Mak M32 Engine Operation Instruction Manual – PDF DOWNLOAD
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Mak M32 Engine Operation Instruction Manual – PDF DOWNLOAD
Engine No.:
38 039
Record No.:
261369
Introduction :
- 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 department service technology.
- 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 Operation Instruction Manual – PDF DOWNLOAD
*1 Lowest avaiable charge air temperature should be chosen. If water condenses in the charge air ........................... 9 *2 Permissible injection viscosity must be set on the viscothermic device to enable a kinematic v........................... 9 1. Storage tank......................................................................................................... 39 2. Settling tank HT5, HT6............................................................................................... 39 • Connect the two tanks alternaly irrespective of the fuel consumed so as to obtain the best sett....................... 39 • Before cutting a tank in, thoroughly remove any water and sludge...................................................... 39 3. Separator HS1, HS2............................................................................................... 39 • Both separators are always to be operated parallel independently of the manufacturer/ system.......................... 39 • The operational capacity is designed according to the rules and regulations of the individual m....................... 39 4. Day tank HT1..................................................................................................... 40 • Daily de-sludging is important........................................................................................ 40 • A temperature level between........................................................................................... 40 5. Fuel pressure pump HP1, HP2...................................................................................... 40 6. Fuel pressure-regulating valve HR1............................................................................... 40 7. Self cleaning fuel filter HF4.................................................................................... 40 8. Mixing tank HT2.................................................................................................. 40 9. Circulating pump HP3, HP4........................................................................................ 41 10. Final preheater HH1............................................................................................. 41 • If the preheater is of electrical type, ensure the temperature switch may be set to at max............................ 41 • If the preheater is of steam type, a condensation trap should be installed at the steam outlet ....................... 41 11. Viscosity measurement and control equipment HR2 (Viscometer).................................................... 41 12. Fine filter HF1................................................................................................. 41 3.1. Prelubrication LP2 (standby or prelubrication pump)............................................................ 45 3.2. Check the operation of the engine-driven force pump LP1........................................................ 45 3.3. Lube oil automatic filter LF2.................................................................................. 45 3.3.1. Lube oil automatic filter LF2 (flushing with oil or compressed air)...................................... 45 If there are more than 100 flushing per day, the cause of the oil contamination must be detected:....................... 45 3.3.2. Lube oil automatic filter (with permanent oil flushing)...................................................... 46 3.4. Duplex lube oil filter LF1 (with indicator).................................................................... 46 3.5. Strainer filter LF4............................................................................................ 46 Initial operation........................................................................................................... 47 Operational supervision..................................................................................................... 58 • Drain the water from the day fuel tank and check it at regular intervals.............................................. 61 • Inspect the fuel treatment plant...................................................................................... 61 • If the engine is running on heavy fuel, change over to distillate fuel in time, see changing th....................... 61 - after lengthy service at partial load operation. (See A3.06.18.nn),............................................... 61 - or before scheduled maintenance work on the fuel system........................................................... 61 1. Storage tank DT4............................................................................................. 62 2. Separator DS1................................................................................................ 62 3. Day tank DT1................................................................................................. 63 4. Fuel preliminary filter DF2 (duplex filter).................................................................. 63 5. Intermediate tank DT2........................................................................................ 63 6. Diesel oil preheater DH1..................................................................................... 63 • If the preheater is of electrical type, ensure that the temperature switch is set to a min. of........................ 63 • If the preheater is of steam type, a condensation trap should be installed at the steam outlet ....................... 63 7. Diesel oil feed pump DP1, diesel oil standby feed pump DP2....................................................... 63 8. Fuel fine filter DF1(duplex filter).............................................................................. 64 9. Fuel pressure regulating valve DR2............................................................................... 64 Removal from operation...................................................................................................... 71 Danger of frost............................................................................................................. 76 The following measures are to be implemented after a light or heavy preservation........................................ 86 Running-in.................................................................................................................. 88 Fault tracing............................................................................................................... 90 Emergency operation......................................................................................................... 96 - disassemble the rotor................................................................................................. 98 - obturate the exhaust gas side against bearing housing and air side by means of a blind flange......................... 98 The cooling water supply is to be interrupted only in case there is a considerable leakage at the....................... 98 If there are two turbochargers feeding into one charge air manifold:.................................................... 