05. 07.05.01.00
M43/VM43
07
2.
Reassembly
2.1
Renew the O-rings (2, 5, 7, 9, 11).
2.2
Daub the O-rings and sealing faces with "Molykote".
2.3
All high-pressure surfaces must be free of dirt and damages.
2.4
Daub the threads of cap screw (8), pressure screw (6), and clamping screw (4) slightly with "Molykote" as well as all high-pressure sealing faces and pressure faces (4 and 6).
Attention: Use only original MaK spare parts!
2.5
Insert the sleeve (12) into the cylinder head and lock by means of the spring ring (10).
2.6
Put the receptacle (14) onto the injection pump connection (17) and tighten the fillister head screws (16) "by hand".
2.7
Introduce the complete radial thrust piece (13) with cap screw (8) through the receptacle (14) into the cylinder head. Dimension “X“ must be at least 25 mm.
Attention: During subsequent tightening of the cap screw (8) and the pressure screws (4) and (6) the indicated sequence of operations must be kept by all means!
2.8
Screw the cap screw (8) into injection nozzle holder (Fig. 1/20) with a torque of M = 250 Nm
Attention: The clamping sleeve (18) has a recess (19) in the aperture on one side which must point towards the pressure screw (6)!
2.9
Insert the transverse thrust piece (15) into the receptacle (14).
2.10
Screw the pressure screw (6) and the clamping screw (4) evenly and alternately by hand into the receptacle (14) until there is a contact between the transverse thrust piece (15) and the injection pump connection (17) and radial thrust piece (13) respectively (without wrench !).
en / 31.01.2008
IB020575
3/4
High-Pressure Injection Pipe
Maintenance / Disassembly and reassembly
A5.05. 07.05.01.00
M43/VM43
2.11
Tighten the pressure screw (6) and the clamping screw (4) alternately and step by step starting with a torque of M = 100 Nm each, until the prescribed torque of M = 250 Nm is reached for pressure screw (6) and clamping screw (4).
2.12
Tighten the fillister head screws (16).
2.13
Tighten cover (3) and O-ring (2) by means of fillister head screws (1).
2.14
Check the injection system for leakage and reassemble the valve cover.
en / 31.01.2008
IB020575
4/4
07
Fuel Injector
A5.05. 07.07.01.02
Maintenance / Disassembly and reassembly M43/VM43
See also:
07.02.01.nn, 07.08.01.nn
Spare parts list:
B1.05.01.432107, B1.05.07.432260
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
07
------------------------------------------------------------------------------------------------------------------------------Tools: Pulling unit for injector valve Cleaning tool for injector seat
W1 W2 *
439111 A 439222 B
* no picture
Auxiliary materials: Molykote Paste "G-Rapid“ ** High temperature thread paste "Dag S 5420 A“ ** ** or equivalent product
Note: When operating the engine with heavy fuel oil, the engine must be operated for at least 0.5 hours with distillate fuel before working on the injector system to rinse the injector valve thoroughly.
Sequence of operations: 1.
Disassembly
1.1
Remove the valve cover.
~
Disassemble the high-pressure injection pipe only after complete mounting of pulling unit (W1).
1.2
Loosen hexagon nuts (Fig. 1/1), remove extension sleeves (12) and flange (3).
1.3
Reassemble extension sleeves (12).
1.4
Bolt the injector valve pulling unit (Fig. 2/W1) securely to the adjuasting screw (Fig. 1/8) of the injector valve (4). To this end:
en / 29.02.2008
IB025651
1/3
Fuel Injector
A5.05. 07.07.01.02
Maintenance / Disassembly and reassembly M43/VM43
1.4.1
Put in place the complete unit.
1.4.2
Loosen the hexagon head bolts (Fig. 2/20) a bit and firmly screw the threaded pieces (21) onto the extension sleeves (2) up to stop.
1.4.3
07
25 24
20
21
Firmly tighten the hexagon head bolts (20).
22
1.4.4
Firmly screw the threaded rod (22) onto the adjusting screw (Fig. 1/8).
1.4.5
Place the torsional lock (Fig. 2/23) on the hexagon of the threaded rod (22).
1.5
Disassemble high-pressure injection pipe (07.05.01.nn).
1.6
Loosen the injector valve by turning the threaded sleeve (24) by means of wrench (25) and screw out until the bottom O-ring (Fig. 1/7) is exposed.
1.7
Remove hexagon head bolts (Fig. 2/20)
1.8
Pull out injector valve with pulling unit.
1.9
Remove the pulling unit completely and reassemble it.
1.10
Clean the injector valve externally, mark it with the cylinder number and carry out a functional check of the injector (07.08.01.nn).
1.11
Clean the injector seat (Fig. 1/9) in the sleeve (6) by scraping with tool (W2). Clean the inside of the sleeve.
2.
Assembly
2.1
Replace O-rings (7).
2 23
22 24
20
25
20 21
Attention: Only use original MaK replacement parts! 23
en / 29.02.2008
IB025651
2/3
Fuel Injector
A5.05. 07.07.01.02
Maintenance / Disassembly and reassembly M43/VM43
2.2
Apply a thin coat of high temperature thread paste to the injector seat, injector element (Fig. 1/5) and nozzle holder.
2.3
Apply a thin coat of Molykote paste to the threads fo the studs (2), contact surfaces of the nuts (1) and O-rings (7).
Note: Excess paste must be removed! Excess paste may cause the O-rings to be squeezed off in the locking groove of the cylinder head!
Attention: No seal between the injector valve and sleeve in area (Fig. 1/X).
2.4
Place injector valve in sleeve, note the position of the locking pin (Fig. 5/10).
2.5
Install flange (Fig. 1/3) with the dowel pin (Fig. 5/11) to the exhaust side and the ring shoulder down.
2.6
Install the sleeves (Fig. 1/12).
2.7
Tighten the hex head nuts (1) evenly by hand. Make sure that the flange (3) rests flush on the injector valve (4).
2.8
Install injector line (07.05.01.nn).
2.9
Tighten the nuts (1) to M = 60 Nm in two steps.
2.10
Check fuel line for leaks.
2.11
Install cylinder head cover.
en / 29.02.2008
IB025651
3/3
07
Fuel Injector
A5.05. 07.08.01.30
Maintenance / Adjust M43/VM43
See also:
07.07.01.nn, 07.09.01.nn
Spare parts list:
B1.05.07.432260, B1.05.07.432267
Time requirement:
1 Pers./ 0,50 h
07
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Nozzle tester Adapter/nozzle support nozzle tester Injector delivery pipe
~
W1 W2 W3
1.9470 H 439206 A 1.9470-051
Safety note: When checking the opening pressure: Risk of accident! Keep your hands off the fuel jet!
Note: Proper function of the injection nozzlescan only be assessed from the behaviour of the exhaust gas temperatures or smoke emission behaviour. The fuel injector should only be checked in case of a significant deviation of the exhaust gas temperature from the respective cylinder value. For this purpose the nozzle tester is provided, which can also be used for checking the nozzle holes for unobstructed passage. By means of the nozzle tester the behaviour of the nozzle in operation cannot be reproduced, because the flow rates and the related pressure build-up are not comparable with the real conditions on the engine, i.e. the spray pattern alone gives no indication of the function of the nozzle. On the nozzle tester the specified opening pressure is to be adjusted after assembly of the nozzle. A drop in opening pressure after a short operating time (setting of nozzle spring and needle) is normal. Corrosive attack and erosion are the consequence of low charge air temperatures or water in the charge air.
en / 10.09.2008
IB026029
1/2
Fuel Injector
A5.05. 07.08.01.30
Maintenance / Adjust M43/VM43
07
Sequence of operations: 1.
