Mak M32 Engine Operating Instructions Manual – PDF DOWNLOAD
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Mak M32 Engine Operating Instructions Manual – PDF DOWNLOAD
The present operating instructions include notes and guidelines for proper handling of the engine plant. It is matched with the equipment condition and the type of fuel sold. Since the type of fuel used considerably influences the service life of the components, the Caterpillar / MaK after-sales service has to be consulted when it is required to change from destillate fuel operation to heavy fuel oil operation, in order to ensure an expert retrofit of the engine plant and to exchange the necessary documentation.
- When changing over from heavy fuel oil operation to destillate operation, the Caterpillar / MaK after-sales service should also be consulted for a longer period of time so that a documentation with extended maintenance intervals can be made available.
With regard to operation and maintenance of the engine including the necessary work to be carried out, the operating instructions are subdivided into the following chapters:
A1 Technical engine data
A3 Operating instructions
A4 Fuels
A5 Maintenance
A6 Tools
With the respective information contained in the individual chapters, the technical personnel is able to maintain the engine in such a manner that regarding its output, reliability, economy and service life optimum operating results can be achieved. If you need further information or if you have any other questions, we kindly ask you to contact our responsible service organization.
- The operating instructions do not release the personnel in charge of this engine plant from their duty to take care. The recognized rules of technology are to be observed, taking into account overriding regulations, observance of the general safety measures and locally applicable accident prevention regulations.
- Data or explanations assumed to be the basic knowledge of trained technical and engine room personnel, are not contained. Caterpillar / MaK is not responsible for damage caused by improper operation and maintenance.
TABLE OF CONTENTS:
Mak M32 Engine Operating Instructions Manual – PDF DOWNLOAD
*1 Lowest avaiable charge air temperature should b........................... 9 *2 The temperature is to be adjusted so that a kin........................... 9 1. Storage tank.......................................................... 21 2. Settling tank HT5, HT6................................................ 21 Connect the two tanks alternaly irrespective of ....................... 21 Before cutting a tank in, thoroughly remove any ....................... 21 3. Separator HS1, HS2................................................ 21 Both separators are always to be operated parall....................... 21 The operational capacity is designed according t....................... 21 4. Day tank HT1...................................................... 22 Daily de-sludging is important......................................... 22 A temperature level between............................................ 22 5. Fuel pressure pump HP1, HP2....................................... 22 6. Fuel pressure-regulating valve HR1................................ 22 7. Self cleaning fuel filter HF4..................................... 22 8. Mixing tank HT2................................................... 22 9. Circulating pump HP3, HP4......................................... 23 10. Final preheater HH1.............................................. 23 If the preheater is of electrical type, ensure t....................... 23 If the preheater is of steam type, a condensatio....................... 23 11. Viscosity measurement and control equipment HR................... 23 12. Fine filter HF1.................................................. 23 3.1. Prelubrication LP2 (standby or prelubrication....................... 27 3.2. Check the operation of the engine-driven forc....................... 27 3.3. Lube oil automatic filter LF2....................................... 27 3.3.1. Lube oil automatic filter LF2 (flushing wit................... 27 If there are more than 100 flushing per day, the c....................... 27 3.3.2. Lube oil automatic filter (with permanent o................... 28 3.4. Duplex lube oil filter LF1 (with indicator)..................... 28 3.5. Strainer filter LF4............................................. 28 Initial operation............................................................ 29 Operational supervision...................................................... 40 Drain the water from the day fuel tank and check....................... 47 Inspect the fuel treatment plant....................................... 47 If the engine is running on heavy fuel, change o....................... 47 - after lengthy service at partial load operation.................... 47 - or before scheduled maintenance work on the fuel................... 47 1. Storage tank DT4.............................................. 48 2. Separator DS1................................................. 48 3. Day tank DT1.................................................. 49 4. Fuel preliminary filter DF2 (duplex filter)................... 49 5. Intermediate tank DT2......................................... 49 6. Diesel oil preheater DH1...................................... 49 If the preheater is of electrical type, ensure t....................... 49 If the preheater is of steam type, a condensatio....................... 49 7. Diesel oil feed pump DP1, diesel oil standby fe................... 49 8. Fuel fine filter DF1(duplex filter)............................... 50 9. Fuel pressure regulating valve DR2................................ 50 Removal from operation....................................................... 57 Danger of frost.............................................................. 62 The following measures are to be implemented after....................... 72 Running-in................................................................... 74 Fault tracing................................................................ 76 Emergency operation.......................................................... 82 - disassemble the rotor.................................................. 84 - obturate the exhaust gas side against bearing ho....................... 84 The cooling water supply is to be interrupted only....................... 84 If there are two turbochargers feeding into one ch....................... 84 1. Misfire........................................................... 88 2. Total misfire..................................................... 89 2.1 Twin engine systems / generator systems...................... 89 Safety instructions.......................................... 93 During all work or contact with:............................. 93 Regulations and care......................................................... 94 Suitable fresh water...................................................113 effective corrosion inhibiting agent...................................113 - corrosion inhibiting oil, soluble......................................113 - chemical corrosion inhibiting agent (chemicals)........................113 exact dosing of the corrosion inhibiting agent.........................113 1. Treatment of cooling water with corrosion inhib...................115 01.......................................................................130 1. Adjust valve bridge...............................................145 1.1 Open indicator valves........................................145 1.2 Engage the barring gear......................................145 1.3 Remove cylinder cover hoods without damaging t...............145 1.4 Turn the crankshaft until the piston of the cy...............145 1.5 Adjust sufficient clearance "S" between 1.5 ro...............146 1.6 Loosen counternut (Fig. 2/3) and 1.6 unscrew a...............146 1.7 In this position screw in adjusting 1.7 screw...............146 1.8 Counter adjusting screw (4)..................................146 2. Adjust valve clearance............................................146 2.1 Measure the clearance (Fig. 1/S) with a 2.1 fe...............146 2.2 Correct clearance "S"........................................146 2.2.1 Loosen counternut......................................146 2.2.2 Turn the valve adjusting screw (2) until 2.2...........146 2.2.3 Tighten the counternut in order to fix 2.2.3...........146 2.2.4 Check clearance again after countering.................146 2.2.5 Disengage the barring gear and close 2.2.5 t...........146 1. Disassembly.......................................................147 1.1 Engage the barring gear......................................147 1.2 Dismount the cylinder head cover.............................147 1.3 Turn the piston to ignition top dead center. I...............147 1.4 Remove fastening nuts (Fig. 1/1).............................147 1.5 Pull up rocker arm axle (2) with inlet and out...............147 1.6 Lift rocker arm bracket (3)..................................147 2. Reassembly........................................................147 2.1 Clean the supporting surfaces of the rocker ar...............147 2.2 Blow through oil overflow holes with compresse...............147 2.3 Place rocker arm brackets (3) and rocker arm a...............147 2.4 Apply a thin film of molykote paste "G-Rapid P...............148 2.5 Adjust valve clearance (01.01.01.nn).........................148 2.6 Check the oil flow...........................................148 2.7 Disengage the barring gear...................................148 2.8 Mount cylinder head cover (check gasket!)....................148 1. Disassembly.......................................................149 1.1 Disassemble rocker arm bracket and 1.1 rocker ...............149 2. Pull out tensioning pins (Fig. 1/4). Pull 2. in...................149 3. Clean all parts and check for damage. 