98 1. Misfire..........................................................................................................102 2. Total misfire....................................................................................................103 2.1 Twin engine systems / generator systems.....................................................................103 Safety instructions.........................................................................................107 During all work or contact with:............................................................................107 Regulations and care........................................................................................................108 1. Engine Lubricating Oil...............................................................................................119 1.1 Base Oil........................................................................................................119 1.2 Additives.......................................................................................................119 1.2.1 Good detergent and dispersant properties (which for heavy fuel operation equals at least th...............119 1.2.2 Have an adequate alkalinity in order to be able to neutralize the sulfur acid compositions ...............119 1.3 Care of lubricating oil.........................................................................................120 1.3.1 Lubricating oil filtering (By-pass).......................................................................120 1.3.2 Lubricating oil filtering (full flow).....................................................................120 1.4 Lubricating oil brand recommendations – Limitation of warranty..................................................120 1.4.1 List of brands of lubricating oil for Operation with distillate fuel......................................121 1.4.2 List of brands of lubricating oil for heavy oil operation.................................................122 1.5 Lubricating oil changing........................................................................................123 1.6 Limits:.........................................................................................................124 1.6.1 Lubricating oil dilution by fuel..........................................................................124 1.6.2 Alkalinity (TBN)..........................................................................................124 1.6.3 Water content.............................................................................................124 1.6.4 Contamination.............................................................................................124 1.7 Lubricating oil for exhaust turbocharger, hydraulic governor and change-over controls...........................125 1.8 Multi-purpose grease – lithium saponified – consistency number 2 (also suitable for pneumatic...................126 • Suitable fresh water..................................................................................................127 • effective corrosion inhibiting agent..................................................................................127 - corrosion inhibiting oil, soluble.....................................................................................127 - chemical corrosion inhibiting agent (chemicals).......................................................................127 • exact dosing of the corrosion inhibiting agent........................................................................127 1. Treatment of cooling water with corrosion inhibitors.............................................................129 01......................................................................................................................144 1. Adjust valve bridge..............................................................................................161 1.1 Open indicator valves.......................................................................................161 1.2 Engage the barring gear.....................................................................................161 1.3 Remove cylinder cover hoods without damaging the gaskets....................................................161 1.4 Turn the crankshaft until the piston of the cylinder to be adjusted comes into the ignition d...............161 1.5 Adjust sufficient clearance "S" between rocker arm (Fig. 1/1) and valve bridge by pressing ba...............162 1.6 Loosen counternut (Fig. 2/3) and unscrew adjusting screw (4). Press down valve bridge until i...............162 1.7 In this position screw in adjusting screw(4) at "Y"........................................................162 1.8 Counter adjusting screw (4).................................................................................162 2. Adjust valve clearance...........................................................................................162 2.1 Measure the clearance (Fig. 1/S) with a feeler gauge. Thereby press the pushrod down........................162 2.2 Correct clearance "S".......................................................................................162 2.2.1 Loosen counternut.....................................................................................162 2.2.2 Turn the valve adjusting screw (2) until the stipulated clearance has been attained...................162 2.2.3 Tighten the counternut in order to fix the position of the adjusting screw............................162 2.2.4 Check clearance again after countering................................................................162 2.2.5 Disengage the barring gear and close the indicator valves.............................................162 1. Disassembly......................................................................................................163 1.1 Engage the barring gear.....................................................................................163 1.2 Dismount the cylinder head cover............................................................................163 1.3 Turn piston to TDC. Inlet and exhaust valves are closed, rocker arms are unloaded...........................163 1.4 Remove fastening nuts (1)...................................................................................163 1.5 Remove rocker arm bracket (3) with rocker arm shaft (2) and inlet and exhaust valve rocker..................163 2. Reassembly.......................................................................................................163 2.1 Clean the supporting surfaces of the rocker arm bracket (3).................................................163 2.2 Blow through oil overflow holes with compressed air.........................................................163 2.3 Place rocker arm bracket (3) with rocker arm shaft (2) and rocker arms by means of stud bolts...............163 2.4 Apply a thin film of Molykote paste "G-Rapid Plus" to thread and nut contact face and tighten...............164 2.5 Adjust valve clearance (01.01.01.nn)........................................................................164 2.6 Check the oil flow..........................................................................................164 2.7 Disengage the barring gear..................................................................................164 2.8 Mount cylinder head cover (check gasket!)...................................................................164 1. Disassembly......................................................................................................165 1.1 Remove securing rings (Fig. 1/4) and thrust washers (5) from the rocker arm shaft (3).......................165 1.2 Remove the intake valve rocker arm (1) and the exhaust valve rocker arm (2) from the rocker a...............165 2. Clean all parts and check for damage. Blow out oil bores with compressed air and check to ensu...................165 3. Check the bearing surfaces of the ball pin (Fig. 2/10) and the adjusting screw (12) for wear a...................166 4. Measure the rocker arm bush (Fig.2/ 13) and shaft (Fig. 1/3) and replace the bush when the c...................166 5. Assembly.........................................................................................................166 5.1 Oil the contact surfaces of the intake (Fig. 1/1) and exhaust rocker arms (2) and the rocker ...............166 5.2 Reinstall the rocker arm bracket and rocker arms on the cylinder cover (01.02.01.nn) and chec...............166 1. Measure the rocker arm bush (1) and (01.02.02.nn)................................................................167 2. Replace..........................................................................................................167 2.1 Drive out the bush (1) with the proper copper punch (W1)....................................................167 2.2 Oil the new bush lightly and press into rocker arm..........................................................167 1. Open lock cap of cylinder head cover and check valve rotation. See mark "X" on spring plate (F...................168 