Remove carbon deposits from the nozzle with a hard brush (no wire brush).
2.
Check the nozzle hole for sharp edges, ovalization, corrosion and damage.
3.
Place the injector with the adapter (W2) in the tester (W1).
4.
Connect the injector delivery pipe (W3).
5.
Increase the pressure by means of the pump until the nozzle opens. Determine injector opening pressure and free passage of the nozzle holes.
Note: If a high portion of fuel is leaking or if the nozzle holes are clogged and the nozzle already opens below the minimum nozzle opening pressure of 390 bar, repair or replace the injector according to (07.09.01.nn). 5.1
For adjusting the opening pressure slacken the lock nut (1) and turn the adjusting screw (2) until the correct opening pressure is adjusted (see 5.2 and 5.3). Tighten the lock nut (1).
5.2
When using a new fuel injector or a new nozzle element (8, 12) and a new nozzle spring (4) the nozzle opening pressure is to be adjusted according to the testbed record (A1.10.).
5.3
When continuing to use the old nozzle element (8, 12) and/or the old nozzle spring (4) the opening pressure is to be adjusted according to the testbed record value (A1.10.) minus 10%. Ptest = 570 bar - 10% = 513 bar
en / 10.09.2008
IB026029
2/2
Fuel Injector
A5.05. 07.09.01.30
Repair / Disassembly and reassembly M43/VM43
7500
See also:
07.07.01.nn, 07.08.01.nn
Spare parts list:
B1.05.07.432267
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
07
------------------------------------------------------------------------------------------------------------------------------Maintenance: Replace all injector elements
every
7,500 h
Tools: Retainer, fuel injector Torque wrench Insert SW55 Hexagon spanner
W1 W2 W3 W4 **
439208 A 435100 A 439208-001 0.9100-055
Auxiliary materials: High temperature thread paste Dag S 5420 A“ * Molykote Paste "G-Rapid‘‘ * * or equivalent product ** not available as figure
Note: The fuel injector must be removed / reassembled every 7,500 operating hours or when an inspection (07.08.01.nn) reveals faults. All parts of the injection system are manufactured to high tolerances in special workshops. This is the only way to ensure proper function. For this reason, repairs cannot be made by the operator and maintenance work should be limited to:
• • • •
Cleaning Checking of nozzle opening pressure and seals Replacement of wearing parts with the use of OEM parts and replacement elements Replacement of all injector elements (injector needle and element).
The CAT customer service permits low cost repair. Injection valves that need to be overhauled are to be sent to the CAT customer service as a complete unit.
en / 16.12.2008
IB026034
1/4
Fuel Injector
A5.05. 07.09.01.30
Repair / Disassembly and reassembly M43/VM43
7500
07
Sequence of operations: 1.
Disassembly
1.1
Insert fuel injector (Fig. 1/13) into retainer (W1). In doing so fit tightly into insert (W3).
1.2
Mount flange (2) with hexagon screws (1) and tighten the hexagon head screws.
Note: Observe the mounting position of the fuel injector in the flange (2)! (Position of the positioning pin Fig. 2/17). 1.3
Slacken nut (3) and relieve nozzle spring (4) by unscrewing the setting screw (11).
Attention: To slacken the nozzle nut (6) only use hexagon spanner (W4), do not use torque wrench (Fig. 3/W2).
1.4
Put hexagon spanner (W4) on the key face (Fig. 1/16) of insert (W3) and slacken nozzle nut (Fig. 2/6).
1.5
Take off hexagon spanner (W4) and remove nozzle nut.
1.6
Take out nozzle element (Fig. 2/8) including nozzle needle (12) without damaging the lapped surfaces.
1.7
Slacken hexagon head screws (Fig. 1/1) and remove with flange (2).
1.8
Take fuel injector out of retainer (W1).
en / 16.12.2008
IB026034
2/4
Fuel Injector
A5.05. 07.09.01.30
Repair / Disassembly and reassembly M43/VM43
7500
1.9
Remove adjusting screw (Fig. 2/11), remove spring guide (10), injector spring (4) and pressure pin (5).
1.10
Inspect injector spring (4) and pressure pin (5).
1.11
Carry out a visual inspection of nozzle spring (4) and pressure pin (5). If any severe indicators of wear (cavitation) are identified, replace them.
1.12
Place injector needle (12) into nozzle (8) with gas oil and check to see if the needle sinks to its seat of its own weight. If the needle hangs or is stuck, the entire injector element (8+12) must be replaced.
1.13
All parts, especially injector needle and sealing surfaces, must be inspected. Replace any defective parts.
2.
Assembly
2.1
Dry all sealing surfaces with lint free paper.
2.2
Install new O-rings (9) and (14) with Molykote paste.
2.3
The fuel injector is installed in the reverse order as disassembly.
07
Attention: When installing the adjusting spindle (1), note the slit position (X) to the fuel injector housing (13)!
2.4
Apply high temperature paste to the outer threads of the fuel injector (13).
2.5
Place fuel injector in retainer (Fig. 3/W1).
2.6
Mount flange (2) with hexagon head screws (1) and tighten the screws.
en / 16.12.2008
IB026034
3/4
Fuel Injector
A5.05. 07.09.01.30
Repair / Disassembly and reassembly M43/VM43
7500
2.7
Put on complete nozzle element (Fig. 2/8+12). Observe position of the pins (7).
2.8
Screw on nozzle nut (6) and tighten by hand.
07
Attention: In order to avoid damages to the hydraulic wrench (W2), adjust a maximum pressure of p = 465 bar on the high-pressure pump. Adjustment instructions see A6.05.90.10.nn .
2.9
Put torque wrench (Fig. 3/W2) on nozzle nut (Fig. 2/6) and tighten with a pressure of p = 465 bar (Equals a torque of M = 680 Nm)
2.10
Slacken hexagon head screws (Fig. 3/1) and remove with flange (2).
2.11
Take fuel injector out of retainer (W1).
2.12
Adjust fuel injector according to (07.08.01.nn), items 3,4, and 5.1.
en / 16.12.2008
IB026034
4/4
Fuel Duplex Filter
A5.05. 07.12.01.08
Maintenance / Cleaning M43
07
See also: Spare parts list:
B1.05.07.n.7667
Time requirement:
1 Pers./ 0,50 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Cleaning pistol Cartridge drift
W1 W2
1.9100-110 1.9100-120
Auxiliary material: Cleansing fluid "Filterclean" from Vecom * * or
a product of equal standard
Note: All maintenance and other work on the filter should be carried out with the greatest care to prevent malfunctions from occurring in the fuel injection system. Never let a full filter cool down when being operated on heavy fuel! The cleaning interval for the filter will depend mainly on the engine operating conditions, fuel quality and the quality of the fuel separation and will thus differ from unit to unit. After commissioning a new system or after working on the fuel pipeline system, the filter should be checked after 24 hrs. and cleaned if necessary. Disassemble the cartridge bundle on every 3rd cleaning (see operation sequence 2.3). Ultrasonic cleaning of the filter cartridges is not permitted. An excessive cleaning period or improper suspension during cleaning might cause damage to the gauze that cannot be detected with the nacked eye.
Sequence of operations: 1.
Change the filter over (see the plate on the filter cover).
2.
Cleaning
2.1
Clean the filter when it is still warm from operation and 50 % of the red mark of the differential pressure gauge (Fig. 1/ 1) becomes visible or a filter alarm is given.
en / 05.03.2002
IB022553
1/4
Fuel Duplex Filter
A5.05. 07.12.01.08
Maintenance / Cleaning M43
2.2
~
07
Cleaning the filter with built-in cartridges.