3. Blow t...................149 4. Inspect the contact surfaces of the ball head p...................150 5. Measure the rocker arm bush (Fig. 2/13) and axl...................150 6. Reassembly........................................................151 6.1 Lubricate the running surfaces of the bushes o...............151 6.2 Mount rocker arm bracket and rocker arm axle w...............151 1. Measure rocker arm bush (Fig. 1/1) 1. (01.02.02...................152 2. Replace rocker arm bush...........................................152 2.1 Knock bush (1) out of rocker arm with 2.1 fitt...............152 2.2 Lubricate new bush slightly and press 2.2 into...............152 1. Open lock cap of cylinder head cover and check ...................153 2. The valve rotator works properly, if a uniform ...................153 2.1 If at nominal engine speed the rotational spee...............153 1. Replacement of oil scraper rings 1. (O-rings).....................154 1.1 Dismount valve cone, clean stem 1.1 thoroughly...............154 1.2 Remove the O-ring (Fig. 1/1) from the 1.2 groo...............154 1.3 Clean groove.................................................154 1.4 Lubricate new O-ring slightly and 1.4 carefull...............154 2. Measurement of the valve guide clearance..........................155 2.1 Measure the outside diameter of the valve stem...............155 2.2 Measure the inside diameter of the guide bush ...............155 3. Replacement of the valve guide....................................155 1. Disassembly.......................................................156 1.1 Loosen the cheese head screws (fig. 2/10) and ...............156 1.2 Pull the sleeves (fig. 2/11) out of the connec...............157 1.3 Check the O-rings (15). Replace faulty O-rings...............157 1.4 Check the gaskets (16) for the connecting flan...............157 2. Reassembly........................................................158 2.1 Mount the connecting flange (fig. 2/2 and 3) w...............158 2.2 Mount the connecting and blank flange (fig. 1/...............158 3. Check operation of the alarm probe for 3. leaka...................158 3.1 Dismantle the alarm probe, refit the 3.1 conne...............158 3.2 Mount the alarm probe........................................158 4. Determine the defective fuel pressure 4. pipe i...................158 4.1 Acknowledge the alarm when a "leakage fuel" al...............158 4.2 Check the bore in the connecting flange (2) fo...............158 4.3 Mount the screw (12) with a new gasket (13)..................158 1. Open indicator valve, turn the piston to igniti...................159 2. Drain the cooling water: loosen the connecting ...................159 3. Loosen and remove the connecting flange (Fig. 1...................159 4. Loosen the union nut of the fuel 4. pressure pi...................160 5. Remove covering cap between exhaust 5. pipe and...................160 6. Loosen the six cylinder head nuts with 6. the h...................160 6.1 Place hydraulic pulling elements (Fig. 2/ 6.1 ...............160 6.2 Screw threaded sleeve (W7) onto 6.2 cylinder h...............160 6.3 Connect hydraulic pulling elements 6.3 (Fig. 4...............160 6.4 Close alve (Z) on high-pressure 6.4 pump(W2) ...............160 6.5 Loosen round nuts (Fig. 3/12) with 6.5 pin(W8...............160 6.6 Relieve pulling elements, remove hydraulic dev...............161 7. Mount cylinder head lifting device (W9) onto th...................161 8. Place the cylinder heads on wooden base...........................161 1. Dismount nozzle sleeve (1)........................................162 1.1 Place wrench (5) with bush (6) on nozzle 1.1 s...............162 1.2 Attach torque wrench (W4) with redu1.2 cer (W5...............162 1.3 Use a brass mandrel (W7) and carefully drive o...............163 1.4 Remove O-rings (3 and 4).....................................163 2. Mount the nozzle sleeve (1).......................................163 2.1 Apply a film of vaseline to the new black O-ri...............163 2.2 Apply a film of vaseline to the new green O-ri...............163 2.3 Apply a film of high-temperature thread paste ...............163 2.4 Insert the nozzle sleeve and tighten it by mea...............163 1. Disassembly.......................................................165 1.1 Dismantle cylinder head (01.06.01.nn)........................165 1.2 Dismantle rocker arm (01.02.01.nn) and 1.2 lif...............165 1.3 Place valve spring clamping 1.3 device(W1) on...............165 1.4 Coat the contact surface (X) of the valve 1.4 ...............165 1.5 Compress valve springs (3) and remove 1.5 cone...............165 1.6 Lift off valve spring clamping device (W1), sp...............165 1.7 Pull valve cone out of cylinder head.........................165 2. Reassembly........................................................165 2.1 Check valve guide clearance, renew O-rings (01...............165 2.2 Lubricate burr-free valve stem before fitting ...............165 2.3 The re-assembly is effected in a reverse disma...............165 2.4 After putting in the cone clamp halves, slowly...............165 1. Checking of condition.............................................166 1.1 Valves may be reused without refinishing when................166 1.2 The valves cannot be reused in the 1.2 followi...............167 2. Cleaning..........................................................168 3. Repairing (refinishing of the sealing 3. surfac...................168 3.1 Regrind sealing surface in accordance 3.1 with...............168 3.2 The appropriate information of the 3.2 grindin...............168 3.3 The dimension between the visible 3.3 edge of ...............168 3.4 Outer edge rounded with stone................................168 4. Maintenance 4. (Checking contact reflexion/grin...................169 4.1 Apply small dots of diamond paste 4.1 Dp30/10...............169 4.2 Insert the lubricated valve stem into the 4.2 ...............169 4.3 When the contact reflexion is poor, the 4.3 va...............170 4.4 Ensure that the components (valve 4.4 cone and...............170 5. Final check.......................................................170 5.1 Ensure that the refinishing limits are 5.1 mai...............170 5.2 Clean valve cone/seat thoroughly and 5.2 check...............170 1. Checking of condition.............................................172 1.1 The valve seat rings are re-usable without ref...............173 1.2 The valve seat rings are not re-usable when..................173 2. Cleaning..........................................................173 3. Maintenance (refinishing of valve seat rings).....................173 3.1 Remilling of the valve seat..................................173 3.1.1 Clean the valve seat ring thoroughly in the ...........173 3.1.2 Insert centering disk (4) with guide mandrel...........173 3.1.3 Place cutter head (Fig. 6/2) on greased 3.1............174 3.1.4 Rotate valve seat clockwise uniformly 3.1.4 ...........174 3.1.5 Prior to finishing the cutting process, 3.1............174 3.1.6 Maximum permissible dimension Ø (x) 3.1.6 fo...........174 3.1.7 When the milling cutters are blunt, the cutt...........175 3.1.8 Dismount the milling device. Grind sharp edg...........175 4. Checking of contact reflexion/grinding............................175 4.1 Apply small dots of diamond paste Dp 30/10 - 1...............175 4.2 Insert the lubricated valve stem into the guid...............175 4.3 When the contact reflexion is poor, the valve ...............175 4.4 Ensure that the components (valve cone and sea...............175 5. Final check.......................................................175 5.1 Check whether the refinishing limit dimensions...............175 5.2 Clean valve cone/seat thoroughly and check the...............175 1. Cut off the unusable valve cone at the 1. shaft...................176 2. Insert the valve cone into the valve seat 2. ri...................176 3. Drive the valve seat ring out by striking 3. th...................176 4. Shrink the new seat ring in.......................................176 4.1 Cool the seat ring to at least -20 C, heat 4................176 4.2 Carefully insert the seat ring with the help o...............177 5. Slightly refinish the seat ring, e.g. with valv...................177 6. Fit valve cone....................................................177 1. Disassembly.......................................................178 1.1 Loosen the fixing screws (10) and remove cover...............178 1.2 Loosen securing nuts (3), thereby holding valv...............178 1.3 Remove disk (5), step piston (6), spring(7), ...............178 1.4 Carefully clean all parts in gas oil.........................178 1.5 Check step piston (6) , compression rings (11)...............178 2. Reassembly........................................................179 2.1 Grease step piston (6) lightly with Moly2.1 ko...............179 2.2 Reassembly according to reverse order 2.2 of d...............179 2.3 Check sealing of starting valve before 2.3 sta...............179 1. Check the gasket between the cylinder 1. head, ...................180 2. Check cylinder head externally for leakage........................180 2.1 In case of lubeoil leakage, check the retainin...............180 2.2 In case of leakage at the wedge parts of the m...............180 3. Remove cylinder head cover, inspect cylinder he...................180 3.1 Observe conformability of valve movement. Irre...............180 3.2 Check function of the valve rotating device (0...............180 3.3 Check valve springs for damage...............................180 3.4 Check lube oil supply of valve lever and valve...............180 1. Wash the cylinder head with a cold cleaner........................181 2. Clean the inlet and outlet ports and the cylind...................181 3. Clean cooling water inlet ports and cooling wat...................181 4. Check underside of cylinder head, especially at...................181 5. Clean the sealing surface for the injection val...................181 6. Check in and outlet holes of the media supply f...................181 7. Check the function of the alarm probe for fuel ...................181 1. Turn piston to ignition top dead center...........................183 2. Clean sealing faces and contact surfaces of cyl...................183 3. Renew the following O-rings. Upper O-ring on cy...................183 4. Carefully place cylinder head with cylinder hea...................184 5. Align cylinder head. Mount clamping ring for ex...................184 6. Tightening of the six cylinder head 6. screws t...................184 6.1 Place hydraulic pulling elements (Fig. 2/ 6.1 ...............184 6.2 Screw threaded sleeve (W7) by hand 6.2 onto cy...............184 6.3 Connect hydraulic pulling elements (Fig. 4/W4)...............185 6.4 Close valve (Z) on high pressure pump and exte...............185 6.5 Tighten round nuts (Fig. 3/12) with pin (W8). ...............185 6.6 Check the firm positioning of the round nuts.................185 6.7 Unload hydraulic pulling elements and dismantl...............185 7. Tighten clamping ring for exhaust pipeline. The...................186 8. Mount the removed connecting flange of the medi...................186 9. Mount the removed pressure gauge pipelines and ...................186 10. Connect fuel pressure pipe with corresponding ...................186 11. Adjust valve clearance (01.01.01.nn) and mount...................186 12. Check sealing of all connections after taking ...................186 1. Open the indicator valves and engage the barrin...................187 2. Open the crank case cover approximately 10 minu...................187 3. Touch the crankshaft and connecting rod bearing...................187 4. Check all screws and nuts for locking.............................187 5. Check the degree of fouling in the crankcase (s...................187 6. Check the appearance of the cylinder liner surf...................187 7. Remove camshaft cover. Check the screws of the ...................187 7.1 Turn engine and check the running surfaces of ...............187 7.2 Check lubeoil flow for camshaft bearings and v...............187 8. Check wheel drive (04.08.01.nn)...................................187 9. Check the sump and crankcase for left behind to...................187 1. Turn the crank pin from bottom dead center in t...................189 2. Set the pointer to the scale value 20 on the me...................189 3. Turn the crankshaft, so that the crank pin turn...................189 4. Watch the gauge continuously and read the value...................189 1. Disassemble the piston (02.06.01.nn)..............................199 2. Turn the connecting rod with the con2. necting ...................199 3. Loosen the cylinder head nuts (Fig. 1/2) 3. wit...................199 3.1 Place the hydraulic jack (W3) with 3.1 support...............199 3.2 Screw the threaded bushs (W5) on the 3.2 big-e...............199 3.3 Connect the hydraulic jacks (Fig. 2/W3) 3.3 vi...............199 4. Close the valve (Fig. 2/6) of the high- 4. pres...................199 5. Slacken the cylinder head nuts (Fig. 1/2) 5. wi...................199 6. Open the valve (Fig. 2/6) of the high-pressure ...................200 7. Wait for the complete pressure drop, disassembl...................200 8. Turn the connecting rod horizontally with the c...................200 9. Preassemble the suspension 1 (Fig. 3/19) and su...................200 10. Insert the sliding rails (18) from the exhaust...................200 11. Hang slide rail and straining screws (17) into...................201 12. Dismount connecting rod support (20) and screw...................201 13. Unscrew round nuts (2) and pull off big-end be...................201 14. Push lower big-end bearing shell (12) aside an...................201 15. Loosen lateral stopper fixing (22) so that it ...................201 16. Pull off connecting rod (10) at least 10 mm fr...................201 17. Turn the top big-end bearing shell (13) by 180...................201 18. Assess the state of the big-end bearing shells...................201 1. Reassembly of the bearing shells..................................202 1.1 Clean crankpin and oil.......................................202 1.2 Oil the bearing shells internally and 1.2 exte...............202 1.3 Attach the evtl. disassembled 1.3 connecting r...............202 1.4 Place the top bearing shell (without 1.4 holes...............202 1.5 Cautiously press the connecting bar 1.5 agains...............202 1.6 Attach the evtl. disassembled big-end 1.6 bear...............203 1.7 Push the con-rod bearing cover furher 1.7 to w...............203 1.8 Cautiously push the big-end bearing 1.8 cap (3...............203 1.9 Reassemble the cylinder head nuts (5) and tigh...............203 1.10 Mount connecting rod support (Fig. 5/13) or e...............203 1.11 Disassemble the big-end bearing as1.11 sembly...............203 1.12 Check the con-rod bearing shell on the 1.12 e...............203 2. Fasten the cylinder head nuts (Fig. 3/5) 2. wit...................203 2.1 Turn down the connecting rod with the 2.1 conn...............203 2.2 Place the hydraulic jacks (W3) with 2.2 suppor...............204 2.3 Tighten the threaded bushs (W5) 2.3 fingertigh...............204 2.4 Connect the hydraulic jacks (Fig. 4/W3) 2.4 vi...............204 2.5 Close the valve (10) of the high- 2.5 pressure...............204 2.6 Tighten the cylinder head nuts (Fig. 3/5) with...............205 2.7 Inspection of the firm rest of the cylinder nu...............205 2.8 Open the valve (Fig. 4/10) of the high-pressur...............205 2.9 Wait for complete pressure loss..............................205 3. Reassemble the piston (02.10.01.nn)...............................205 1. Remove main bearing...............................................207 1.1 Open corresponding drive cap on the 1.1 clutch...............207 1.2 Turn the crankshaft to suitable position 1.2 f...............207 1.3 Turn a connecting rod adjacent to the 1.3 main...............207 1.4 Slacken the round nuts (Fig. 1/2) of the 1.4 l...............207 1.4.1 Slacken and remove the protective 1.4.1 caps...........207 1.4.2 Place the hydraulic jacks (Fig. 2/W4) 1.4.2 ...........207 1.4.3 Tighten tapped bushes (W8) to anti- 1.4.3 fa...........207 1.4.4 Connect the hydraulic jacks (Fig. 3/W4) 1.4............207 1.4.5 Close valve (Fig. 3/13) of the high- 1.4.5 p...........208 1.4.6 Slack round nuts (Fig. 2/2) by means of 1.4............208 1.4.7 Open valve (Fig. 3/13) of the high- 1.4.7 pr...........208 1.4.8 Wait until the pressure has completely 1.4.8...........208 1.4.9 Slacken and unscrew anti-fatigue stud 1.4.9 ...........208 1.4.10 Just slacken the round nuts (2) of the 1.4............208 1.5 Employ device (Fig. 4/W10)...................................208 1.5.1 Move device by means of the threaded 1.5.1 r...........208 1.5.2 Disassemble desk (19), lift the device 1.5.2...........209 1.5.3 Reassemble desk and insert device 1.5.3 bene...........209 1.6 Slacken round nuts (Fig. 5/23) of the 1.6 main...............209 1.6.1 Place hydraulic jacks (W5) and 1.6.1 support...........209 1.6.2 Lift device (W10) until the supporting 1.6.2...........209 1.6.3 Slack tapped bushes (W9) from below 1.6.3 th...........209 1.6.4 Connect hydraulic jacks (Fig. 7/W5) via 1.6............209 1.6.5 Close valve (30) of high-pressure pump 1.6.5...........210 1.6.6 Slack round nuts (23) by means of 1.6.6 pin...........210 1.7 Open valve (Fig. 7/30) of the high-pressure pu...............210 1.7.1 Wait until the pressure has completely dropp...........210 1.7.2 Move device down to the stop limit and take ...........210 1.8 See step 2 for measurement of the gap........................210 1.9 Move device to main bearing cap and 1.9 slack ...............210 1.10 Take out lower bearing shell................................210 1.11 Insert dog (Fig. 8/W11) into the oil bore 1.1...............210 1.12 Turn out and take out top bearing shell.....................210 1.13 See 02.03.03.nn and 02.03.07.nn for 1.13 eval...............211 1.14 Check wear of the wall thickness in the 1.14 ...............211 1.15 If the wear exceeds 0.05 mm, the 1.15 bearing...............211 2. Measurement of the gap............................................211 2.1 Remove anti-fatigue stud bolts (Fig. 10/1) of ...............211 2.1.1 Slack both round nuts (23) hydraulically acc...........211 2.1.2 Slack round nuts further, but do not take th...........212 2.1.3 Measure the gap "K" between cylinder crankca...........212 1. Assemble bearing shells...........................................213 1.1 Oil the running surface of the top shell 1.1 w...............214 1.2 Insert the mounting device (W12) in the 1.2 be...............214 1.3 Turn top bearing shell in and see that 1.3 the...............214 1.4 Bring the device (W10) up, remove 1.4 round nu...............214 1.5 Oil plated overlay of the lower bearing 1.5 sh...............214 1.6 Place the possibly disassembled lower 1.6 star...............214 2. Preliminary mounting of the main 2. bearing bol...................215 2.1 Lift device (Fig. 3/W10) with main 2.1 bearing...............215 2.2 Hand-tighten round nuts (6) evenly to 2.2 main...............215 2.3 Slacken and take out possibly placed 2.3 count...............215 2.4 Lower device (W10)...........................................215 3. Assemble lateral anti-fatigue stud bolts 3. (Fi...................215 3.1 Grease thread of the anti-fatigue stud 3.1 bol...............215 3.2 Hand-tighten round nuts (12) to the 3.2 anti-f...............215 3.3 Place hydraulic jacks (Fig.5/W4) with 3.3 the...............216 3.4 Hand-tighten tapped bushes (W8) to the 3.4 ant...............216 3.5 Connect hydraulic jacks (W4) on the 3.5 operat...............216 3.6 Close valve (Fig.6/18) of the high-pres3.6 su...............216 3.7 Tighten round nut (Fig.5/12) firmly by 3.7 me...............216 3.8 Open valve (Fig.6/18) of high-pressure 3.8 pu...............216 3.9 Connect hydraulic jack (Fig.5/W4) with high-p...............216 3.10 Close valve (18) of the high-pressure pump (W...............216 3.11 Check firm support of round nut.............................217 3.12 Open valve (Fig. 6/18) of the high-pressure p...............217 3.13 Wait until the pressure has completely droppe...............217 3.14 Tighten round nuts (Fig. 4/12) of the lateral...............217 3.15 Screw protective caps (13) to anti-fatigue st...............217 4. Tightening of the main bearing bolts..............................217 4.1 Place hydraulic jacks (Fig. 7/W5) and 4.1 supp...............217 4.2 Lift device (W10) until the supporting 4.2 sle...............217 4.3 Hand-tighten tapped bushes (W9) from 4.3 below...............217 4.4 Connect hydraulic jacks (W5) via high- 4.4 pre...............217 4.5 Close valve (Fig. 8/23) of the high-pressure p...............217 4.6 Tighten round nuts (Fig. 7/6) firmly by 4.6 me...............218 4.7 Check firm rest of the round nut.............................218 4.8 Open valve (Fig. 8/23) of the high-pres4.8 sur...............218 4.9 Wait until the pressure has completely 4.9 dro...............218 4.10 Move device down until it rests on the 4.10 l...............218 4.11 Check the oil flow..........................................218 4.12 Close crankcase door on the control and exhau...............218 1. Measure the end clearance "s".....................................220 1.1 Open cap beneath the gear drive and the first ...............220 1.2 Fit the dial gauge with a magnet on the flywhe...............220 1.3 Shift the crankshaft in axial direction by mea...............220 1.4 Axial clearance "s":.........................................220 2. Disassemble main thrust bearing...................................221 2.1 Turn the crankshaft to suitable position 2.1 f...............221 2.2 Turn the connecting rod of the first 2.2 cylin...............221 2.3 Slacken the round nuts (Fig. 2/7) of the 2.3 l...............221 2.3.1 Slacken and remove the protective 2.3.1 caps...........221 2.3.2 Place the hydraulic jacks (Fig. 3/W4) 2.3.2 ...........221 2.3.3 Tighten tapped bushes (W8) to anti- 2.3.3 fa...........221 2.3.4 Connect the hydraulic jacks (Fig. 4/W4) 2.3............221 2.3.5 Close valve (Fig. 4/13) of the high- 2.3.5 p...........221 2.3.6 Slack round nuts (Fig. 3/7) by means of 2.3............221 2.3.7 Open valve (Fig. 4/13) of the high- 2.3.7 pr...........222 2.3.8 Wait until the pressure has completely 2.3.8...........222 2.3.9 Slacken and unscrew anti-fatigue stud 2.3.9 ...........222 2.3.10 Just slacken the round nuts (7) of the 2.3............222 2.4 Employ device (Fig. 5/W10)...................................222 2.4.1 Move device by means of the threaded 2.4.1 r...........222 2.4.2 Disassemble desk (19), lift the device 2.4.2...........222 2.4.3 Reassemble desk and insert device 2.4.3 bene...........222 2.5 Slacken round nuts (Fig. 6/23) of the 2.5 main...............223 2.5.1 Place hydraulic jacks (W5) and 2.5.1 support...........223 2.5.2 Lift device (W10) until the supporting 2.5.2...........223 2.5.3 Slack tapped bushes (W9) from below 2.5.3 th...........223 2.5.4 Connect hydraulic jacks (Fig. 8/W5) via 2.5............223 2.5.5 Close valve (30) of high-pressure 2.5.5 pump...........223 2.5.6 Slack round nuts (23) by means of 2.5.6 pin...........223 2.6 Open valve (Fig. 8/30) of the high-pressure pu...............224 2.6.1 Wait until the pressure has completely dropp...........224 2.6.2 Move device down to the stop limit and take ...........224 2.7 See step 3 for measurement of the gap........................224 2.8 Move device to main bearing cap and slack roun...............224 2.9 Take out lower bearing shell.................................224 2.10 Insert dog (Fig. 9/W11) into the oil bore 2.1...............224 2.11 Turn out and take out top bearing shell.....................224 2.12 See 02.03.03.nn and 02.03.07.nn for 2.12 eval...............224 2.13 Check wear of the wall thickness in the 2.13 ...............225 2.14 If the wear exceeds 0.05 mm, the 2.14 bearing...............225 3. Measurement of the gap............................................225 3.1 Remove anti-fatigue stud bolts (Fig. 11/6) of ...............225 3.1.1 Slack both round nuts (23) hydraulically acc...........225 3.1.2 Slack round nuts further, but do not take th...........225 3.1.3 Measure the gap "K" between cylinder crankca...........225 1. Open indicator valves, remove 1. propulsion com...................226 2. Turn crankshaft pin to approx. 