2. The valve rotator works properly, if a uniform engine speed-dependent rotation can be detected...................168 2.1 If at nominal engine speed the rotational speed goes down to approx. n Å 1 min-1, the valve r...............168 1. Replacement of oil scraper rings (O-rings).......................................................................169 1.1 Dismount valve cone, clean stem thoroughly..................................................................169 1.2 Remove the O-ring (Fig. 1/1) from the groove with a sharp-angled wire.......................................169 1.3 Clean groove................................................................................................169 1.4 Lubricate new O-ring slightly and carefully place in groove. The ring must not be twisted in ...............169 2. Measurement of the valve guide clearance.........................................................................170 2.1 Measure the outside diameter of the valve stem in the guide zone of the bush................................170 2.2 Measure the inside diameter of the guide bush in traverse direction of the engine...........................170 2.3.............................................................................................................170 3. Replacement of the valve guide...................................................................................170 1. Disassembly..................................................................................................171 1.1 Loosen the cheese head screws (fig. 2/10) and the connecting flanges (fig. 1/2, 3) together w...........171 1.2 Pull the sleeves (fig. 2/11) out of the connecting flanges (2, 3).......................................172 1.3 Check the O-rings (15). Replace faulty O-rings (15). Insert the O-rings in the grooves using ...........172 1.4 Check the gaskets (16) for the connecting flanges (2, 3) as well as the gaskets for the conne...........172 1.5 Pull the sleeves (fig. 3/30) out of the media block (31)................................................173 1.6 Replace O-rings (32)....................................................................................173 1.7 Remove media block (31).................................................................................173 1.8 Replace O-ring (33) and clean all sealing surfaces......................................................173 2. Reassembly...................................................................................................173 2.1 Mount the connecting flanges (fig. 2/2 and 3) with inserted sleeves (11). Replace faulty gask...........173 2.2 Mount the media block (fig. 3/31). Insert sleeves (30) with new O-rings (32)............................173 2.3 Put the connecting flange (1) onto the sleeves (30) and mount it. Replace faulty gasket (16) ...........173 2.4 Mount the blank flange (fig. 1/4). Replace faulty gaskets (fig. 2/16) beforehand........................174 3. Check operation of the alarm probe for leakage fuel (fig. 3/20)..............................................174 3.1 Dismantle the alarm probe, refit the connector and submerge the tip of the alarm probe in a m...........174 3.2 Mount the alarm probe...................................................................................174 4. Determine the defective fuel delivery pipe in the event of a "leakage fuel" alarm............................174 4.1 Acknowledge the alarm when a "leakage fuel" alarm is given and, beginning with cylinder1, re...........174 4.2 Check the bore in the connecting flange (2) for leakage fuel. If, for example, leakage fuel i...........174 4.3 Mount the screw (12) with a new gasket (13).............................................................174 1. Open indicator valves, turn the piston to top dead center, remove cylinder head cover and pump...................175 2. Drain the cooling water: loosen the connecting line from the stand-by pump to the cooling wate...................175 3. Loosen and remove the connecting flanges (Fig. 1/1) of the media duct to the cylinder head tha...................176 4. Disassemble rocker arm bracket (01.02.01.nn).....................................................................176 5. Loosen the union nut of the fuel delivery pipe on the injection pump. Loosen union nut of nozz...................176 6. Remove covering cap between exhaust pipe and cylinder head. Loosen clamp ring on the exhaust p...................176 7. Loosen the six cylinder head nuts with the hydraulic tightening device...........................................176 7.1 Place hydraulic jack (Fig. 2/W3) connected with support ring (W5) and threaded sleeve (W6) ov...............177 7.2 Screw threaded sleeve (W6) onto cylinder head screw (11) until a step ...............177 7.3 Place hydraulic jacks (Fig. 2/W3) connected with support rings (W7) and threaded sleeves (W8)...............177 7.4 Screw threaded sleeves (W8) onto cylinder head screw (11) until a step ...............177 7.5 Connect hydraulic jack (Fig. 4/W3) and distributor (W4) to high pressure pump (W1) via high p...............177 7.6 Close valve (Z) on high-pressure pump(W2) and extend all six cylinder head screws simultaneo...............177 7.7 Loosen round nuts (Fig. 3/12) with pin(W9). Turn round nuts back by at least eight holes...................177 7.8 Relieve jacks, remove hydraulic devices and unscrew round nuts..............................................178 8. Screw the eye bolts (Fig. 5/W10)into the cylinder head and attach to the lifting device (W11)....................179 9. Place the cylinder head on wooden base...........................................................................179 1. Dismount nozzle sleeve (1)...................................................................................180 1.1 Place wrench (5) with bush (6) on nozzle sleeve (1) so that nozzle sleeve and wrench (5) are ...........180 1.2 Attach torque wrench (W4) with reducer (W5) and extension (W6) to wrench (5) and unscrew nozz...........180 Attention: The threads of nozzle sleeve and cylinder head must be exposed...................................................181 1.3 Use a brass mandrel (W7) and carefully drive out the nozzle sleeve..................................................181 1.4 Remove O-rings (3 and 4)............................................................................................181 2. Mount the nozzle sleeve (1)..........................................................................................181 2.1 Apply a film of vaseline to the new black O-ring,insert O-ring in groove (4) and make sure th...................181 2.2 Apply a film of vaseline to the new green O-ring, insert O-ring in groove (3) and make sure t...................181 Attention: Do not exchange the position of the O-rings; observe the mounting instructions...................................181 2.3 Apply a film of high-temperature thread paste “Loctite 510 “ to the threads of the nozzle sle.......................181 2.4 Insert the nozzle sleeve and tighten it by means of wrench (5) at a torque of .......................181 1. Unscrew hexagon nut (1)..............................................................................................182 2. Remove cover (2).....................................................................................................182 3. Slacken relief valve (3) by means of a wrench and remove it..........................................................183 4. Lubricate the thread of the new relief valve with high-temperature thread paste “Dag S 5080“.........................183 5. Mount new relief valve (3) with new joint ring (4)...................................................................183 6. Firmly tighten the relief valve by means of a wrench.................................................................183 7. Mount cover (2). In doing so mind disc spring (5)....................................................................183 8. Firmly tighten hexagon nut (1).......................................................................................183 1. Disassembly......................................................................................................184 1.1 Dismantle cylinder head (01.06.01.nn).......................................................................184 1.2 Dismantle rocker arm (01.02.01.nn) and lift valve bridge....................................................184 1.3 Screw off clamping sleeve (5) by hand until it can be placed on valve stem (9)..............................185 1.4 Screw down by hand clamping sleeve (5)......................................................................185 1.5 Coat the contact surface (X) of the valve spring clamping device (W1) with „G-Rapid Plus“Moly...............185 1.6 Place valve spring clamping device (W1) on spring plate (2) and with the clamping screw (6) f...............185 1.7 Remove circlip (10). Compress valve spring (3) and remove cone clamp halves (4). Carefully un...............185 1.8 Lift off valve spring clamping device (W1), spring plate (2), valve spring (3) as well as the...............185 1.9 Pull valve cone out of cylinder head........................................................................185 2. Reassembly.......................................................................................................185 2.1 Check valve guide clearance, renew O-rings (01.05.01.nn)....................................................185 2.2 Lubricate burr-free valve stem before fitting and put in valve cone screwing so that the O-ri...............185 2.3 The re-assembly is effected in a reverse dismantling sequence...............................................185 2.4 After putting in the cone clamp halves, slowly unload the valve spring and make sure that the...............185 1. Checking of condition................................................................................................186 1.1 Valves may be reused without refinishing when...................................................................186 1.2 The valves cannot be reused in the following cases..............................................................187 2. Cleaning.............................................................................................................188 3. Repairing (refinishing of the sealing surface).......................................................................188 3.1 Regrind sealing surface in accordance with the prescribed angle (Fig. 3). Do not refinish exi...................188 3.2 The appropriate information of the grinding machine manufacturer is to be observed when grind...................188 3.3 The dimension between the visible edge of the base metal arm ring "X" and the outer edge of t...................188 3.4 Outer edge rounded with stone...................................................................................188 4. Maintenance (Checking contact reflexion/grinding)....................................................................189 4.1 Apply small dots of diamond paste Dp30/10 - 15 µm with a syringe to the fitting surface of t...................189 4.2 Insert the lubricated valve stem into the guide. Fasten the device (Fig. 5/W1) to the valve h...................189 4.3 When the contact reflexion is poor, the valve must not be reground anymore, however, both sea...................190 4.4 Ensure that the components (valve cone and seat ring) refaced to one another stay together......................190 5. Final check..........................................................................................................190 5.1 Ensure that the refinishing limits are maintained...............................................................190 5.2 Clean valve cone/seat thoroughly and check the sealing surfaces with an illuminated magnifyin...................190 1. Checking of condition................................................................................................192 1.1 The valve seat rings are re-usable without refinishing when.....................................................193 1.2 The valve seat rings are not re-usable when.....................................................................193 2. Cleaning.............................................................................................................193 3. Maintenance (refinishing of valve seat rings)........................................................................193 3.1 Remilling of the valve seat.....................................................................................193 3.1.1 Clean the valve seat ring thoroughly in the contact area (3) of the centering disk (4) in o...............193 3.1.2 Insert centering disk (4) with guide mandrel (5) and tighten with star handle (6).........................193 3.1.3 Place cutter head (Fig. 6/2) on greased guide mandrel, screw in knurled screw(1) until res...............194 3.1.4 Rotate valve seat clockwise uniformly and slowly and remill the seat in one operation pass................194 3.1.5 Prior to finishing the cutting process, slowly unscrew the knurled screw (1), at the same t...............194 3.1.6 Maximum permissible dimension Ø (x) for refinishing (Fig. 7):.............................................194 3.1.7 When the milling cutters are blunt, the cutter head is to be sent to the MaK for refinishing..............195 3.1.8 Dismount the milling device. Grind sharp edges with fine emery cloth......................................195 4. Checking of contact reflexion/grinding...............................................................................195 4.1 Apply small dots of diamond paste Dp 30/10 - 15 µm with a syringe to the seat face of the new...................195 4.2 Insert the lubricated valve stem into the guide bush. Fasten the device (W1) (01.08.01.nn) to...................195 4.3 When the contact reflexion is poor, the valve must not be reground anymore, however, both sea...................195 4.4 Ensure that the components (valve cone and seat ring) reface to one another stay together.......................195 5. Final check..........................................................................................................195 5.1 Check whether the refinishing limit dimensions are observed.....................................................195 5.2 Clean valve cone/seat thoroughly and check the sealing face with an illuminated magnifying gl...................195 1. Cut off the unusable valve cone at the shaft end (Fig. 1/1) and bevel the resulting cutting su.......................196 2. Insert the valve cone into the valve seat ring and hold in the shown position. Connect cone an.......................196 3. Drive the valve seat ring out by striking the valve spindle forcefully. Clean the bore where t.......................196 4. Shrink the new seat ring in..........................................................................................196 4.1 Cool the seat ring to at least -20 C, heat the cylinder head to 130 C.........................................196 4.2 Carefully insert the seat ring with the help of a valve cone to the bottom of the cylinder he...................197 5. Slightly refinish the seat ring, e.g. with valve seat grinding machine or valve seat milling m.......................197 6. Fit valve cone.......................................................................................................197 1. Loosen fixing screws (1) and remove cover (2) with sealing ring (3)..................................................198 2. Push down piston (4) and spindle (5) approx. 