Safety note: Depressurize filter chambers!
2.2.1
Remove the cover (2) from the shut-off filter chamber. Remove contaminated liquid by opening the drain.
2.2.2
Remove filter insert.
2.2.3
Connect cleaning pistol (Fig. 2/W1) to compressed-air supply and load. (6 - max. 10 bar)
2.2.4
Shift the spouting guard (13) to the stop on the pistol nozzle, put it into the cartridge opening and hold it tight. Pull the trigger of the pistol and introduce the nozzle gradually down to the bottom of each cartridge (14).
2.2.5
Replace seals and mount cover.
2.2.6
Fill the filter chamber and vent it (see the plate on the filter cover).
2.3
Cleaning the filter with cartridges removed (every 3rd cleaning).
2.3.1
Open sludge drain and empty filter chamber.
2.3.2
Remove filter insert.
2.3.3
Flush the filter chamber with gas oil.
en / 05.03.2002
IB022553
2/4
Fuel Duplex Filter
A5.05. 07.12.01.08
Maintenance / Cleaning M43
2.3.4
Put the filter insert in a container filled with a suitable cleansing liquid. The cleansing liquid must only reach up to the bottom edge of the element plate (Fig. 3/26) so that no contaminated liquid can enter the cartridges from the top (14) (clean side). The top area of the gauze must be visible in the cartridge. Soaking time as required by the supplier of the cleanser, but maximum 4 h.
2.3.5
Take the filter insert out of the cleansing container and blow out cartridges (14) with the cleaning pistol (Fig. 2/W1) (operation sequence 2.2.4). Air pressure max. 10 bar.
2.3.6
Submerge filter insert again in clean cleansing liquid, let it drip off and then blow it out with the cleaning piston (W1). Place filter insert upside down so that cleansing liquid can drain off.
2.3.7
Intermittent check of cartridges for damage (operation sequence 2.4).
2.3.8
Place filter insert in filter chamber, mount cover, replace seals if necessary.
2.3.9
Fill filter chamber and vent (see plate on filter cover).
2.4
Cleaning of cartridges in the case of persistent fouling
Note: In the case of heavy fouling of the filter insert (hardening, tar deposits, fibers, chips) remove the cartridges and clean them individually. 2.4.1
Soak filter insert in cleansing liquid (max. 4 h).
2.4.2
Loosen base plate and carefully remove protective jacket from filter insert.
2.4.3
Remove cartridges (14) with the drift (Fig. 3/W2) downwards and tilt them out. Remove the O-rings (25) between the cartridge and the element plate (26) because O-rings must not come into contact with the cleansing liquid.
2.4.4
Inspect the cartridges and replace them if damaged or if the gauze is badly crinkled.
Attention: Damage to only one cartridge means malfunction of the whole filter. When removed, do not stack the removed cartridges on top of each other as this might damage the gauze.
2.4.5
Connect cleaning pistol (Fig. 2/W1) to compressed-air supply. Air pressure max. 10 bar.
en / 05.03.2002
IB022553
3/4
07
Fuel Duplex Filter
A5.05. 07.12.01.08
Maintenance / Cleaning M43
07 2.4.6
Introduce the cleaning pistol into the cartridge, pull the trigger and move down to the bottom of each cartridge.
2.4.7
Remove sticking dirt with a soft brush.
Note: If a high-pressure cleaner is available, blast the cartridges from the outside with a fan jet nozzle. Operating pressure of the high-pressure cleaner max. 60 bar. Cleansing agent: warm water or water with cleansing fluid.
Attention: When cleaning with a high-pressure cleaner, do not hold the nozzle too close to the gauze in order to prevent damage or displacement of the gauze wires.
2.4.8
Rinse the cartridges in clean cleaning fluid, blow them out and let them dry with the opening facing downwards.
2.4.9
Put a strong light behind the gauze and check the cleaning operation. Repeat it if necessary.
2.4.10
Install cartridges in reverse sequence as described under 2.4.3. O-ring between element plate and cartridge must be free from cracks and deformation.
3.
Check the seal between the element plate and filter housing and replace if necessary.
4.
Mount filter insert in filter chamber.
5.
Fit cover (replace seal).
6.
Fill the filter chamber and vent it (see the plate on the filter cover).
en / 05.03.2002
IB022553
4/4
Fuel Distributor/Collector Line
A5.05. 07.15.01.30
Repair / Disassembly and reassembly M43
07
See also:
-
Spare parts list:
B1.05.07.438510
Time requirement:
1 Pers./ 0,50 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
------------------------------------------------------------------------------------------------------------------------------Auxiliary materials: Molykote Paste "G-Rapid‘‘ *
Procedure: 1.
Disassembly
1.1
Remove pump area shroud.
1.2
Close shut-off valve.
1.3
Drain fuel distributor line by means of the leakage line.
1.4
Remove the fuel leakage line (Fig. 1/1) at the flange.
en / 11.05.2004
IB024483
1/3
Fuel Distributor/Collector Line
A5.05. 07.15.01.30
Repair / Disassembly and reassembly M43
1.5
Remove the fuel line at the flange (Fig. 2/4).
1.6
Loosen the locking rings (6) and slide towards the middle of the line.
07
Note: When loosening and sliding the locking rings, be careful not to damage the pipe sealing surfaces! 1.7
Slide the fuel line (Fig. 1/5) to the side with a 55mm open jawed wrench and then remove.
1.8
Loosen hex head bolts (Fig. 2/10).
1.9
Remove the hex head bolts and pull the flange (2) from the injection pump bushings (3).
1.10
Remove the bushings (3) with the O-rings (7) and support ring (11).
en / 11.05.2004
IB024483
2/3
Fuel Distributor/Collector Line
A5.05. 07.15.01.30
Repair / Disassembly and reassembly M43
07
1.11
Remove fuel lines (supply and return).
1.12
Loosen cap screws (9).
1.13
Remove cap screws and pull the flange (4) from the injection pump bushing (3). Remove O-rings (12).
1.14
Remove the bushings (3) with the O-rings (7) and support ring (11).
2.
Assembly
2.1
Check the O-rings (7) and (8) on the injection pumps for damage. Replace if necessary.
2.2
Insert bushings (3) with O-rings (7) and support ring (11) into the injection pump / flange.
2.3
Apply Molykote to hex head bolts (10).
2.4
Install flange (2) with hex head bolts.
2.5
Tighten bolts to M = 130 Nm
2.6
Insert bushings (3) with O-rings (7) and (8) and support ring (11) into the injection pump / flange.
2.7
Mount flange with cap screws (9).
2.8
Tighten cap screws to M = 130 Nm
2.9
Insert O-rings (12). Install fuel lines (supply and return).
2.10
Insert fuel line with O-rings (8), support ring (11) and locking rings (6).
2.11
Turn locking rings firmly into locked position.
2.12
Mount fuel leakage line (Fig. 1/1) on flange (2).
2.13
Open shut-off valve.
2.14
Fill fuel system with reserve pump and bleed air from system by circulating fuel with reserve pump.
2.15
Install pump area shroud.
en / 11.05.2004
IB024483
3/3
Fuel Pressure Damper
A5.05. 07.17.00.01
Maintenance / Replace M43
7500
07
See also:
07.15.01.nn
Spare parts list:
B1.05.07.438533, B1.05.07.438510
Time requirement:
1 Pers./ 1,00 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: Replacement of the fuel pulsation dampers
every
7,500 h
Auxiliary materials: Molykote-Paste "G-Rapid “ ** ** or equivalent product
Procedure: 1.
Disassembly
1.1
Close the fuel shut-off valves.