20° 2. before TD...................226 3. Remove cylinder head (01.06.01.nn)................................226 4. Mount cylinder liner retainer (Fig. 1/W6) 4. on...................226 5. Fill ring gap between piston and 5. cylinder li...................226 6. Use a copper hammer and gently beat 6. the gaug...................226 7. Re-tap bores (2; M12, 11 mm deep) in 7. piston ...................226 8. Carefully scrape off carbon deposits in 8. the ...................227 9. Screw lifting gear for piston (Fig. 1/W1) 9. to...................227 10. Attach crane to carrying ring of lifting 10. g...................227 11. Split con-rod shank, to do this:.................................227 11.1 Mount both supports for torque wrench 11.1 (F...............227 11.2 Loosen necked down screws (5) with 11.2 torqu...............227 11.3 Remove both supports for torque 11.3 wrench (...............227 12. Mount con-rod retainer (Fig. 3/W5) on 12. the ...................227 13. Pull piston carefully. Make sure the top 13. p...................227 14. Cover the oil bore in the con-rod shank divisi...................227 1. Turn piston.......................................................228 1.1 Attach crane to lifting gear for piston 1.1 (F...............228 1.2 Mount second lifting gear for piston 1.2 (W1) ...............228 1.3 Carefully turn piston and place on 1.3 suitabl...............228 2. Disassembly of piston crown.......................................228 2.1 Attach lifting gear for piston (W1, 2.1 connec...............228 2.2 Measure small-end bearing (3) 2.2 (02.09.01.nn...............228 2.3 Loosen hexagon nuts (Fig. 2/5) and 2.3 remove ...............229 2.4 Clean piston crown (8) and piston lower 2.4 pa...............229 2.5 Remove locking ring (9), remove sliding 2.5 bl...............229 2.6 Check and clean oil bores and sliding 2.6 surf...............229 2.7 Determine length projection (IÜ) of 2.7 piston...............229 2.8 Mounting of piston...........................................229 2.9 Screw piston screws (if removed) into piston c...............229 2.10 Mount piston lower part (12), centering hole ...............229 2.11 Mount thrust pieces (6) onto piston screws (7...............229 2.12 Coat inner thread and contact surfaces of the...............229 2.13 Tighten hexagon nuts (5) crosswise with a tor...............230 2.14 Loosen hexagon nuts again. 2.14.............................230 2.15 Tighten up tapering of piston screws (7) in p...............230 2.16 Tighten hexagon nuts (5) crosswise with a tor...............230 2.17 Check:......................................................230 1. Piston inspection (6,000 h).......................................231 1.1 Open all crankcase covers....................................231 1.2 Check the running surfaces of the cylinder lin...............231 1.3 Draw the piston from the liner with the worst ...............231 1.4 Remove piston rings only with the 1.4 piston r...............232 1.5 Clean the piston rings.......................................232 1.6 Check the chromium layer for wear, 1.6 particu...............232 1.7 Clean the piston, ring grooves and oil return ...............232 1.8 Smooth light friction and seazing marks with a...............232 1.9 Measure the groove width hN (Fig. 2) in the fr...............232 1.10 Measure the ring thickness hR (Fig. 2) at 4 o...............232 1.11 Calculate the limit tolerances and check acco...............233 1.12 Insert piston rings with inscription 1.12 upw...............233 2. Maintenance (12,000 h)............................................233 2.1 Draw all pistons (02.06.01.nn)...............................233 2.2 Check the state of lubrication and 2.2 appeara...............233 2.3 Remove the piston rings with the 2.3 expander ...............233 2.4 Clean all ring grooves and check wear 2.4 of t...............233 2.5 Measure the groove width hN according to opera...............233 2.6 Replace oil scraper ring and all compression r...............233 2.6.1 Insert piston rings with inscription (Fig. 3...........233 2.7 Fit all pistons (02.10.01.nn)................................233 1. Turn piston.......................................................234 1.1 Attach crane to lifting gear for piston 1.1 (F...............234 1.2 Mount second lifting gear (W1) to 1.2 connecti...............234 1.3 Turn piston and place it on suitable 1.3 base................234 2. Disassembly (Fig. 1)..............................................234 2.1 Mark connecting rod boss (1), piston (2) 2.1 a...............234 2.2 Lift connecting rod boss slightly with 2.2 cra...............234 2.3 Remove locking rings (4).....................................234 2.4 Push piston pin (3) out of piston bore 2.4 and...............234 2.5 Check oil bores (6) in connecting rod boss and...............235 2.6 Check piston pin surface for cracks and damage...............235 2.7 Measure piston pin, piston pin bush and piston...............235 3. Assembly..........................................................235 3.1 Insert one locking ring (4) in the piston bore...............235 3.2 Insert connecting rod boss (1) in the piston s...............235 3.3 Lubricate piston pin (3) and push into piston ...............235 3.4 Secure piston pin with second locking ring...................235 1. Measure small-end bush............................................236 1.1 Clean piston pin (Fig. 2/1), small-end bush (2...............236 1.2 Determine axial clearance [piston boss distanc...............236 2. Disassemble small-end bush........................................238 2.1 When disassembling the small-end 2.1 bush make...............238 3. Assemble the small-end bush.......................................238 3.1 Cool a piston bush by means of CO2 snow to app...............238 3.2 Insert bush into the connecting rod boss.....................238 3.3 After reaching the normal temperature, the dim...............238 1. Insert all piston rings with the ring cuts 1. i...................239 2. Loosen the tensioning screw (Fig. 1/1), 2. unti...................239 3. Apply Molykote paste "G-Rapid Plus" to 3. the t...................239 4. Place the piston mounting device (W7) 4. above ...................239 5. Check the free motion of rings by 5. turning th...................240 6. Mount the lifting device for pistons 6. (Fig.2...................240 7. Mount the piston mounting ring (W10)..............................240 8. Attach the piston to a crane and lift it..........................240 9. Cautiously insert the piston into the 9. cylind...................240 10. Lower the piston, it must not get 10. jammed i...................240 11. Let sit the piston mounting device 11. (Fig.1...................240 12. Assemble the cylinder liner support 12. (Fig. ...................240 13. Mount piston and connecting-rod..................................241 13.1 Apply Molykote to the threads and contact fac...............241 13.2 Attach segments (10) to con-rod shank partiti...............241 13.3 Disassemble the connecting rod support (02.06...............241 13.4 Assemble both supports for torque wrenchs (W4...............241 13.5 Use a torque wrench (W2), change-over ratched...............242 13.6 Visual check of tightening torque acc. to ang...............242 13.7 Disassemble both supports for torque wrench (...............242 14. Turn the pistons jointly to TDC with the crane...................242 15. Disassemble the piston mounting device (Fig. 1...................242 16. Clean the contact face of the cylinder liner (...................242 17. Mount new gauging ring...........................................242 18. Assemble the cylinder head (01.11.01.nn).........................242 19. Disassemble the cylinder liner support (Fig. 2...................242 1. Disassembly of counter-balance....................................244 1.1 Turn crankshaft to position according 1.1 to (...............244 1.2 Loosen both round nuts (1) on the 1.2 necked-d...............244 1.2.1 Place hydraulic tightening element (W4) 1.2............244 1.2.2 Screw threaded sleeve (W6) onto 1.2.2 necked...........244 1.2.3 Connect hydraulic tightening element (Fig. 2...........244 1.2.4 Close valve (Fig. 2/10) on the high-pressure...........245 1.2.5 Loosen round nut (Fig. 1/1) with pin (W3). T...........245 1.2.6 Open valve (Fig. 2/10) on the high-pressure ...........245 1.2.7 Wait for pressure to drop completely, then r...........245 1.2.8 Loosen the second round nut (1), see operati...........245 1.3 Mount the removal and installation device for ...............245 1.3.1 Support device (W7) with a hoist connected t...........245 1.3.2 Screw hexagon nuts (W8) onto necked-down bol...........246 1.3.3 Loosen necked-down bolts and slowly unscrew ...........246 1.3.4 After completely unscrewing the necked-down ...........246 2. Reassembly of counter-balance.....................................246 2.1 Turn crankshaft to position according to (Fig................246 2.2 Clean contact surfaces on the counter-balance ...............246 2.3 Apply a thin coat of Molykote paste to the nec...............246 2.4 Position counter-balance at crankshaft with de...............246 2.5 Disassemble hexagon nuts (W8)................................246 2.6 Screw round nuts (1) by hand onto the necked-d...............246 2.7 Dismantle device (W7)........................................246 3. Tighten round nuts (1) of the necked-down bolts...................246 3.1 Place hydraulic tightening element 3.1 (Fig.4...............247 3.2 Screw threaded sleeve (W6) by hand 3.2 onto ne...............247 3.3 Connect hydraulic tightening element 3.3 (Fig................247 3.4 Close valve (Fig. 2/10) on the high-pressure p...............247 3.5 Tighten round nut (Fig. 4/1) with pin (W3)...................247 3.6 Open valve (Fig. 2/10) on the high-pressure pu...............247 3.7 Wait for pressure to drop completely, then uns...............247 3.8 Place hydraulic tightening element (Fig. 4/W4)...............247 3.9 Close valve (Fig. 2/10) on the high-pressure p...............247 3.10 Tighten round nut (Fig. 4/1) with pin (W3)..................248 3.11 Reduce hydraulic pressure by...............248 3.12 Relieve hydraulic tightening device according...............248 3.13 Place hydraulic tightening element (Fig. 4/W4...............248 3.14 Also tighten the first necked-down bolt with ...............248 3.15 Tighten round nut (1) with pin (W3).........................248 3.16 Relieve tightening element according to 3.6 a...............248 1. Retain the flexible mounting......................................249 1.1 Dismantle nuts and bolts (Fig. 1/20, 21 and 22...............249 1.2 Loosen stud bolts (23).......................................249 1.3 Screw down lock ring (24) together with tube (...............249 1.4 Apply a thin coating of oil to hold-down bolts...............249 2. Dismantle cylinder head (01.06.01.nn).............................249 3. Dismantle push rods for inlet valve and exhaust...................249 4. Mount retaining device for rockingl 4. lever (W...................251 5. Screw in the hexagon head screw (2) 5. until th...................251 6. Draw piston (02.06.01.nn).........................................251 6.1 Dismantle cylinder liner retainers...........................251 7. Dismantle connecting rod bearing with 7. bearin...................251 7.1 Place connecting rod on suitable base........................251 8. Dismantle one counter-balance from the averaged...................251 9. Seal off oil bore in connecting pin of 9. avera...................251 9.1 Tighten castellated nut (13) by hand and 9.1 s...............251 10. Mount cylinder head (01.11.01.nn)................................251 11. Mount crankcase cover on control and 11. exhau...................251 12. Start engine in emergency operation 12. mode (...................251 13. Repair averaged engine...........................................252 13.1 Disassemble cylinder head, locking bolt in cr...............252 13.2 Release fixation of flexible mounting.......................252 13.3 Replace / repair defective parts............................252 13.4 Mount connecting rod, connecting rod bearing ...............252 13.5 Mount crankcase cover on control and exhaust ...............252 13.6 Take engine into operation (A3.05.00.nn)....................252 1. Dismantle cylinder head (01.06.01.nn) and suppo...................253 2. Loosen round nuts (1) with hydraulic device (02...................253 3. Loosen nuts (1) approx. 