7 mm using the handle of the hammer. The piston a.......................198 3. Ensure that the piston und spindle return to the original position quickly and easily................................198 4. If the parts do not move freely, lubricate the piston (4) and guide in the cylinder head with .......................198 5. Fit cover (2) with new sealing ring (3). Tighten fixing screws (1)...................................................198 1. Check the gasket between the cylinder head, cylinder liner and cooling water distributor housi.......................199 2. Check cylinder head externally for leakage...........................................................................199 2.1 In case of lubeoil leakage, check the retaining screws of the cylinder head cover for tightne...................199 2.2 In case of leakage at the wedge parts of the media supply, check retaining screws for tightne...................199 3. Remove cylinder head cover, inspect cylinder head upper side.........................................................199 3.1 Observe conformability of valve movement. Irregularities can be seen better at low engine rev...................199 3.2 Check function of the valve rotating device (01.03.01.nn).......................................................199 3.3 Check valve springs for damage..................................................................................199 3.4 Check lube oil supply of valve lever and valve lever bearing....................................................199 1. Wash the cylinder head with a cold cleaner...........................................................................200 2. Clean the inlet and outlet ports and the cylinder head underside (not the valve seats!) of car.......................200 3. Clean cooling water inlet ports and cooling water outlet.............................................................200 4. Check underside of cylinder head, especially at the valve webs, for cracks...........................................200 5. Clean the sealing surface for the injection valve....................................................................200 6. Check in and outlet holes of the media supply for free passage. (especially leak fuel of press.......................200 7. Check the function of the alarm probe for fuel leakage in the distributor plate at the connect.......................200 1. Turn piston to ignition top dead center..............................................................................202 2. Clean sealing faces and contact surfaces of cylinder head and liner thoroughly and check for d.......................202 3. Renew the following O-rings. Upper O-ring on cylinder liner collar (2) on the cylinder head (3.......................202 4. Carefully place cylinder head with cylinder head lifting device (W11) and lifting gear onto co.......................203 5. Align cylinder head. Mount clamping ring for exhaust pipeline and hook in chain links (06.01.0.......................203 6. Tightening of the six cylinder head screws together with the hydraulic tightening device.............................203 6.1 Hydr. Zugelemente (Fig. 2/W3) verbunden mit Stützringen (W5/W7) und Gewindehülsen (W6/W8) üb...................203 6.2 Gewindehülsen (W6/W8)) auf Zylinderkopfschrauben (11) handfest aufschrauben.....................................203 6.3 Connect hydraulic pulling elements (Fig. 4/W3) and distributor (W4) to high pressure pump (W1...................204 6.4 Close valve (Z) on high pressure pump and extend all six cylinder head screws simultaneously ...................204 6.5 Tighten round nuts (Fig. 3/12) with pin (W9). Pay attention to easy movement....................................204 6.6 Check the firm positioning of the round nuts....................................................................204 6.7 Unload hydraulic pulling elements and dismantle.................................................................204 7. Tighten clamping ring for exhaust pipeline. The position of the clamping ring is fixed at the .......................205 8. Mount the removed connecting flange of the media supply with new seals. Pay attention to the p.......................205 9. Mount the removed pressure gauge pipelines and fill up with cooling water. Venting at cooling .......................205 10. Insert the pushrods into the cylinder head..........................................................................205 11. Assemble rocker arm bracket (01.02.01.nn)...........................................................................205 12. Connect fuel pressure pipe with corresponding injection pump........................................................205 13. Adjust valve clearance (01.01.01.nn) and mount pump compartment panelling...........................................205 14. Check sealing of all connections after taking engine into service...................................................205 1. Open the indicator valves and engage the barring gear................................................................206 2. Open the crank case cover approximately 10 minutes after engine shutdown.............................................206 3. Touch the crankshaft and connecting rod bearings to see whether they are of uniform and normal.......................206 4. Check all screws and nuts for locking................................................................................206 5. Check the degree of fouling in the crankcase (sludge, corrosion, bearing metal deposits), loos.......................206 6. Check the appearance of the cylinder liner surface. Check the lubeoil flow and oil outlet at t.......................206 7. Remove camshaft cover. Check the screws of the camshaft section pieces and the lower valve dri.......................206 7.1 Turn engine and check the running surfaces of the camshafts and rollers. Replace defective ca...................206 7.2 Check lubeoil flow for camshaft bearings and valve drive........................................................206 8. Check wheel drive (04.08.01.nn)......................................................................................206 9. Check the sump and crankcase for left behind tools, rags etc. Check the seals of all crankcase.......................206 1. Turn the crank pin from bottom dead center in the direction of the exhaust side so that the me.......................208 2. Set the pointer to the scale value 20 on the measuring gauge: 1st measuring point (initial pos.......................208 3. Turn the crankshaft, so that the crank pin turns in the direction of the exhaust side and the .......................208 4. Watch the gauge continuously and read the values at the measuring points2 -5 . If a .......................208 1. Disassemble the piston (02.06.01.nn).................................................................................218 2. Turn the connecting rod with the connecting rod division down by abt. 15. Both cylinder head .......................218 3. Loosen the cylinder head nuts (Fig. 1/2) with the set of hydraulic tools.............................................218 3.1 Place the hydraulic jack (W3) with supporting sleeves (W4) above the cylinder head nuts (2). ...................218 3.2 Screw the threaded bushs (W5) on the big-end screws (3), until reaching the clearance of........................218 3.3 Connect the hydraulic jacks (Fig. 2/W3) via high-pressure hoses (W2) with the high-pressure p...................218 4. Close the valve (Fig. 2/6) of the high- pressure pump (W1) and simultaneously load both big-en.......................218 5. Slacken the cylinder head nuts (Fig. 1/2) with the pin (W6). Turn back the cylinder head nuts .......................218 6. Open the valve (Fig. 2/6) of the high-pressure pump (W1), the tensioning jacks are relieved..........................219 7. Wait for the complete pressure drop, disassemble the hydraulic tools (W3, W4 and W5).................................219 8. Turn the connecting rod horizontally with the connecting rod division to the exhaust side............................219 9. Preassemble the suspension 1 (Fig. 3/19) and suspension 2 (16) of the big-end bearing assembly.......................219 10. Insert the sliding rails (18) from the exhaust side in the crankcase and hang in the suspensi.......................219 11. Hang slide rail and straining screws (17) into suspension 2 (16)) and align slide rail togeth.......................220 12. Dismount connecting rod support (20) and screw together connecting rod and stopper (21).............................220 13. Unscrew round nuts (2) and pull off big-end bearing cap piece (11) approx. 