1.2
Drain the fuel distributing pipe via the corresponding leakage pipe.
1.3
Dismantle the leakage monitoring pipe on the fuel pulsation damper (1) (counterhold the union).
1.4
Loosen fastening clamps (2). Loosen locknut (4) (right-hand thread) and dismantle fuel pulsation damper.
en / 14.11.2007
IB025781
1/2
Fuel Pressure Damper
A5.05. 07.17.00.01
Maintenance / Replace M43
7500
07
2.
Assembly
2.1
Assemble new fuel pulsation dampers (1) in reverse order.
Attention: When mounting the leakage monitoring pipe the valve body (3) of the fuel pulsation damper must not be twisted. Hold in place the valve body by means of a second wrench!
2.2
Open the fuel shut-off valves.
2.3
Fill the fuel system by means of the stand-by pump and vent it..
en / 14.11.2007
IB025781
2/2
Lubricating Oil Pump
A5.05. 08.03.02.04
Maintenance / Disassembly and reassembly M43
08
See also: Spare parts list:
B1.05.08.436417
Time requirement:
0 Pers./ 0,00 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Torque wrench 20 - 200 Nm Torque wrench 200 - 500 Nm
W1 * W2 *
1.9454-202 1.9454-500
* not shown
Also needed: "G-Rapid Plus" ** Molykote paste „Dirco Grau“ ** silicone sealant ** or comparable product
Note If necessary, the lube oil pump should be removed from the engine to check the gears, gear shafts and bushes for wear or replace them, if necessary.
Sequence: 1.
Disassembly
1.1
Drain lube oil system.
1.2
Remove suction (Fig. 1/4) and pressure lines (2).
1.3
Loosen hex nuts (1) and pull lube oil pump (3) with gear (6) from the cylinder crank case. Watch out for resilient sleeves.
en / 31.01.2008
IB025414
1/4
Lubricating Oil Pump
A5.05. 08.03.02.04
Maintenance / Disassembly and reassembly M43
08
1.4
Loosen hex bolt (7) and pull gear (6) from the drive gear shaft (Fig. 2/10) using puller.
1.5
Check tooth faces for wear (pitting, unevenness, spalling).
1.6
Loosen bolts (16,18). Remove cover (21) und cover (17) from pump housing (20).
1.7
Remove drive gear (10) and impeller shaft (19).
1.8
Check bushes (11, 14, and 15), bearing areas of drive and impeller gear shafts for wear and replace with genuine MaK parts, if necessary. Replace O-rings (12).
Note Cool new bushes before assembly.
en / 31.01.2008
IB025414
2/4
Lubricating Oil Pump
A5.05. 08.03.02.04
Maintenance / Disassembly and reassembly M43
08
2.
Assembly:
2.1
Assemble lube oil pump by reversing above steps.
2.2
Mount cover (21). Tighten hex bolts (18) to a torque of M = 410 Nm.
2.3
Mount cover flange (17). Tighten hex bolts (16) to a torque of M = 206 Nm.
2.4
Before mounting gears, check wear pattern between gear cone (Fig. 1/6) and drive gear shaft cone (Fig. 2/10) by applying ink. The wear pattern should be even, and the wear pattern percentage > 80 %.
2.5
Clean, degrease and dry gear cone and drive gear cone shaft.
Attention: Gear should always be mounted with the drive gear shaft in the vertical position (cone pointing up).
2.6
Place gear (Fig. 1/6) on drive gear shaft cone, measure dimension S (Fig. 1/X) and note down.
2.7
Heat gear by approx. 110 °C to 120 °C above the temperature of the drive gear shaft and shrink firmly to the drive gear shaft cone all the way to the stop.
2.8
Then immediately mount hex bolt (7) with washer (8) and tighten to a torque of M = 100 Nm .
2.9
After the connection has cooled down to room temperature, loosen hex bolt (7). Then coat threads with „G-Rapid Plus“ Molykote paste and tighten to a torque of M = 140 Nm.
en / 31.01.2008
IB025414
3/4
Lubricating Oil Pump
A5.05. 08.03.02.04
Maintenance / Disassembly and reassembly M43
08
2.10
Check distance S; it should be smaller than measured under 2.6 by 0.57 - 0.67 mm (sliding travel).
2.11
Clean pump flange surface (Fig. 2/17) and pump support surface (Fig. 1/5) and coat with sealant.
2.12
Carefully insert lube oil pump (3) with gear (6) into the cylinder crankcase (tooth faces of drive gears need to engage) and install.
2.13
Install resilient sleeves. Coat hex nuts (1) and bolt threads with „G-Rapid Plus“ Molykote paste and tighten to a torque of M = 130 Nm.
2.14
Install suction (4) and pressure (2) lines using new seals.
2.15
Fill with new lube oil (for lube oil quality see A4.05.08.nn) to the mark on the circulating tank.
2.16
Refill lube oil system and start lube oil prelube pump. Purge air from system. Check system for leakage.
2.17
Check lube oil supply to gears.
en / 31.01.2008
IB025414
4/4
Lubricating Oil Duplex Filter
A5.05. 08.04.01.01
Maintenance / Cleaning M43
08
See also: Spare parts list:
B1.05.08.437657
Time requirement:
1 Pers./ 0,50 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Cleaning pistol Cartridge drift
W1 W2
1.9100-114 1.9100-120
Auxiliary material: Cleansing fluid "Filterclean" from Vecom * * or a product of equal standard
Note: Operation and servicing of the filter have to be carried out with atmost care. The ingress of dirt from the tanks and piping could cause serious engine damage. The cleaning interval of the filter is influenced by part load operation with heavy fuel, poor combustion, poor centrifugal purifying or a defective automatic backflashing filter. When starting up a new plant after major repairs or work on the lubricating oil piping, check the filter after 24 - 48 h and clean it if necessary. Disassemble the cartridge bundle on every 3rd cleaning (see operation sequence 2.3). Ultrasonic cleaning of the filter cartridges is not permitted. An excessive cleaning period or improper suspension during cleaning might cause damage to the gauze that cannot be detected with the nacked eye.
Sequence of operations: 1.
Change the filter over (see the plate on the filter cover).
2.
Cleaning
2.1
Clean the filter when it is still warm from operation and 50 % of the red mark of the differential pressure gauge (Fig. 1/ 1) becomes visible or a filter alarm is given.
en / 23.03.2007
IB020307
1/4
Lubricating Oil Duplex Filter
A5.05. 08.04.01.01
Maintenance / Cleaning M43
2.2
~
08
Cleaning the filter with built-in cartridges.
Safety note: Depressurize filter chambers!
2.2.1
Remove the cover (2) from the shut-off filter chamber. Remove contaminated liquid by opening the drain.
2.2.2
Remove filter insert.
2.2.3
Connect cleaning pistol (Fig. 2/W1) to compressed-air supply and load. (6 - max. 10 bar)
2.2.4
Shift the spouting guard (13) to the stop on the pistol nozzle, put it into the cartridge opening and hold it tight. Pull the trigger of the pistol and introduce the nozzle gradually down to the bottom of each cartridge (14).
2.2.5
Replace seals and mount cover.
2.2.6
Fill the filter chamber and vent it (see the plate on the filter cover).
2.3
Cleaning the filter with cartridges removed (every 3rd cleaning).
2.3.1
Open sludge drain and empty filter chamber.
2.3.2
Remove filter insert.