20 mm from support on c...................253 3.1 Turn crankshaft through an angle of approx. 20...............253 4. Disassembly of the necked-down bolts (5) on the...................253 4.1 Tie extension (W2) with mounted 22 mm insert (...............253 4.2 Position ratchet (W1) with mounted tube (W4) a...............253 4.3 Loosen screws (5)............................................253 4.4 Remove screws (5) and segment (6)............................254 4.5 In order to loosen the necked-down bolts (5) o...............254 4.6 Secure both the cylinder liner and connecting ...............254 4.7 Move connecting rod to bottom dead centre and ...............254 1. Check the relief valve from the inside of 1. th...................255 2. If the valve is not free, disassemble the 2. re...................255 3. Check pressure spring (3) and renew if 3. neces...................255 4. Check the guide bolt (7) and the valve 4. head ...................255 5. Check O-ring (4) on the guide bolt and 5. renew...................255 6. When fitting a new O-ring, cover the 6. thread ...................255 7. Check the seal (5) of the valve head (6) 7. and...................255 8. Assemble the relief valve, fit the splint 8. pi...................255 9. Check the seal (9) prior to assembling 9. and r...................255 1. Disassembly of cooling water distributor housin...................256 1.1 Dismantle bracket for exhaust line (Fig. 1/2)................256 1.2 Dismantle the connection to the cooling water ...............257 1.3 Push sleeves from starting air duct (3) into t...............257 1.4 Remove retaining screws (4). Screw ring bolt (...............257 1.5 Renew O-rings (5) on cooling water distributor...............257 1.6 Renew O-rings at starting air transition (Fig................257 2. Reassembly of cooling water 2. distributor hous...................258 2.1 Place cooling water distributor housing 2.1 (6...............258 2.2 Press housing against cooling water 2.2 distri...............258 2.3 Push sleeves (3) from starting air duct into c...............258 2.4 Mount bracket for exhaust line (Fig. 1/2)....................258 2.5 Tighten retaining screws (Fig. 2/1) for coolin...............258 2.6 Remove ring bolts (W1).......................................258 1. Check the cylinder liner..........................................259 1.1 Remove fire ring and pull piston.............................259 1.2 Clean the cylinder liner internally (thoroughl...............259 1.3 Measure the cylinder liner with the precision ...............259 1.4..............................................................259 1.5 Enter the measured values in the table (Fig. 2...............260 1.6 When the wear limit, normally in the area of t...............260 1. Disassemble the cylinder liner....................................261 1.1 Disassemble the piston (02.06.01.nn). Disassem...............261 1.2 Measure the wear.............................................261 1.3 Place the upper cross piece half (W1) with thr...............261 1.4 Mount the lower cross piece half (1) and brace...............261 1.5 Connect the lifting gear and pull out the cyli...............261 1.6 Remove the O-ring (13) in the cooling water di...............261 1.7 Carefully clean the sealing surface and the gr...............261 1.8 Carefully clean the cooling water area on the ...............261 1.9 Clean the cylinder liner support, upper and lo...............261 1. Clean the inside of the cooling water 1. distri...................263 2. Fit a new O-ring (4) in the groove on the 2. co...................263 3. Coat the contact surfaces of the cylinder 3. li...................263 4. Remove the device (fig. 1/W1) from the drawn cy...................264 5. Mount the device on the cylinder liner which is...................264 6. Connect the lifting gear to the ring nut on the...................264 7. Remove the device (W1) from the 7. cylinder lin...................264 1. Check for good mounting and leaks of flanged co...................265 2. Check the expansion joints for leaks and the su...................265 3. Check the tight fitting of the suspensions and ...................265 4. Retighten the fixing bolts of the brackets of t...................265 5. Check the monitoring and control equipment for ...................265 6. Check the foundation bolts and chocks by knocki...................265 7. Check elastic bedding elements for damages........................265 1. Check the camshaft bearing clearance..............................266 1.1 Open corresponding inspection glass lid of the...............266 1.2 Measure clearance camshaft bearing / bearing n...............266 1. Check the running surface of one camshaft beari...................267 1.1 Dismount the valve lifter from camshaft sectio...............267 1.2 Unscrew the hexagon nuts (Fig.1/1) on the left...............268 1.3 Unscrew the fixing screw (Fig. 2/11).........................269 1.4 Use a suitable wood block and rubber 1.4 hamme...............269 1.5 Place cardboard or similar material 1.5 around...............269 1.6 Use a squared timber and move the 1.6 camshaft...............269 1.7 Remove the screws (Fig. 1/W1) and the 1.7 nuts...............269 1.8 Check the camshaft bearing. 1.8 1.8 Replace th...............269 1.9 Check the back of the camshaft bearings for we...............269 1.10 Check the running surfaces of the bearing jou...............269 1.11 Replace the defective camshaft sections and c...............269 1.12 Mount the camshaft (04.04.01.nn)............................269 1.13 Mount the fixing screw (Fig. 2/11). Tighten s...............270 2. Check the running surfaces of all camshaft bear...................270 2.1 Unload all valve lifters and lift them (04.04................270 2.2 Loosen the hexagon nuts (Fig.1/1) on the left-...............270 2.3 Remove the fixing screws (Fig. 2/11) on the ca...............270 2.4 Use a suitable wood block and a rubber hammer ...............270 2.5 Move the camshaft (1.4 to1.7)................................270 2.6 Support vibration damper and camshaft section ...............270 2.7 Check the running surfaces of the bearing jour...............270 2.8 Replace the defective camshaft sections (04.04...............270 2.9 Mount the camshaft (04.04.01.nn).............................270 2.10 Mount the fixing screw (11). Tighten screw at...............270 2.11 Disengage the turning device................................270 2.12 Unload the valve lifter, dismount the support...............270 1. Disassembly.......................................................271 1.1 Open indicator valves and dismount camshaft co...............271 1.2 Dismount all valve lifters of the appropriate ...............271 1.3 Dismount fuel injection pump of the appropriat...............272 1.4 Dismount push-rods from the camshaft section o...............272 1.5 Disassembly of the last camshaft section.....................272 1.5.1 Dismount vibration damper (Fig. 2/10) (04.09...........272 1.5.2 Remove intermediate piece (12).........................272 1.6 Loosen hexagon nuts (Fig. 1/1) on both flanges...............272 1.7 Place the round sling (Fig. 3/W1) 1.7 around t...............273 1.8 Slightly tightened the round sling (W1) 1.8 wi...............273 1.9 Remove the fixing screw (11).................................273 1.10 Use a suitable wood block and a rubber 1.10 h...............273 1.11 Place cardboard or similar material 1.11 arou...............273 1.12 Use a squared timber and move the 1.12 camsha...............273 1.13 Secure right part of camshaft with wood wedge...............274 1.14 Line the camshaft trough with cardboard or si...............274 1.15 Pull the camshaft section (Fig. 4/3) to the l...............274 1.16 Remove the camshaft bearing (4) from the lift...............274 2. Mounting..........................................................275 2.1 Press the parallel pin (Fig. 5/5) into the fla...............275 2.2 Lubricate the camshaft bearing (Fig. 1/4) insi...............275 2.3 Place the camshaft section (3) in the appropri...............275 2.4 Place the round sling (Fig. 3/W1) around camsh...............275 2.5 Slowly lift the lifting gear and carefully gui...............275 2.6 Use the parallel pin and align the camshaft se...............276 2.7 Use two opposite studs (Fig. 1/2) and appropri...............276 2.8 Use a squared timber and carefully move the ca...............276 2.9 Use Molykote and insert all studs (2) and nuts...............276 2.10 Insert studs and nuts into the left-hand flan...............276 2.11 Align the location bore hole of the camshaft ...............276 2.12 Push-in the camshaft bearing (4) with a suita...............276 2.13 Use Molykote and insert the fixing screw (11)...............276 2.14 Insert the remaining studs and nuts into the ...............276 2.15 Lower the lifting gear and remove the round s...............277 2.16 When the last camshaft section is mounted:..................277 2.16.1 Firmly attach the intermediate piece (Fig. ...........277 2.16.2 2.16.2 Insert the studs (2) into the connec...........277 2.16.3 Mount the vibration damper (10) (04.09.01.n...........277 2.17 Mount the valve mechanisms and fuel injection...............277 2.18 Mount the push-rods.........................................277 2.19 Mount the valve lifters and check the valve c...............277 2.20 Mount the fuel injection pumps (07.02.01.nn)................277 2.21 Check the lube oil flow through the camshaft................277 2.22 Mount the housing cover.....................................277 2.23 Close the indicating valves.................................277 2.24 Disengage the turning device (12.08.01.nn)..................277 1. Check the tooth profiles and oil nozzles..........................278 1.1 Remove the lid of the gear housing on 1.1 the ...............278 1.2 Check the tooth profiles of the cam 1.2 shaft ...............278 1.3 Measure the play of the gears between 1.3 the ...............278 1.4 Setpoints x = 0.20 - 0.37 mm 1.4 ...............278 1.5 Check whether the oil nozzles (4,5 and 1.5 6) ...............278 2. Measure the axial play of the intermediate whee...................279 2.1 Check the seals and install the lids to the ge...............279 1. Replace the O-ring (Fig. 2/6) of the inter1. me...................280 1.1 Loosen the hex screws (Fig. 2/3); 1.1 remove u...............280 1.2 Remove the gear space lid of the 1st 1.2 cylin...............280 1.3 Press the intermediate wheel axle (1) of 1.3 t...............280 1.4 Replace the O-ring (6).......................................280 1.5 Coat the thread and contact surfaces of 1.5 th...............281 1.6 Install the hex screws (3) with the 1.6 resili...............281 1.7 Press the tightening plate (5) onto the 1.7 he...............281 1.8 Check the size of the gap (Fig. 3/X) 1.8 betwe...............281 