100 mm from bearing......................220 14. Push lower big-end bearing shell (12) aside and remove it from journal..............................................220 15. Loosen lateral stopper fixing (22) so that it can slide in the slots................................................220 16. Pull off connecting rod (10) at least 10 mm from the bearing........................................................220 17. Turn the top big-end bearing shell (13) by 180 on the crankpin, push aside and remove it fro.......................220 18. Assess the state of the big-end bearing shells (02.03.03.nn and 02.03.07.nn)........................................220 1. Reassembly of the bearing shells.....................................................................................221 1.1 Clean crankpin and oil..........................................................................................221 1.2 Oil the bearing shells internally and externally................................................................221 1.3 Attach the evtl. disassembled connecting rod (1) with a sling to the crane, place it on the s...................221 1.4 Mount connecting rod support for cylinders 1, 2, 4, 6, 8 or 9 (Fig. 5/13) or evtl. 3, 7, see ...................221 1.5 Place the top bearing shell (without holes) on the crankpin and turn by 180 below the connec...................222 1.6 Cautiously press the connecting bar against the bearing shell. The fixing nose of bearing she...................222 1.7 Attach the evtl. disassembled big-end bearing cap (3) with a sling to a crane, place it on th...................222 1.8 Push the con-rod bearing cover furher to within approx. 100 mm of the crank pin and insert th...................222 1.9 Cautiously push the big-end bearing cap (3) against bearing shell and big-end. The nose of be...................222 1.10 Reassemble the cylinder head nuts (5) and tighten fingertightly................................................222 1.11 Disassemble the big-end bearing assembly/disassembly tool (W7, sliding rail with suspensions...................222 1.12 Check the con-rod bearing shell on the exhaust side for misalignment in ax axial direction. ...................222 2. Fasten the cylinder head nuts (Fig. 3/5) with the set of hydraulic tools.............................................223 2.1 Turn down the connecting rod with the connecting rod division by about 15 - 30, see shown po...................223 2.2 Place the hydraulic jacks (W3) with supporting sleeves (W4) above the cylinder head nuts (5)....................223 2.3 Tighten the threaded bushs (W5) fingertightly on the big-end screws (6).........................................223 2.4 Connect the hydraulic jacks (Fig. 4/W3) via high-pressure hoses (W2) to the high-pressure pum...................223 2.5 Close the valve (Fig. 4/10) of the high- pressure pump (W1) and simultaneously extend both bi...................222 2.6 Tighten the cylinder head nuts (Fig. 3/5) with pin (W6). Be aware of smooth running.............................224 2.7 Inspection of the firm rest of the cylinder nut • Lower pressure by 50 bar. • Cylinder head n...................224 2.8 Open the valve (Fig. 4/10) of the high-pressure pump (W1), hydraulic jacks are released.........................224 2.9 Wait for complete pressure loss.................................................................................224 3. Reassemble the piston (02.10.01.nn)..................................................................................224 1. Remove main bearing..................................................................................................226 1.1 Open corresponding drive cap on the clutch side of the control and exhaust side.................................226 1.2 Turn the crankshaft to suitable position for disassembling......................................................226 1.3 Turn a connecting rod adjacent to the main bearing to be disassembled to 90° after TDC or 90°...................226 1.4 Slacken the round nuts (Fig. 1/2) of the lateral anti-fatigue stud bolts (1) by means of the ...................226 1.4.1 Slacken and remove the protective caps(3)................................................................226 1.4.2 Place the hydraulic jacks (Fig. 2/W4) with the supporting sleeves (W6) above the round nuts...............226 1.4.3 Tighten tapped bushes (W8) to anti- fatigue stud bolts (1) until a clearance of...........................226 1.4.4 Connect the hydraulic jacks (Fig. 3/W4) via high-pressure hoses (W2) to the high-pressure p...............226 1.4.5 Close valve (Fig. 3/13) of the high- pressure pump (W1) and burden both anti-fatigue stud b...............227 1.4.6 Slack round nuts (Fig. 2/2) by means of pin (W3). Turn back round nuts by at least 8 holes................227 1.4.7 Open valve (Fig. 3/13) of the high- pressure pump (W1), hydraulic jacks get unloaded......................227 1.4.8 Wait until the pressure has completely dropped, remove tapped bushes (W8) and disassemble h...............227 1.4.9 Slacken and unscrew anti-fatigue stud bolts (Fig. 2/1) completely.........................................227 1.4.10 Just slacken the round nuts (2) of the lateral anti-fatigue stud bolts (1) on the adjacent...............227 1.5 Employ device (Fig. 4/W10)......................................................................................227 1.5.1 Move device by means of the threaded rod (15) to its lowest position (limit stop). Check cl...............227 1.5.2 Disassemble desk (19), lift the device (W10) into the crankcase and place in the crankcase ...............228 1.5.3 Reassemble desk and insert device beneath the corresponding main bearing to the limit stop ...............228 1.6 Slacken round nuts (Fig. 5/23) of the main bearing bolts by means of the hydraulic device set...................228 1.6.1 Place hydraulic jacks (W5) and supporting sleeves (W7) plane on the desk and pull outwards ...............228 1.6.2 Lift device (W10) until the supporting sleeves (W7) rest on the main bearing cap. Make sure...............228 1.6.3 Slack tapped bushes (W9) from below through the desk to the main bearing bolts (22) until a...............228 1.6.4 Connect hydraulic jacks (Fig. 7/W5) via high-pressure hoses (W2) to the high- pressure pump...............228 1.6.5 Close valve (30) of high-pressure pump (W1) and burden both main bearing bolts simultaneous...............229 1.6.6 Slack round nuts (23) by means of pin(W3). Turn back round nuts by at least 8holes......................229 1.7 Open valve (Fig. 7/30) of the high-pressure pump (W1), the pressure of the hydraulic jacks is...................229 1.7.1 Wait until the pressure has completely dropped, take out tapped bushes (W9)...............................229 1.7.2 Move device down to the stop limit and take out supporting sleeves and hydraulic jacks....................229 1.8 See step 2 for measurement of the gap...........................................................................229 1.9 Move device to main bearing cap and slack round nuts. Move down device with main bearing cap ...................229 1.10 Take out lower bearing shell...................................................................................229 1.11 Insert dog (Fig. 8/W11) into the oil bore of the crankshaft until it rests on the stop limit...................229 1.12 Turn out and take out top bearing shell........................................................................229 1.13 See 02.03.03.nn and 02.03.07.nn for evaluation of the bearing shells...........................................230 1.14 Check wear of the wall thickness in the main load area at the measuring points (Fig. 9/X) by...................230 1.15 If the wear exceeds 0.05 mm, the bearing shells must be renewed................................................230 2. Measurement of the gap...............................................................................................230 2.1 Remove anti-fatigue stud bolts (Fig. 10/1) of the main thrust bearings on the exhaust and con...................230 2.1.1 Slack both round nuts (23) hydraulically according to steps 1.5 and 1.6. Move down device(...............230 2.1.2 Slack round nuts further, but do not take them out. Now tighten round nuts alternately and ...............231 2.1.3 Measure the gap "K" between cylinder crankcase and bearing cap at exhaust and control side ...............231 1. Assemble bearing shells......................................................................................232 1.1 Oil the running surface of the top shell well, dry back of the bearing and turn the bearing s...........233 Attention: Marking of the bearing shells at both sides of the separation at camshaft