2.3.3
Flush the filter chamber with gas oil.
en / 23.03.2007
IB020307
2/4
Lubricating Oil Duplex Filter
A5.05. 08.04.01.01
Maintenance / Cleaning M43
2.3.4
Put the filter insert in a container filled with a suitable cleansing liquid. The cleansing liquid must only reach up to the bottom edge of the element plate (Fig. 3/26) so that no contaminated liquid can enter the cartridges from the top (14) (clean side). The top area of the gauze must be visible in the cartridge. Soaking time as required by the supplier of the cleanser, but maximum 4 h.
2.3.5
Take the filter insert out of the cleansing container and blow out cartridges (14) with the cleaning pistol (Fig. 2/W1) (operation sequence 2.2.4). Air pressure max. 10 bar.
2.3.6
Submerge filter insert again in clean cleansing liquid, let it drip off and then blow it out with the cleaning piston (W1). Place filter insert upside down so that cleansing liquid can drain off.
2.3.7
Intermittent check of cartridges for damage (operation sequence 2.4).
2.3.8
Place filter insert in filter chamber, mount cover, replace seals if necessary.
2.3.9
Fill filter chamber and vent (see plate on filter cover).
2.4
Cleaning of cartridges in the case of persistent fouling
Note: In the case of heavy fouling of the filter insert (hardening, tar deposits, fibers, chips) remove the cartridges and clean them individually. 2.4.1
Soak filter insert in cleansing liquid (max. 4 h).
2.4.2
Loosen base plate and carefully remove protective jacket from filter insert.
2.4.3
Remove cartridges (14) with the drift (Fig. 3/W2) downwards and tilt them out. Remove the O-rings (25) between the cartridge and the element plate (26) because O-rings must not come into contact with the cleansing liquid.
2.4.4
Inspect the cartridges and replace them if damaged or if the gauze is badly crinkled.
Attention: Damage to only one cartridge means malfunction of the whole filter. When removed, do not stack the removed cartridges on top of each other as this might damage the gauze.
2.4.5
Connect cleaning pistol (Fig. 2/W1) to compressed-air supply. Air pressure max. 10 bar.
en / 23.03.2007
IB020307
3/4
08
Lubricating Oil Duplex Filter
A5.05. 08.04.01.01
Maintenance / Cleaning M43
08 2.4.6
Introduce the cleaning pistol into the cartridge, pull the trigger and move down to the bottom of each cartridge.
2.4.7
Remove sticking dirt with a soft brush.
Note: If a high-pressure cleaner is available, blast the cartridges from the outside with a fan jet nozzle. Operating pressure of the high-pressure cleaner max. 60 bar. Cleansing agent: warm water or water with cleansing fluid.
Attention: When cleaning with a high-pressure cleaner, do not hold the nozzle too close to the gauze in order to prevent damage or displacement of the gauze wires.
2.4.8
Rinse the cartridges in clean cleaning fluid, blow them out and let them dry with the opening facing downwards.
2.4.9
Put a strong light behind the gauze and check the cleaning operation. Repeat it if necessary.
2.4.10
Install cartridges in reverse sequence as described under 2.4.3. O-ring between element plate and cartridge must be free from cracks and deformation.
3.
Check the seal between the element plate and filter housing and replace if necessary.
4.
Mount filter insert in filter chamber.
5.
Fit cover (replace seal).
6.
Fill the filter chamber and vent it (see the plate on the filter cover).
en / 23.03.2007
IB020307
4/4
Oil pressure control valve
A5.05. 08.05.01.01
Maintenance / Adjust M20/M25/M32/M43
15000
08
See also: Spare parts list:
B1.05.08.n.7810
Time requirement:
1 Pers./ 1,00 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: Disassembly and adjustment of the oil pressure control valve
every
15,000 h
Note: Disassembly of the pressure control valve during the repair interval is only necessary if the necessary lubricating oil pressure can no longer be set by adjusting the initial tension of the spring. The lubricating oil pressure (see A1.05, engine data) is only allowed to be adjusted at the nominal engine speed (A1.10) and at the specified lubricating oil temperature (see A1.06).
Sequence of operations: 1.
Disassembly
~
Safety note:
1.1
Loosen the cheese head screws (8) evenly to relieve the pressure spring (3).
1.2
Remove and dismantle the control valve (1).
~
Safety note:
Pay attention to the tension of the pressure spring (Fig. 1/3) on the control valve (1)!
Pay attention to the tension of the pressure spring (13) on the screwed connection (17)!
1.2.1
Loosen the hexagon nut (18) and completely unscrew the spindle (19) by turning it counterclockwise and remove it together with the ball (16).
1.2.2
Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush (10).
1.2.3
Remove the locking ring (9) and take out the piston (11) with washer (15) and pressure spring (13).
1.2.4
Remove the screw plug (26) of the pilot control unit (A-A) with the sealing ring (25), washers (27), pressure spring (28) and ball (29).
en / 31.01.2008
IB022593
1/3
Oil pressure control valve
A5.05. 08.05.01.01
Maintenance / Adjust M20/M25/M32/M43
15000
08
1.3
Clean all parts with gas oil and check them.
1.4
Check the free passage of the control oil bore (12) in the pressure control valve and in the set screw (5) and remove any deposits.
1.5
Check the valve seats, balls, piston seating as well as the slide faces and grind them if necessary.
en / 31.01.2008
IB022593
2/3
Oil pressure control valve
A5.05. 08.05.01.01
Maintenance / Adjust M20/M25/M32/M43
15000
08
2.
Reassembly
2.1
Check the O-rings (2 and 7) and sealing ring (14) and replace them if necessary.
2.2
Assembly is effected in the reverse sequence of disassembly. Pay attention to the free movement of the pistons (4 and 11)!
2.3
Check the lubricating oil pressure at the pressure gauge on the control panel and adjust it if necessary.
3.
Adjustment
3.1
Pressure to be set (see engine data A1.05).
3.2
Loosen the hexagon nut (18). Regulate the pressure by turning the spindle (19). Counter-clockwise: Clockwise:
3.3
Oil pressure drops Oil pressure increases
Secure the setting with the hexagon nut (18).
en / 31.01.2008
IB022593
3/3
Prelubricating pump/Prelubrication
A5.05. 08.10.00.00
Maintenance / Checking M20/M25/M32/M43/M453C/M552C/M601C
See also:
150
08
C5.05.08.10.00.nn
Spare parts list: Time requirement:
1 Pers./ 0,20 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: Prelubrication and turning
approximately every
150 h
Note: When multi-engine systems run on rigid bearings, the bearings might be damaged by vibration when individual engines are shut down for more than 3 days. Prelubrication alone is no guarantee that damage caused by vibration is prevented, since the components which run on sliding bearings, are not able to float in the bearing because of the prelubricating pressure. No or only a little quantity of oil is carried to the endangered contact surfaces. Damage caused by vibration during engine shut-down can only be avoided when the engine is lubricated and turned simultaneously. The following method is to be applied to avoid damage caused by engine shut-down, without affecting the unattended operation of the system:
Sequence of operations: 1.
Carry out steps 1.1 and 1.2 simultaneously for approx. 5 min.
1.1
Start the stand-by pump
1.2
Turn the engine by means of the barring gear.
en / 18.11.1999
IB004168
1/1
Stop Piston
A5.05. 10.03.01.00
Inspection / Checking M43/VM43
750
10
See also:
07.03.01.nn
Spare parts list:
B1.05.05.434210, B1.05.07.433597
Time requirement:
1 Pers./ 0,20 h
Personnel qualification:
skilled engine hand
Operating medium:
Heavy fuel and distillate fuel
------------------------------------------------------------------------------------------------------------------------------Inspection: Check the emergency stop function of the stop piston
every
750 h
Note: The functional check may only be completed when the engine is stopped for other maintenance or repair work!
Procedure: 1.