1. Disassembly.......................................................282 1.1 Loosen the controller filling gear from 1.1 th...............282 1.2 Loosen and remove the lid (Fig. 1/1) on 1.2 th...............282 1.3 Clean the contact surfaces on the lid 1.3 and ...............282 1.4 Remove the splint (6); unscrew the 1.4 castell...............282 1.5 Pull the spiral-toothed gear wheel (2) from th...............283 1.6 Inspection the tooth profiles of the spiral-to...............283 1.7 Remove the hex screws (Fig. 2/15) and lift the...............283 1.8 Inspection the axial play of the wearing 1.8 d...............283 1.9 Disassemble the safety ring (18) and 1.9 remov...............283 1.10 Pull the controller drive shaft (10) 1.10 upw...............283 1.11 Inspection the serration of the 1.11 controll...............283 1.12 Loosen the hex screws (17) and lift off 1.12 ...............283 1.13 Remove the O-ring (22) and clean the 1.13 con...............283 1.14 Inspection the flow of all oil lubrication 1................283 2. Assembly..........................................................284 2.1 If necessary, lightly oil the new bushes (Fig................284 2.2 Insert a new O-ring (Fig. 2/22) and apply a th...............284 2.3 Set the controller console onto the cylinder c...............284 2.4 Oil the controller drive shaft (10); insert it...............284 2.5 Oil the wearing disk (19), insert it and tight...............284 2.6 Use a face plate (4) to push the spiral-toothe...............285 2.7 Tighten the castellated nut (5) with a torque ...............285 2.8 Set the controller (Fig. 2/16) onto the contro...............285 2.9 Tighten the controller using the hex screws (1...............285 2.10 Connect the controller filling gear to the co...............285 2.11 Inspection the flow of the lubricating oil..................285 2.12 Attach the lid (Fig. 1/1) to the cylinder cra...............285 2.13 Inspection the axial play on the cam 2.13 sha...............285 2.14 Inspection the seal of the lid to the 2.14 wh...............285 2.15 Install the starting air distributor........................285 1. Disassambly.......................................................286 1.1 Remove the lateral and end housing 1.1 lids..................286 1.2 Loosen the screws (2) and remove them 1.2 toge...............286 1.3 Lift the vibration damper (1) from the 1.3 ada...............286 2. Assembly..........................................................287 2.1 Clean and remove grease from the surfaces of t...............287 2.2 Lubricate the threads of the screw (2) with Mo...............287 2.3 Push the new damper (1) onto the adapter (4) a...............287 2.4 Tighten the screws (2) with a torque of 2.4 2................287 2.5 Install the lateral and end housing lids.....................287 1. Remove control shaft/injection pumps and contro...................288 2. Check control shaft and spindle to emergency-of...................288 3. Grease the following bearings with multi-purpos...................288 Note:............................................................288 At V-engines the swivel heads of the intermediate ...............288 4. Oil all moving bearings of the swivel arm betwe...................288 5. Assemble covers...................................................288 1. Secure the engine against unauthorized 1. start...................289 2. Disconnect pipes and with the governor 2. empty...................289 3. Record free length of the limiting screw 3. (3)...................289 4. Loosen nuts (6) uniformly (caution: 4. spring s...................289 5. Pour oil, push out piston (5).....................................289 6. Clean all parts, using non-ravelling rags 6. on...................289 7. Assemble in reverse order, lightly oil the part...................290 8. Fit starting aid to the engine, mount air (1) a...................290 9. Filling of the starting aid through the governo...................290 10. Carry out functional check by starting the eng...................290 1. Functional check..................................................291 1.1 Check the air connection for leaks...........................291 1.2 Check whether the piston moves easily 1.2 unde...............291 1.3 Check the setting............................................291 1.3.1 If maximum fuel limitation has been 1.3.1 pr...........291 1.3.2 Check whether 40 % fuel is admitted 1.3.2 wh...........291 1.4 Check whether full fuel is admitted within..................292 2. Venting...........................................................292 2.1 Slip a transparent hose over vent screw (12) a...............292 2.2 Remove plug (13), spring (14) and piston (15)................292 2.3 Fill oil in as far as 7 mm below the housing t...............292 2.4 Insert the piston. Drive the air out by screwi...............292 2.5 Proceed according to 2.3 and 2.4 until no air ...............292 2.6 If the cylinder is of the older type, the air ...............292 3. Disassembly.......................................................292 3.1 Close the main air valve. Remove the air conne...............292 3.2 Remove the unit from the engine..............................292 3.3 Measure and note down the position of throttle...............292 3.4 Disassemble the unit entirely and clean it in ...............292 3.5 Inspect all parts............................................292 4. Reassembly........................................................293 4.1 Renew all gaskets and seals 4.1 (Fig. 2/1 - 9)...............293 4.2 Assemble the unit observing the 4.2 following...............293 4.2.1 Tighten the socket head cap screws (17) 4.2............293 4.2.2 Before fitting vent screw (12), plug (13), 4...........293 4.2.3 Fill oil (SAE 20) in as far as 7 mm below 4............293 4.2.4 Tighten the throttle screw (10) and 4.2.4 so...........293 4.2.5 Vent the unit according para 2.........................293 4.2.6 Adjust the unit and fit it on the engine...............293 4.2.7 Mount air connection...................................293 4.2.8 Open main air shut-off valve...........................293 4.2.9 Check the operation according to para.1...............293 1. Dismount the bushes (1).......................................294 1.1 Dismount linkage between injection 1.1 pump co...........294 1.2 Remove bracket (6) from hinged lever.....................294 1.3 Remove bushes (Fig. 2/1) from bracket 1.3 (6)............294 2. Mounting of bushes (1)........................................294 2.1 Insert new bushes (1) in bracket (6).....................294 2.2 Mount bolt (3), washers (4 and 5) and 2.2 nut ...........294 2.3 Mount bolt (3), washers (4 and 5) and nut (2) ...........295 1. Drain compressed-air filte....................................300 1.1 Loosen drain plug (Fig. 1/7) and empty 1.1 fil...........300 1.2 Close drain plug.........................................300 2. Disassemble compressed-air filter and 2. clean................300 2.1 Loosen drain plug (Fig. 1/7) and drain 2.1 fil...........300 2.2 Close compressed-air feed line and 2.2 secure............300 2.3 Relieve compressed-air filter via drain 2.3 pl...........300 2.4 Loosen housing cap (5) and remove, 2.4 check O...........300 2.5 Loosen Phillips screw (4), remove with 2.5 gui...........300 2.6 Remove locking ring (8), unscrew drain 2.6 plu...........300 2.7 Clean all disassembled parts and check for reu...........300 2.8 Assemble compressed-air filter in reverse sequ...........300 2.9 Close drain plug after a short while.....................300 1. Remove the covering from the exhaust manifold.................301 2. Check all screw connections for firm seating..................301 3. The accumulation of soot, especially at flanges...............301 4. Replace defective exhaust pipe, thereby:......................302 4.1 Loosen adjacent expansion joints (4) and remov...........302 4.2 Loosen hexagon cap screw (1) so far that both ...........302 4.3 Move clamp upper parts, unhook the chain links...........302 4.4 Lift off both clamp upper parts together, repl...........302 4.5 Make fitting pieces (Fig. 1/X, Y or Z) for ins...........302 4.6 Screw new fitting piece/pieces to new exhaust ...........302 4.7 Mount exhaust pipe and clamp upper parts.................302 4.8 Remove fitting piece/pieces, mount expansion j...........302 5. Replace expansion joints which have cracks in t...............302 6. Mount covering. 6.............................................302 1. Connect the cleaning pipe (5) to the water supp...............305 2. Reduce the engine output until the exhaust temp...............305 3. Open the cocks (1) and (3), set the water press...............305 4. Continually check permanent drain (4) for free ...............305 5. Reduce or increase engine output (exhaust tempe...............305 6. Note the engine speed setting, filling and exha...............305 7. Remove the hose part (2) with pressure gauge (6...............305 8. Continue to run the engine with the same output...............305 1. Disassembly...................................................306 1.1 Open indicator valves....................................306 1.2 Remove corresponding camshaft cover 1.2 on the...........306 1.3 Turn the engine so that the rocker 1.3 (Fig.3...........306 1.4 Close the shut-off cocks and drain the 1.4 fue...........306 1.5 Disassemble the fuel overflow line on 1.5 the ...........306 1.6 Remove the fuel distributor/collecting 1.6 pip...........306 1.7 Loosen screwed connection (Fig. 2/16) 1.7 and ...........307 1.8 Push the control rod (15) right into the 1.8 i...........307 1.9 Loosen the pipe clamp (12)...............................307 1.10 Loosen hexagon cap screw (14) and 1.10 remove...........307 1.11 Loosen bracket (9) for stop cylinder (10) 1.1...........307 1.12 Completely loosen pressure screw (6) 1.12 and...........307 1.13 Loosen nuts (11) evenly and lift the 1.13 inj...........307 2. Assembly......................................................308 2.1 Clean the contact surfaces on the injection pu...........308 2.2 Replace O-rings (22), place the injection pump...........308 2.3 Coat the threads and contact surfaces of the n...........308 2.4 Tighten the nuts (11) with a torque of...................308 2.5 Mount the control air line (Fig. 1/3) in front...........308 2.6 Screw regulating shaft to control rod (15) of ...........308 2.7 Remove seals from the fuel bores (injection pu...........308 2.8 Check O-ring (7) and replace if necessary................308 2.9 Insert forced fuel pipe with pressure screw (6...........308 2.10 Tighten union nut (8) and pressure screw (6) ...........308 2.11 Check compressed-air lines for stop cylinder ...........308 2.12 Close indicator valves and mount camshaft cov...........308 2.13 Open shut-off cocks, fill up fuel system with...........308 1. Checking the pressure keeping valve 1. (Fig. 1/...............310 1.1 Place the injection pump next to the 1.1 nozzl...........310 1.2 Screw the pressure pipe (W1) onto the 1.2 conn...........310 1.3 Pump with tester and increase the 1.3 pressure...........310 2. Disassembly...................................................310 2.1 Clean the outside of the injection pump..................310 2.2 Remove the baffle screws (Fig. 1/7), 2.2 check...........310 2.3 Clamp the pump with the mounting 2.3 flange (1...........310 2.4 Loosen fillister head screws (18) and re2.4 mo...........310 2.5 Load the tappet axially in a vice, 2.5 remove ...........310 2.6 Remove plunger foot plate (20) with tappet (16...........311 2.7 Remove control sleeve (22) with spring plate (...........311 2.8 Remove locking ring (10), pull out retaining p...........311 2.9 Clamp injection pump housing (1) with connecti...........311 2.10 Remove fillister head screws (3)........................311 2.11 Loosen fillister head screws (2) alternately ...........311 2.12 Force pump element (25) out of housing (1) wi...........311 2.13 Clean all parts with gas oil and a hard brush...........311 2.14 Replace all O-rings and gaskets.........................311 2.15 Unscrew hexagon socket head cap screws (30) a...........311 2.16 After replacement of O-ring (29) and rotary s...........311 3. Assembly......................................................312 3.1 Assembling is carried out in reverse sequence ...........312 3.2 Insert the rotary shaft seals (Fig. 2/23, 3.2 ...........312 3.3 Apply engine oil to the thread and contact 3.3...........312 3.4 Check free movement of the control 3.4 rod...............312 1. Disassembly...................................................313 1.1 Switch off the standby lubricating oil 1.1 pum...........313 1.2 Dismantle the cylinder head cover and 1.2 the ...........313 1.3 Dismantle the nuts (fig. 1/1) and remove 1.3 t...........313 1.4 Screw the fuel injector extractor (fig.2 / 1............314 1.4.1 Screw the threaded rod (20) firmly onto 1.4........314 1.4.2 Mount the device (19) on the threaded 1.4.2 .......314 1.4.3 Mount the hexagon nut (18).........................314 1.5 Loosen the fuel injector by tightening 1.5 the...........314 1.6 Use the extractor to pull out the fuel 1.6 inj...........314 1.7 Clean the outside of the fuel injector. 