side...................................233 1.2 Insert the mounting device (W12) in the bearing caps. In doing so ensure that it rests on the.......................233 1.3 Turn top bearing shell in and see that the shell is well centered. The lug must slide into th.......................233 1.4 Bring the device (W10) up, remove round nut. Bring the device (W10) down again and take out d.......................233 1.5 Oil plated overlay of the lower bearing shell (Fig. 2/4), wipe bearing back dry and insert in.......................233 Attention: The bearing lug of the lower shell is on the control side........................................................233 1.6 Place the possibly disassembled lower starting disk segments (1; only at main thrust bearing).......................233 2. Preliminary mounting of the main bearing bolts.......................................................................234 2.1 Lift device (Fig. 3/W10) with main bearing cap (3), until it rests on its limit stop. Do not ...................234 2.2 Hand-tighten round nuts (6) evenly to main bearing bolts (5) by means of pin(W3)...............................234 2.3 Slacken and take out possibly placed countersunk bolts (8)......................................................234 2.4 Lower device (W10)..............................................................................................234 3. Assemble lateral anti-fatigue stud bolts (Fig. 4/11).................................................................234 3.1 Grease thread of the anti-fatigue stud bolts (11) with Molykote and screw in and tighten by m...................234 3.2 Hand-tighten round nuts (12) to the anti-fatigue stud bolts.....................................................234 3.3 Place hydraulic jacks (Fig.5/W4) with the supporting sleeves (W6) above round nuts (12). Mak...................235 3.4 Hand-tighten tapped bushes (W8) to the anti-fatigue stud bolts (11).............................................235 3.5 Connect hydraulic jacks (W4) on the operating side with high-pressure pump (W1) via high-pres...................235 Attention: The maximum stroke indicator (Fig.5/ 15) must not be moved beyond the top edge of the...........................235 3.6 Close valve (Fig.6/18) of the high-pressure pump (W1) and stretch anti-fatigue stud bolt ste.......................235 Attention: Pressure must remain constant when hydraulic pump is non-operational, otherwise tighte...........................235 3.7 Tighten round nut (Fig.5/12) firmly by means of pin (W3)...........................................................235 3.8 Open valve (Fig.6/18) of high-pressure pump (W1), jack is unloaded.................................................235 3.9 Connect hydraulic jack (Fig.5/W4) with high-pressure pump (W1) on exhaust side via high- pre.......................235 3.10 Close valve (18) of the high-pressure pump (W1) and stretch both anti-fatigue stud bolts ste.......................235 3.11 Check firm support of round nut....................................................................................236 3.12 Open valve (Fig. 6/18) of the high-pressure pump (W1), hydraulic jacks get unloaded................................236 3.13 Wait until the pressure has completely dropped, remove tapped bushes (Fig. 5/W8) and disasse.......................236 3.14 Tighten round nuts (Fig. 4/12) of the lateral anti-fatigue stud bolts (11) to the adjacent b.......................236 3.15 Screw protective caps (13) to anti-fatigue stud bolts..............................................................236 4. Tightening of the main bearing bolts.................................................................................236 4.1 Place hydraulic jacks (Fig. 7/W5) and supporting sleeves (W7) plane on the desk (Fig. 3/7) an...................236 4.2 Lift device (W10) until the supporting sleeves (Fig. 7/W7) rest on the main bearing cap. Make...................236 4.3 Hand-tighten tapped bushes (W9) from below through the desk to the main bearing bolts (5).......................236 4.4 Connect hydraulic jacks (W5) via high- pressure hoses (Fig. 8/W2) to high- pressure pump (W1)...................236 4.5 Close valve (Fig. 8/23) of the high-pressure pump (W1) and stretch both main bearing bolts si...................236 Attention: The pressure must remain constant with not operated hydraulic pump, otherwise tighteni...........................237 4.6 Tighten round nuts (Fig. 7/6) firmly by means of pin (W3). Make sure the nuts are smooth runn.......................237 4.7 Check firm rest of the round nut....................................................................................237 4.8 Open valve (Fig. 8/23) of the high-pressure pump (W1), hydraulic jacks get unloaded.................................237 4.9 Wait until the pressure has completely dropped and slacken out tapped bushes (Fig. 7/W9)............................237 4.10 Move device down until it rests on the limit stop and take out supporting rings and hydrauli.......................237 4.11 Check the oil flow.................................................................................................237 4.12 Close crankcase door on the control and exhaust side as well as door below the gear drive..........................237 1. Measure the end clearance "s"........................................................................................239 1.1 Open cap beneath the gear drive and the first drive cap on the clutch side of the control and...................239 1.2 Fit the dial gauge with a magnet on the flywheel and align it against the crankcase.............................239 1.3 Shift the crankshaft in axial direction by means of the hydraulic device until it rests on th...................239 1.4 Axial clearance "s":............................................................................................239 2. Disassemble main thrust bearing......................................................................................240 2.1 Turn the connecting rod of the first cylinder to 90° after TDC or 90° before TDC................................240 2.2 Slacken the round nuts (Fig. 2/7) of the lateral anti-fatigue stud bolts (6) by means of the ...................240 2.2.1 Slacken and remove the protective caps(8)................................................................240 2.2.2 Place the hydraulic jacks (Fig. 3/W4) with the supporting sleeves (W6) above the round nuts...............240 2.2.3 Tighten tapped bushes (W8) to anti- fatigue stud bolts (6) until a clearance of...........................240 2.2.4 Connect the hydraulic jacks (Fig. 4/W4) via high-pressure hoses (W2) to the high-pressure p...............240 2.2.5 Close valve (Fig. 4/13) of the high- pressure pump (W1) and burden both anti-fatigue stud b...............240 2.2.6 Slack round nuts (Fig. 3/7) by means of pin (W3). Turn back round nuts by at least 8 holes................240 2.2.7 Open valve (Fig. 4/13) of the high- pressure pump (W1), hydraulic jacks get unloaded......................241 2.2.8 Wait until the pressure has completely dropped, remove tapped bushes (W8) and disassemble h...............241 2.2.9 Slacken and unscrew anti-fatigue stud bolts (Fig. 3/6) completely.........................................241 2.2.10 Just slacken the round nuts (7) of the lateral anti-fatigue stud bolts (6) on the adjacent...............241 2.3 Employ device (Fig. 5/W10)......................................................................................241 2.3.1 Move device by means of the threaded rod (15) to its lowest position (limit stop). Check cl...............241 2.3.2 Disassemble desk (19), lift the device (W10) into the crankcase and place in the crankcase ...............241 2.3.3 Reassemble desk and insert device beneath the corresponding main bearing to the limit stop ...............241 2.4 Slacken round nuts (Fig. 6/23) of the main bearing bolts by means of the hydraulic device set...................242 2.4.1 Place hydraulic jacks (W5) and supporting sleeves (W7) plane on the desk and pull outwards ...............242 2.4.2 Lift device (W10) until the supporting sleeves (W7) rest on the main bearing cap. Make sure...............242 2.4.3 Slack tapped bushes (W9) from below through the desk to the main bearing