Actuate emergency stop.
2.
Check the position of the control rods.
Attention: The control rods must be in the "Zero Filling“ position.
3.
Check the stop piston (3) in the injection pump, press the control rod (2) into the injection pump by applying pressure to the jointed lever (1) on the control rod.
Note: Check all injection pumps. If individual or one control rod can be forced into the injection pump against the pressure of the stop piston, check the stop piston in the respective injection pump and overhaul if necessary (07.03.01.nn). If all control rods can be pushed into the injection pump, check the control air lines for leaks or damage. 4.
Actuate the "Reset“ button on the safety system.
Note: The stop piston is reset and the emergency stop system depressurized.
en / 31.07.2008
IB020372
1/2
Stop Piston
A5.05. 10.03.01.00
Inspection / Checking M43/VM43
750
10
Attention: This document only describes the pneumatic and mechanical release of an engine stop. In connection with this inspection work all of the emergency stop equipment on the engine is to be checked for proper function. (Please refer to (C5.05.05.10.50.nn) ). 13 5.
(Fig. 2/T3) Measuring point 6105 (function of the safety system) in the maintenance unit (C5.05.05.45.23.01).
5.1
Venting by loosening screw (13). If the shutdown air pressure is decreased below the switching value of 6 bar an alarm "Low shutdown pressure" will be released.
10
2
6.
T3
Check the emergency stop by actuating the emergency stop lever (Fig. 3/20) on the control stand.
en / 31.07.2008
IB020372
2/2
Pressure Switches
A5.05. 11.01.02.01
Inspection / Adjust M20-M601C
3750
11
See also: Spare parts list:
B1.05.11.nn.4843
Time requirement:
1 Pers./ 1,00 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Adjusting device, electro test instrument
Inspection: Inspect the pressure switch for the set operating values every 3,750 working hours.
Note: The following test and adjustment instruction is valid for the following types:
• Pressure range • Pressure range • Pressure range • Pressure range • Pressure range
0.2 - 2.5 bar 0 - 6 bar 1 - 16 bar 0.9 - 1.5 bar 2 - 25 bar
mechanical switching differential: mechanical switching differential: mechanical switching differential: mechanical switching differential: mechanical switching differential:
0.15 bar 0.2 bar 0.4 bar 0.08 bar 1,5 bar
Sequence of operations: 1.
Connection of the adjusting device
1.1
Close the cock of the pressure piping (Fig. 1/1).
1.2
Loosen the union nut (2) and remove the dummy plug (pressure release of the piping, at liquid medium collect the liquid with a rag).
en / 31.05.2000
IB021686
1/3
Pressure Switches
A5.05. 11.01.02.01
Inspection / Adjust M20-M601C
3750
11 Attention: When loosen/thighten the union nut directly located at the pressure joint of the pressure switch, it should be simultaneously counter acted at the key faces of the pressure joint.
1.3
Connect the hose (with union nut and cutting) with the adjusting device (Fig. 2).
2.
Inspection of the set values
2.1
Ventilate the pressure switch via the adjustment device.
Attention: For setting the differential pressure switch, the adjusting device must be equipped with two text connections (+, –, pressure difference) refer to view “X”.
Pressure monitor
Difference pressure monitor
2.2
Inspect the pressure control via the pressure gauge (of the device) and simultaneously the switch point at the instrument or alarm unit for coincidence of the switch point with the set value.
2.3
At any deviation correct the adjustment due to item 3.
2.4
Deaerate the pressure switch slightly and simultaneously check the switch point via the test instrument. Inspect the displayed switch difference.
en / 31.05.2000
IB021686
2/3
Pressure Switches
A5.05. 11.01.02.01
Inspection / Adjust M20-M601C
3.
3750
11
Correction of the adjustment (Performance with fixed switch difference) (Fig. 3)
Note: The scale accuracy is ± 2 % of the span. The instrument is individually calibrated (1 - 2 on) so that no gauge inspection is necessary. 3.1
Remove the case cover by loosening the 4 locking screws.
3.2
Connect terminal (1 + 4) via cable with the adjusting device.
3.3
Loosen the stop screw (A).
3.4
Remove the cover aside by loosening the locking screw (B).
3.5
Set the upper or lower switching point (differential pressure switch) by means of the range spindle (C). The lower or upper switching point (differential pressure switch) results in the fixed switching difference.
3.6
Tighten stop screw (A).
4.
Removal of the adjusting device
4.1
Loosen the cable connection (terminal 1 + 4).
4.2
Loosen the connection hose of the adjusting device screw on the union nuts with plug (Fig. 1/2).
4.3
Fit the cover.
4.4
Tighten the cover of the range spindle.
4.5
Mark or lead the impected or corrected pressure switches.
en / 31.05.2000
IB021686
3/3
RPM Switch
A5.05. 11.05.01.02
Inspection / Adjust M20/M25/M32/M43
See also:
7500
11
C5.05.05.70.06.43
Spare parts list: Time requirement:
1 Pers./ 1,00 h
Personnel qualification: E-specialist Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Inspection: Check the function of the rpm switches every 7,500 operating hours.
Note: The engine speed must be constant whilst testing.
Sequence of operations: 1.
Note the rpm switch point setting. Loosen the pointer locking plate (2) and set the pointer (1) at the highest engine speed. The output relay on the plug-in card must switch and the luminous diode (3) on the dial will go out (Fig. 1).
2.
Turn the pointer carefully to the left towards 0 rpm. When reaching the engine speed, the output relay will switch and the diode on the dial must light up (switch hysteresis ± 25 rpm).
3.
Set the pointer again at the original rpm switch point and lock it. If the rpm switch does not work, proceed as follows in order to locate the defect:
4.
The automatic cut-out F 1.1 and F 2.1 on the plug-in card A1 in the rpm switch installation must be switched on. At constant speed and with the setting as under point 1, continue as follows:
5.
Voltage check at the plug-in socket contacts of the plug-in frame.
5.1
Supply (24 V DC at contact z16 and z20, contact z20 positive).
en / 25.05.2005
IB021724
1/2
RPM Switch
A5.05. 11.05.01.02
Inspection / Adjust M20/M25/M32/M43
5.2
7500
11
PICK UP IMPULSE (dependent upon engine speed up to 1500 Hz at contact b14 and d14). If nothing could be detected whilst checking points 4 - 6, renew the plug-in card.
Attention: Carry out the rpm adjustment of the new plug-in card. For this see the "Plant components file (C), section 5, rpm switch".
en / 25.05.2005
IB021724
2/2
Lubricating Oil/Cooling Water Thermostat
A5.05. 11.06.01.01
Maintenance / Checking M20-M601C
7500
11
See also: Spare parts list:
B1.05.11.1.7837
Time requirement:
1 Pers./ 1,00 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: Disassembly of lubricating oil/cooling water thermostat, making a funcional check of thermostatic element every
7,500 h
Note: The thermostatic elements (Fig. 1/5) are adjusted by the manufacturer to the required temperature. Modification of the adjustment or repair is impossible. Defective elements must be exchanged completely. Controlling the thermostatic elements in case of failure is enabled by a manual control facility. Hereto slacken counter nut (3) and turn set screw (4) clockwisely in order to get a lower temperature. After setting counter again. The cooling line is fully opened and the bypass closed when the set screw (4) flushes with the surface of the counternut (3). This setting procedure may only be carried out if the thermostat fails. With mounting a new thermostat, the set screw (4) must be set to its initial position by the nut (3).
Sequence of operations: 1.
Disassembly
1.1
Drain lubricating oil/cooling water lines.
1.2
Unscrew hexagon nuts (2) of housing cover (6).