1.7 Ma...........314 1.8 Clean the injector seat (fig. 1/9) in the 1.8 ...........314 2. Reassembly....................................................314 2.1 Replace the O-rings (7). 2.1 Make sure the O-r...........314 2.2 Apply a thin film of high-temperature thread p...........315 2.3 Apply a thin film of Molykote paste to the stu...........315 2.4 Insert the fuel injector in the sleeve. Pay 2............315 2.5 Mount the flange (fig. 1/3) with the 2.5 dowel...........315 2.6 Uniformly tighten nuts (1) by hand. 2.6 Make s...........315 2.7 Mount the fuel delivery pipe 2.7 (07.02.01.nn)...........315 2.8 Check the lubricating oil and fuel 2.8 circula...........315 1. Remove carbon deposits from the 1. nozzle with ...............317 2. Check the nozzle hole for sharp edges, 2. ovali...............317 3. Place the injector with the adapter 3. (Fig.1/...............317 4. Screw the adapter (W4) into the injector 4. and...............317 5. Increase the pressure gradually until 5. the no...............317 5.1 If the opening pressure is not correct, 5.1 sl...........317 1. Disassembly...................................................319 1.1 Slacken nut (Fig. 1/1) and relieve nozzle spri...........319 1.2 Slacken nozzle nut (6) by turning left and uns...........319 1.3 Extract nozzle (8) including nozzle needle wit...........319 1.4 Unscrew adjusting screw (2) and locking screw ...........319 1.5 Submit nozzle spring (4) and setbolt (5) to vi...........319 1.6 Clean the parts with gasoil..............................319 1.7 Fit a nozzle needle with gasoil in the nozzle ...........319 1.8 Submit all parts particularly seat and sealing...........319 2. Reassembly....................................................319 2.1 Wipe all sealing surfaces dry with clean, anti...........319 2.2 Check O-ring-type sealing ring (9) and renew e...........319 2.3 Apply a film of lubricating oil to the thread ...........319 2.4 To assemble, reverse the dismantling sequence............319 2.5 Degrease and dry locking screw (3) and bore ho...........320 2.6 Apply “ Hydraulic sealing compound Loctite 566...........320 2.7 Tighten the locking screw (3) with a torque of...........320 2.8 Remove residues of adhesive from housing (11) ...........320 2.9 Tighten the nozzle nut (6) with a torque of..............320 2.10 Check the injector according to 07.08.01.nn a...........320 1. Changeover to the clean filter chamber. Changeo...............321 2. Cleaning......................................................322 2.1 Clean the filter during normal operation of th...........322 2.2 Loosen the hexagon screw (6) and com2.2 pensat...........322 2.3 Open the plug key (8) and drain the fil2.3 ter...........322 2.4 Remove the cover (5) of the filter 2.4 chamber...........322 2.5 Loosen the self-locking nut (3) on the tie 2.5...........322 2.6 Place the individual screen elements in 2.6 a ...........323 2.7 Blow out the clean screen elements 2.7 with th...........323 2.8 In the case of obstinate dirt (paint, 2.8 crus...........323 2.9 Remove the screen elements and treat 2.9 them ...........323 2.10 If necessary, repeat the cleaning 2.10 proced...........323 2.11 Rinse the screen elements in clean cleaning f...........323 2.12 Check the inside and outside of the cloth of ...........323 2.13 Use a powerful source of light behind the clo...........323 2.14 Mount the screen elements (Fig. 1/X) in each ...........323 2.15 Check the seal (Fig. 1/4), replace if necessa...........324 2.16 Fill up the filter chamber and vent (see plat...........324 2.16.1 Loosen the hexagon screw (6) and turn the k.......324 2.16.2 Fill up the filter chamber and turn the key.......324 2.16.3 Tighten the hexagon screw (6).....................324 1. Cleaning......................................................326 1.1 Change over to operable filter chamber...................326 1.2 Open the vent screw (1) of the filter 1.2 cham...........326 1.3 Remove the drain plug (2) of the filter 1.3 ch...........326 1.4 Dismantle the housing cap (3) of the fil1.4 te...........326 1.5 Withdraw the screen basket (7) vertical1.5 ly ...........326 1.6 Remove coarse dirt by shaking the 1.6 screen b...........326 1.7 Put the screen basket (7) into a solvent. 1.7 ...........326 1.8 After taking the screen basket (7) out of 1.8 ...........326 1.9 Remove tenacious dirt by means of a soft brush...........326 1.10 Insert the screen basket (7) into the filter ...........326 1.11 Check the O-ring (8) and replace it if necess...........326 1.12 Insert and tighten the drain plug (2)...................326 1.13 To vent the filter chamber carefully set the ...........326 1.14 When the fuel emerges without bubbles at the ...........326 1.15 Reset the operating lever (4)...........................326 1. Disassambly...................................................327 1.1 Remove the pump space cover..............................327 1.2 Close the fuel shut-off cocks and loosen the s...........327 1.3 Loosen the circlips (Fig. 2/2). Move the sleev...........327 1.4 Pull out the fuel pipes (4)..............................327 1.5 To remove the sealing flange (5) on the inject...........327 1.6 .Remove the tube (Fig. 3/7)..............................328 1.7 Loosen the cheese head screws (8) until 1.7 th...........328 2. Assembly......................................................329 2.1 Inspection the O-ring seals (Fig. 2/10) on the...........329 2.2 Use sleeves to set the sealing flange (5) and ...........329 2.3 Tighten the cheese head screws (Fig. 3/8) and ...........329 2.4 Install the tube (7).....................................329 2.5 Install the nozzle leakage pipe (Fig. 1/6)...............329 2.6 Insert the fuel pipes (Fig. 2/4). Move the sle...........329 2.7 Open the fuel shut-off cock and loosen the scr...........329 2.8 Fill the fuel system using the reserve pump an...........329 2.9 Install the pump space cover.............................329 1. Switch off lubricating oil prelubricating 1. pu...............330 2. Drain the engine circulation system and 2. lubr...............330 3. If necessary, clean the lubricating oil 3. circ...............330 4. If necessary, remove and check 4. lubricating o...............330 5. Check the filter in the suction lines of 5. the...............330 6. Clean the lubricating oil duplex filter (1) 6. ...............330 7. Clean the lubricating oil automatic filter....................330 8. Remove the lubricating oil cooler and 8. clean ...............330 9. Fill in new lubricating oil (lubricating oil qu...............331 10. Fill up the lubricating oil system and take lu...............331 1. Disassembly...................................................332 1.1 Drain lubricating oil system.............................332 1.2 Remove suction (Fig. 1/4) and pressure line (2...........332 1.3 Loosen hexagon nuts (1) and pull lubricating o...........333 1.4 Loosen hexagon cap screw (8) and pull gearwhee...........333 1.5 Check tooth profiles for wear (pitting, slanti...........333 1.6 Loosen fillister head screws (16) and remove e...........333 1.7 Remove drive gearwheel (10) and intermediate g...........333 1.8 Check the bushes (11 and 14), bearing areas of...........333 2. Assembly......................................................333 2.1 Mount lubricating oil pump in reverse sequence...........333 2.2 Before mounting the gearwheel, check the conta...........333 2.3 Clean, free from grease and dry gearwheel cone...........333 2.4 Put gearwheel (Fig. 1/6) on drive gearwheel sh...........333 2.5 Heat gearwheel in oil bath to approx. 110 °C t...........334 2.6 Check the distance S, it must be smaller by 0............334 2.7 Coat the thread and contact surface of the hex...........334 2.8 Clean the contact surfaces of the pump flange ...........334 2.9 Carefully insert the lubricating oil pump (3) ...........334 2.10 Mount suction (4) and pressure lines (2) with...........334 2.11 Fill in new lubricating oil (lubricating oil ...........334 2.12 Fill up lubricating oil system and take lubri...........334 2.13 Check oil supply of the gearwheels......................334 1. Change the filter over (see the plate on 1. the...............335 2. Cleaning......................................................335 2.1 Clean the filter when it is still warm 2.1 fro...........335 2.2 Cleaning the filter with built-in 2.2 cartridg...........336 2.2.1 Remove the cover (2) from the shut-off 2.2.1.......336 2.2.2 Remove filter insert...............................336 2.2.3 Connect cleaning pistol (Fig. 2/W1) to 2.2.3.......336 2.2.4 Shift the spouting guard (13) to the stop 2........336 2.2.5 Replace seals and mount cover......................336 2.2.6 Fill the filter chamber and vent it (see 2.2.......336 2.3 Cleaning the filter with cartridges 2.3 remove...........336 2.3.1 Open sludge drain and empty filter 2.3.1 cha.......336 2.3.2 Remove filter insert...............................336 2.3.3 Flush the filter chamber with gas oil..............336 2.3.4 Put the filter insert in a container filled .......337 2.3.5 Take the filter insert out of the cleansing .......337 2.3.6 Submerge filter insert again in clean cleans.......337 2.3.7 Intermittent check of cartridges for damage .......337 2.3.8 Place filter insert in filter chamber, mount.......337 2.3.9 Fill filter chamber and vent (see plate on f.......337 2.4 Cleaning of cartridges in the case of persiste...........337 2.4.1 Soak filter insert in cleansing liquid (max........337 2.4.2 Loosen base plate and carefully remove prote.......337 2.4.3 Remove cartridges (14) with the drift (Fig. .......337 2.4.4 Inspect the cartridges and replace them if d.......337 2.4.5 Connect cleaning pistol (Fig. 2/W1) to compr.......337 2.4.6 Introduce the cleaning pistol into the cartr.......338 2.4.7 Remove sticking dirt with a soft brush.............338 2.4.8 Rinse the cartridges in clean cleaning fluid.......338 2.4.9 Put a strong light behind the gauze and chec.......338 2.4.10 Install cartridges in reverse sequence as