1.3
Remove cover (6) with O-ring (1).
1.4
Turn out thermostatic element (5) from valve housing (7).
1.5
Wash parts in gas oil and blow them clean.
1.6
Wipe clean thermostat housing with lintfree cloth and check for corrosion and deposits.
en / 31.05.2000
IB021750
1/2
Lubricating Oil/Cooling Water Thermostat
A5.05. 11.06.01.01
Maintenance / Checking M20-M601C
7500
11
2.
Functional check of thermostatic element
2.1
Put thermostatic element (Fig. 1/5) into a water bath of temperature of approx. 15 K above the temperature specified on the strap (XX) (specification in degree C).
2.2
The thermostatic element (5) must open steadiliy.
3.
Assembly
3.1
Repalce O-rings (1 and 9) and gasket (8).
3.2
Assembly is done in reverse order of disassembly.
3.3
Top up lubricating oil/cooling water system and check thermostat for leakages.
en / 31.05.2000
IB021750
2/2
Pressure Switch
A5.05. 11.06.05.02
Inspection / Replace M32/M43
22500
See also:
11
11.06.06.nn
Spare parts list: Time requirement:
1 Pers./ 2,00 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: Replacement of all pressure switches
after
22,500 h
Tools: Metric standard tools.
Set of replacement parts: Pressure switch M2103 (emergency stop - cooling water pressure) Pressure switch M1106 (emergency stop - lubricating oil pressure) Depending on the equipment status all other pressure switches are to be replaced as well.
Attention: - Ensure that the engine cannot be started! - When exchanging the pressure pipe or draining off the cooling water it is possible that "hot" cooling water leaks out. - There is a danger of scalding. - Avoid skin contact with cooling water emulsions, observe the safety data sheets of the manufacturers.
en / 06.10.2008
IB025581
1/3
Pressure Switch
A5.05. 11.06.05.02
Inspection / Replace M32/M43
22500
11
Procedure: 1.
Put the engine and the related safety systems out of operation. - > Notify the engine to be ’’unserviceable’’ < -.
Attention: Prior to replacing the pressure switches the shut-off cocks of the media must be closed. Prior to installation the pressure switches are to be adjusted to the specified pressure values.
2.
Replacement of the pressure switches.
Note: The measuring point designations are always provided on the engine cable and the engine. 2.1
Remove the old pressure switch.
2.2
Mount the new pressure switch. When doing so, slightly grease the O-ring (Fig. 1/1) at the foot of the new pressure switch before inserting it.
2.3
Replacement of the plug.
3.
Testing of the completed work:
3.1
Cooling water system
3.1.1
Start the engine and run up to nominal speed.
3.1.2
Simulate "Low cooling water pressure" by means of test valve (Fig. 2, 3, 4/2). The engine has to stop automatically latest after 20 seconds.
3.1.3
Put test valve (2) into "Operation" position again.
3.1.4
Lubricating oil system
3.1.5
Start the engine and run up to nominal speed.
3.1.6
Simulate "Low lubricating oil pressure" by means of test valve (2). The engine has to stop automatically without any delay.
3.1.7
Put test valve (2) into "Operation" position again.
3.1.8
The other pressure switches are to be tested according to the same procedure.
en / 06.10.2008
1
IB025581
2/3
Pressure Switch
A5.05. 11.06.05.02
Inspection / Replace M32/M43
4.
22500
11
Put the engine and the safety system into normal operating condition again. -> Notify the engine to be "ready for operation" <-.
2
2
2
en / 06.10.2008
IB025581
3/3
Pressure Switch
A5.05. 11.06.06.02
Maintenance / Adjust M20/M25/M32/M43
See also:
11
11.06.05.nn
Spare parts list: Time requirement:
1 Pers./ 0,25 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Tools: Pressure calibrating device Electric continuity tester (multimeter)
W1* W2*
* no picture
Procedure: 1.
Mount new pressure switch, see A5.05.11.06.05.nn.
2.
Close shut-off valve (Fig. 3/6) of the corresponding medium to the pressure pipe.
2.1
Remove the plug from the pressure switch and connect the pressure calibrating device (W1) to the test connection. The adjustment value is to be inferred from the list of measuring points in
Book C. 2.2
In pressureless state the pressure switch contacts (Fig. 1) 1 + 2 are closed and contacts 1 + 3 are open (ohmic flow).
2.3
When the pressure drops, the pressure switch should switch at the measuring point value, in this state contacts 1 + 2 are open and contacts 1 + 3 are closed.
2.4
If a pressure switch is replaced, the switching value is to be inferred from the list of measuring points. (The measuring point number is indicated on the cable or the related nameplate.)
Note: If the pressure switch responds before or after the read limit, the switching point has to be readjusted, see item 3.
en / 14.08.2008
IB025583
1/2
Pressure Switch
A5.05. 11.06.06.02
Maintenance / Adjust M20/M25/M32/M43
11
3.
Adjustment of switching point
3.1
Remove cover (Fig. 2/4).
3.2
By turning the hexagon socket screw (5) the switching point can be adjusted correspondingly.
4.
Assembly:
4.1
Mount cover (4).
4.2
Remove pressure calibrating device (W1).
4.3
Clip on plug to the pressure switch.
4.4
Open shut-off valve (Fig. 3/6) of the corresponding medium to the pressure pipe.
Replacement of the complete switch, see A5.05.11.06.05.nn. .
en / 14.08.2008
IB025583
2/2
Crankcase Monitoring Device
A5.05. 11.09.01.03
Inspection / Checking M20/M25/M32/M43/M453C/M552C/M601C
1500, 750, 7500
11
See also: Spare parts list:
B1.05.11.nn4810
Time requirement:
2 Pers./ 1,00 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: a) Check the underpressure in the measuring chamber every
750 h
b) Clean the infrared filter and replace the sintered bronze filter in the measuring attachment every
1.500 h
c) Replace the sintered bronze filter in the pressure control every
7.500 h
Tools: Test equipment and spare parts. Service box
Maintenance and trouble shooting: refer to manual C
Attention: The engine is not monitored in the event of the device malfunctioning. his can result in engine damage!
en / 12.12.2008
IB021758
1/1
Vibration Damper
A5.05. 12.04.01.00
Maintenance / Disassembly and reassembly M43/VM43
30000
See also:
08.03.02.nn
Spare parts list:
B1.05.12.436347
Time requirement:
0 Pers./ 0,00 h
12
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: of the vibration damper after
30,000 h
check size of gap "s" between the spring ends and the flanks of the interior grooves. Renew all seals.
Auxiliaries: Molykote "G-Rapid Plus" * Molykote lubricant "Typ 60 G" * Silicon sealant "Dirco-Grau" * Loctite 275 * or product of equivalent quality
Note: The oscillation damper is connected to the engine lubrication system. The system must be bled before the first operation and after maintenance work (operation sequence 5.1). At every lubrication oil change, the system must be completely drained of oil (operation sequence 1.3), even in the case of self-bleeding dampers, and the oil replaced (operation sequence 5.1). If running abnormalities appear at certain speeds, the cause may be a defective damper. To avoid extensive damage, avoid critical speeds and attempt to narrow down the fault as soon as possible by measuring the torsional oscillation. In damper replacement (possible in AT procedure) or damper assembly lubricate the screw thread plate and screw head of the antifatigue screws (Fig. 1/1) with Molykote "G-Rapid Plus" paste and set with a pre-torque of M = 600 Nm and finally tighten at
torque angle = 120°
The fastening screws of the pump bearing plate (4), the pump wheel carrier (15) and the pump gear wheel (14) must be tightened at the torque values given (see Assembly, Molykote Lubrication).
en / 15.01.2001
IB020552
1/4
Vibration Damper
A5.05. 12.04.01.00
Maintenance / Disassembly and reassembly M43/VM43
30000
12
Sequence of operations: 1.
Dismantling
1.1
Dismantle the lubricant pump (08.03.02.nn).
1.2
Dismantle lubricant piping and pump bearer plate (4), completely removing all silicon sealant.
1.3
0,3 C
C 0,2
C
4 30
Drain the oil:
14
• Turn oil flow boring to lower position • 1.4
1
(30). For full drainage turn the damper through 180° m several times.
12
Mark the position of the damper to the crankshaft.
15
1.5
Remove the antifatigue screws and fastening screws (1) (12).
1.6
Dismantle the pump wheel carrier (15) and pump gear wheel (14).
1.7
Remove fastening screws (13).
1.8
Remove the oscillation damper and forcing screw from the crankshaft and dismantle.
1.9
Dismantle side plates (18); forcing may be carried out through tapping bore holes.
1.10
Remove O rings (20 and 21).
1.11
Clean all parts thoroughly. Check oil flow bores and oil feed bores are clear.
13 20 18
X
18
21
22 23
X
24
1
en / 15.01.2001
IB020552
2/4
Vibration Damper
A5.05. 12.04.01.00
Maintenance / Disassembly and reassembly M43/VM43
1.12
30000
12
Measure gap (Fig. 2/"s" ) between spring ends and groove flanks of the interior using a feeler gauge. Maximum permitted value for gap "s" between spring ends and groove flanks:
Damper No. D 134/5
1.13
Tightening angle (Pos 23) 57° - 62°
Gap "s" (mm) 0,43
Apply an adequate quantity of "Loctite 275" to both sides of the cup spring (Fig. 1/22). Tighten hexagonal screw (23) until cup spring (22) lies flat, then continue turning to a tightening angle of 57°° - 62°°.
Attention: In the case of one-sided positioning of groove flank: gap "s" x 2.
Y
2
en / 15.01.2001
IB020552
3/4
Vibration Damper
A5.05. 12.04.01.00
Maintenance / Disassembly and reassembly M43/VM43
30000
12
Note: When critical values have been reached the damper should be replaced (AT procedure). If critical values have been exceeded, the engine should be operated only at reduced power and avoiding critical speeds; the damper should be replaced as soon as possible. 2.
Apply Molykote "Typ 60 G" across the inner side of the side plates (18).
3.
Insert new greased O rings (20 and 21).
4.
Set the side plates so that the oil flow bore holes are positioned between the oil feed bore holes. Screw the side plates tightly with the corresponding starting torque. Seal screw threads and cup springs with oil-resistant sealant.
5.
Assembly of oscillation damper:
• Observe the marking of the damper position to the crankshaft! 5.1
Check the run-out tolerances of the vibration damper (Fig. 1).
5.2
Bleed the air from the oscillation damper:
• Turn an oil flow bore hole (30) to the highest position (30). • Operate reserve lubricant pump until oil flows evenly out of the oil feed bore hole. • Turn the vibration damper through 180°. • Operate reserve lubricant pump until oil flows evenly out of the second oil feed bore hole • Wait until no more air bubbles are visible. 5.3
Further assembly procedure takes place in reverse order from dismantling procedure.. Apply Molykote "G-Rapid Plus" to the screw threads and screw head plates of the screws. Starting torque of screws: M16 = 130 Nm ; M20 = 260 Nm
5.4
Apply "Dirco-Grau" silicon sealant to the pump bearer plate (4) , position over the tapered pins (24) and tighten screws. Assemble lubricant piping.
5.5
Assemble the lubricant pump (08.03.02.nn), check systems for sealing and check lubricant supply to gearwheels.
en / 15.01.2001
IB020552
4/4
Vibration Damper
A5.05. 12.04.02.00
Maintenance / Replace M43
45000
12
See also: Spare parts list:
B1.05.02.432520, B1.05.12.436347
Time requirement:
2 Pers./ 2,00 h
Personnel qualification: Cat/MaK-specialist Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance/ replace: Vibration damper: Replacement (on an exchange basis)
after
45,000 h
Note: We have to point out that this maintenance sheet was prepared only for the purpose of maintenance planning. Please contact the Caterpillar/ Kiel Customer Service in time before reaching the 45,000 hours deadline.
en / 25.02.2008
IB024239
1/1
Turning Device
A5.05. 12.08.01.01
Maintenance / Disassembly and reassembly M43
30000, 750, 3750
12
See also: Spare parts list:
B1.05.12.437330, B1.05.12.437332
Time requirement:
1 Pers./ 0,10 h
Personnel qualification: skilled engine hand Operating medium:
Heavy fuel and distillate fuel
-------------------------------------------------------------------------------------------------------------------------------Maintenance: Oil level check
every
3.750 h
or 6 months
Lubricating / greasing of shaft and gearwheel
every
750 h
or monthlys
Oil change
every
30.000 h
or 4 years
Auxiliary material: Bearing grease „Klüber Altemp. QNB 50“ * Gear oil „Shell Omala Oil 460“ * *or a product of equal standard 1.
Operating the turning device
~
Safety note:
1.1
Engaging the turning device
1.1.1
Move blockinglever (1) to position “V“ and hold.
1.1.2
Move lever (2) to position“ X“, so that the gearwheel of the turning device engages completely in the flywheel toothing.
1.1.3
Let off blockinglever and make sure that the blockinglever engages in position “Z“.
Protect engine against unintentional start-up!
Attention: When the turning device is engaged, the position switch (11) is automatically set to position “engine OFF“ . The engine cannot be started during turning !
1.1.4
Turn the engine.
en / 25.09.2002
IB023850
1/3
Turning Device
A5.05. 12.08.01.01
Maintenance / Disassembly and reassembly M43
30000, 750, 3750
12
1.2
Disengaging the turning device
1.2.1
Move blockinglever (1) to position “V“ and hold.
1.2.2
Move lever (2) to position“ Y “, so that the gearwheel of the turning device is disengaged from the flywheel toothing.
1.2.3
Let off blockinglever and make sure that the blockinglever is engaged in position “Z“.
Attention: The engine can only be started if the turning device is disengaged ! The position switch (11) is then in position „engine-ON“)
en / 25.09.2002
IB023850
2/3
Turning Device
A5.05. 12.08.01.01
Maintenance / Disassembly and reassembly M43
30000, 750, 3750
2.
Maintenance
2.1
Oil level check
12
Note: If a topping up should be necessary, only the prescribed gear oil is to be used ! 2.1.1
Check oil level at the oil level glas (10) and fill in gear oil ( e.g. Shell Omala Oil 460 ) up to the oil level marke.
2.2
Lubricating / greasing of shaft and gearwheel
Note: Grease the notch on the output shaft and the gearwheel only if the turning device is engaged. 2.2.1
Grease the notch on the output shaft (9) and the gearwheel (3) with bearing grease by means of the grease nipple (4).
Attention: Grease the gearwheel toothing only if the turning device is disengaged.
2.2.2
Coat toothing of gearwheel thinly with bearing grease.
2.3
Oil change
2.3.1
Remove screw plug (5) on the driving gear of the turning device.
2.3.2
Drain the oil from the driving gear of the turning device.
2.3.3
Mount the screw plug (5) with new gasket (6).
2.3.4
Remove the vent socket (7) on the gear of the turning device.
2.3.5
Fill in new oil (e.g. Shell Omala Oil 460 ; ca.9 l) up to the oil level mark (10).
2.3.6
Mount vent socket (7).
en / 25.09.2002
IB023850
3/3