d.......338 3. Check the seal between the element plate and fi...............338 4. Mount filter insert in filter chamber.........................338 5. Fit cover (replace seal)......................................338 6. Fill the filter chamber and vent it (see the pl...............338 1. Disassembly...................................................339 1.1 Loosen the cheese head screws (8) evenly to re...........339 1.2 Remove and dismantle the control valve (1)...............339 1.2.1 Loosen the hexagon nut (18) and completely u.......339 1.2.2 Loosen the screw connection (17) and remove .......339 1.2.3 Remove the locking ring (9) and take out the.......339 1.2.4 Remove the screw plug (26) of the pilot cont.......339 1.3 Clean all parts with gas oil and check them..............340 1.4 Check the free passage of the control oil bore...........340 1.5 Check the valve seats, balls, piston seating a...........340 2. Reassembly....................................................341 2.1 Check the O-rings (2 and 7) and sealing ring (...........341 2.2 Assembly is effected in the reverse sequence o...........341 2.3 Check the lubricating oil pressure at the pres...........341 3. Adjustment....................................................341 3.1 Pressure to be set (see engine data A1.05)...............341 3.2 Loosen the hexagon nut (18)..............................341 3.3 Secure the setting with the hexagon nut (18).............341 1. Carry out steps 1.1 and 1.2 simultaneously for .......342 1.1 Start the stand-by pump..........................342 1.2 Turn the engine by means of the barring gear.....342 1. Disassembly...................................................343 1.1 Remove air pipes from the swivelling 1.1 screw...........343 1.2 Loosen cover (4), remove and take out 1.2 cont...........343 1.3 Loosen fillister head screws (11) and 1.3 pull...........343 1.4 Clean all parts, blow out with 1.4 compressed ...........343 2. Assembly......................................................344 2.1 Reassembly is effected in reverse sequence...............344 2.2 Threads and contact surfaces of the loosened h...........344 2.3 Install starting air distributor with shaft (3...........344 2.4 Threads and contact surfaces of the hexagon ca...........344 2.5 Check setting according to 3. and tighten cove...........344 2.6 Fix compressed-air pipelines with new seals up...........344 3. Setting the starting air distributor..........................344 3.1 Turn the piston of the 1st cylinder to 3.1 ign...........344 3.2 Disk slot (Fig. 2/20) of the control 3.2 disk...........344 3.2.1 If necessary, loosen hexagon nut (14) 3.2.1 .......344 3.2.2 Set control disk with disk slot according to.......344 3.2.3 Clamp shaft in vice with soft blocks, fix co.......344 3.3 Recheck the position of the disk and shaft and...........344 1. Open the drain screw (1), completely drain the ...................345 2. Open the drain screw (1) and release the compre...................345 3. Loosen and unscrew the hexigon nuts (2)...........................345 4. Remove the base plate (3) and the case (4) and ...................345 5. Unscrew and remove the plate (5), the filter co...................345 6. Clean all removed parts and check for reusabili...................345 7. Reassemble the compressed air filter in the rev...................345 8. Close the drain screw (1) after a short period ...................345 1. Activate the emergency stop facility 1. (machin...............346 2. Check the position of the control rods........................346 3. Check the stop cylinder (3). To do so, 3. press...............346 4. Press the "Reset" button on the safety system.................346 1. Connection of the adjusting device............................347 1.1 Close the cock of the pressure piping (Fig. 1/...........347 1.2 Loosen the union nut (2) and remove the dummy ...........347 1.3 Connect the hose (with union nut and cutting) ...........348 2. Inspection of the set values..................................348 2.1 Ventilate the pressure switch via the adjustme...........348 2.2 Inspect the pressure control via the pressure ...........348 2.3 At any deviation correct the adjustment due to...........348 2.4 Deaerate the pressure switch slightly and simu...........348 3. Correction of the adjustment (Perfor3. mance wi...............349 3.1 Remove the case cover by loosening 3.1 the 4 l...........349 3.2 Connect terminal (1 + 4) via cable with 3.2 th...........349 3.3 Loosen the stop screw (A)................................349 3.4 Remove the cover aside by loosening 3.4 the lo...........349 3.5 Set the upper or lower switching point 3.5 (di...........349 3.6 Tighten stop screw (A)...................................349 4. Removal of the adjusting device...............................349 4.1 Loosen the cable connection 4.1 (terminal 1 + ...........349 4.2 Loosen the connection hose of the 4.2 adjusti...........349 4.3 Fit the cover............................................349 4.4 Tighten the cover of the range spindle...................349 4.5 Mark or lead the impected or corrected 4.5 pre...........349 1. Note the rpm switch point setting. 1. Loosen th...............350 2. Turn the pointer carefully to the left 2. towar...............350 3. Set the pointer again at the original rpm 3. sw...............350 4. The automatic cut-out F 1.1 and F 2.1 on the pl...............350 5. Voltage check at the plug-in socket contacts of...............350 5.1 Supply (24 V DC at contact z16 and z20, contac...........350 5.2 PICK UP IMPULSE (dependent upon engine speed u...........351 1. Disassembly...................................................352 1.1 Drain lubricating oil/cooling water lines................352 1.2 Unscrew hexagon nuts (2) of housing 1.2 cover ...........352 1.3 Remove cover (6) with O-ring (1).........................352 1.4 Turn out thermostatic element (5) 1.4 fromval...........352 1.5 Wash parts in gas oil and blow them 1.5 clean............352 1.6 Wipe clean thermostat housing with 1.6 lint-fr...........352 2. Functional check of thermostatic element......................353 2.1 Put thermostatic element (Fig. 1/5) into a wat...........353 2.2 The thermostatic element (5) must open steadil...........353 3. Assembly......................................................353 3.1 Repalce O-rings (1 and 9) and gasket (8).................353 3.2 Assembly is done in reverse order of disassemb...........353 3.3 Top up lubricating oil/cooling water system an...........353 Maintenance and trouble shooting: refer to manual .......................354 1. Dismantling.......................................................356 1.1 Dismantle fuel feed pump 1.1 (07.13.01.nn)), l...............356 1.2 Dismantle lubricant piping and pump 1.2 bearer...............356 1.3 Drain the oil: 1.3 1.3 • Turn oil flow boring ...............356 1.4 Mark the position of the damper to the 1.4 cra...............356 1.5 Remove the antifatigue screws and fa1.5 stenin...............356 1.6 Dismantle the pump wheel carrier (15) 1.6 and ...............356 1.7 Remove fastening screws (13).................................356 1.8 Remove the oscillation damper and for1.8 cing ...............356 1.9 Dismantle side plates (18); forcing may 1.9 be...............356 1.10 Remove O rings (20 and 21)..................................356 1.11 Clean all parts thoroughly. Check oil 1.11 fl...............356 1.12 Measure gap (Fig. 2/"s" ) between spring ends...............357 1.13 Apply an adequate quantity of "Loctite 275" t...............357 2. Apply Molykote "Typ 60 G" across the inner side...................358 3. Insert new greased O rings (20 and 21)............................358 4. Set the side plates so that the oil flow bore h...................358 5. Assembly of oscillation damper:...................................358 5.1 Bleed the air from the oscillation damper:...................358 5.2 Further assembly procedure takes place in reve...............358 5.3 Apply "Dirco-Grau" silicon sealant to the pump...............358 5.4 Assemble fuel feed pump (07.13.01.nn), lubrica...............358 1. Operating the turning device......................................359 1.1 Engaging the turning device..................................359 1.1.1 Move blockinglever (1) to position “V“ and h...........359 1.1.2 Move lever (2) to position“ X“, so that the ...........359 1.1.3 Let off blockinglever and make sure that the...........359 1.1.4 Turn the engine........................................359 1.2 Disengaging the turning device...............................360 1.2.1 Move blockinglever (1) to position “V“ and h...........360 1.2.2 Move lever (2) to position“ Y “, so that the...........360 1.2.3 Let off blockinglever and make sure that the...........360 2. Maintenance.......................................................361 2.1 Oil level check..............................................361 2.1.1 Check oil level at the oil level glas (10) a...........361 2.2 Lubricating / greasing of shaft and gearwheel................361 2.2.1 Grease the notch on the output shaft (9) and...........361 2.2.2 Coat toothing of gearwheel thinly with beari...........361 2.3 Oil change...................................................361 2.3.1 Remove screw plug (5) on the driving gear of...........361 2.3.2 Drain the oil from the driving gear of the t...........361 2.3.3 Mount the screw plug (5) with new gasket (6)...........361 2.3.4 Remove screw plug (7)ont the driving gear of...........361 2.3.5 Fill in new oil (e.g. Shell Omala Oil 460 ; ...........361 2.3.6 Mount the screw plug (7) with new gasket (8)...........361 Charge Air Cooler............................................................691 Crankcase Oil Mist Detector..................................................711 Please select target document for B1.05.10.n.861n ...........................769 B1.05.10.9.8610 HH.....................................................769 B1.05.10.9.8618 CC.....................................................769 Please select target document for B1.05.10.n.861n ...........................770 B1.05.10.9.8610 HH.....................................................770 B1.05.10.9.8618 CC.....................................................770 Please select target document for B1.05.06.9.725n ...........................771 B1.05.06.9.7250 RR.....................................................771 B1.05.06.9.7259 ZE.....................................................771 B1.05.06.9.7259 ZM.....................................................771 Please select target document for B1.05.06.9.7259 ...........................772 B1.05.06.9.7259 ZE.....................................................772 B1.05.06.9.7259 ZM.....................................................772 Please select target document for B1.05.06.9.7259 ...........................773 B1.05.06.9.7259 ZE.....................................................773 B1.05.06.9.7259 ZM.....................................................773 Please select target document for B1.05.08.9.641n ...........................774 B1.05.08.9.6410 CC.....................................................774 B1.05.08.9.6414 AA.....................................................774 B1.05.08.9.6417 LL.....................................................774 Please select target document for B1.05.11.1.4877 ...........................775 B1.05.11.1.4877 GG.....................................................775 B1.05.11.1.4877 MM.....................................................775
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