bolts (22) until a...............242 2.4.4 Connect hydraulic jacks (Fig. 8/W5) via high-pressure hoses (W2) to the high- pressure pump...............242 2.4.5 Close valve (30) of high-pressure pump(W1) and burden both main bearing bolts simultaneous...............242 2.4.6 Slack round nuts (23) by means of pin(W3). Turn back round nuts by at least 8 holes......................242 2.5 Open valve (Fig. 8/30) of the high-pressure pump (W1), the pressure of the hydraulic jacks is...................243 2.5.1 Wait until the pressure has completely dropped, take out tapped bushes (W9)...............................243 2.5.2 Move device down to the stop limit and take out supporting sleeves and hydraulic jacks....................243 2.6 See step 3 for measurement of the gap...........................................................................243 2.7 Move device to main bearing cap and slack round nuts. Move down device with main bearing cap ...................243 2.8 Take out lower bearing shell....................................................................................243 2.9 Insert dog (Fig. 9/W11) into the oil bore of the crankshaft until it rests on the stop limit....................243 2.10 Turn out and take out top bearing shell........................................................................243 2.11 See 02.03.03.nn and 02.03.07.nn for evaluation of the bearing shells...........................................243 2.12 Check wear of the wall thickness in the main load area at the measuring points (Fig. 10/X) b...................244 2.13 If the wear exceeds 0.05 mm, the bearing shells must be renewed................................................244 3. Measurement of the gap...............................................................................................244 3.1 Remove anti-fatigue stud bolts (Fig. 11/6) of the main thrust bearings on the exhaust and con...................244 3.1.1 Slack both round nuts (23) hydraulically according to steps 2.4 and 2.5. Move down device (...............244 3.1.2 Slack round nuts further, but do not take them out. Now tighten round nuts alternately and ...............244 3.1.3 Measure the gap "K" between cylinder crankcase and main bearing cap at exhaust and control ...............244 1. Open the indicator valves, remove the crankcase cover for the respective cylinder on both sides......................245 2. Remove cylinder head (01.06.01.nn)...................................................................................245 3. Turn crank journal to the control side to ca.20° before TDC.........................................................245 4. Mount the cylinder liner retainer (W8) on the cylinder liner (3). Tighten the hex head bolt ha.......................245 5. Clean carbon deposits from the area above TDC for 1st piston ring up to gauging ring. Do not d.......................245 6. Turn the upper piston edge to just below the gauging ring (Fig. 2/4).................................................246 7. Insert disassembly rig (W9) so that the recess is inside the gauging ring............................................246 8. Tighten the disassembly unit slightly by turning the spindle nut.....................................................246 9. Press out and remove the gauging ring by turning the engine to raise the piston......................................246 10. Remove the disassembly rig (W7).....................................................................................246 11. Rethread the threaded holes (2; M12, 11 mm deep) in the piston crown................................................246 12. Bolt the piston lifting unit (W1) onto the piston crown.............................................................246 13. Connect the crane to the eye of the lifting unit, turn the piston to BDC together with the cr.......................246 14. Split the connecting rod shank:.....................................................................................246 14.1 Mount the both supports for the torque wrench (Fig. 3/W4) on the control and exhaust side......................246 14.2 Loosen the uniform strength bolts (5) with the torque wrench (W2), reversible ratchet (W3) a...................246 14.3 Remove both torque wrench (W4) supports........................................................................246 15. Mount the corresponding piston rod holder (W5, W6 or W7)............................................................246 15.1 Mount the piston rod holder (Fig. 4/W7) for cylinder 5 on the round nuts (11) on the counter...................247 15.2 Mount the piston rod holder (Fig. 5, 6/ W5) for cylinders 1, 2, 4, 6, 8 and 9..................................247 15.2.1 Mount the holding arm (14) according to the marking with the base plate holder (15) for Cy...............247 15.2.2 Place the base plate holder (15) on the piston rod (6) and bolt the holding arm (14) to th...............247 15.3 Mount piston rod holder (Fig. 7/W6) for cylinder 3 and 7.......................................................248 15.3.1 Mount the holding arm (21) on the inside of the base plate holder (15) as shown in Fig. 6................248 15.3.2 Place the base plate holder (15) on the piston rod (6) and bolt the holding arm (14) to th...............248 15.3.3 Bolt the piston rod holder (W6) to the crankshaft with hex head bolts (22)...............................248 15.3.4 Place the bar (25) on studs (24) and secure with nuts (23)...............................................248 15.3.5 Bolt the pressure pieces securely to the connecting rod shank split with pressure bolts (22).............248 16. Pull the piston carefully and place on a suitable surface...........................................................248 17. Seal off the oil bore (Fig. 6/20) in the piston rod shank split with a protective cap...............................248 1. Turn piston..........................................................................................................249 1.1 Attach crane to lifting gear for piston (Fig. 1/W1), lift piston................................................249 1.2 Mount second lifting gear for piston (W1) to connecting rod boss (1) and attach to second crane.................249 1.3 Carefully turn piston and place on suitable base................................................................249 2. Disassembly of piston crown..........................................................................................249 2.1 Attach lifting gear for piston (W1, connecting rod shank division) to crane, remove piston pi...................249 2.2 Measure small-end bearing (3) (02.09.01.nn) and evaluate (02.03.03.nn)..........................................249 2.3 Loosen hexagon nuts (Fig. 2/5) and remove with piston lower part (12)...........................................250 2.4 Clean piston crown (8) and piston lower part (12). Pay attention to cleanliness of contact su...................250 2.5 Remove locking ring (9), remove sliding block (10)..............................................................250 2.6 Check and clean oil bores and sliding surfaces on sliding block (10) as well as piston lower ...................250 2.7 Determine length projection (IÜ) of piston screws (7) from contact surface; replace piston sc...................250 2.8 Mounting of piston..............................................................................................250 2.9 Screw piston screws (if removed) into piston crown and tighten with a torque of.................................250 2.10 Mount piston lower part (12), centering hole and dowel pin (11) must coincide..................................250 2.11 Mount thrust pieces (6) onto piston screws (7) with crowned surface facing the piston lower ...................250 2.12 Coat inner thread and contact surfaces of the hexagon nuts (5) with Molykote paste.............................250 2.13 Tighten hexagon nuts (5) crosswise with a torque of............................................................251 2.14 Loosen hexagon nuts again......................................................................................251 2.15 Tighten up tapering of piston screws (7) in piston crown, torque:..............................................251 2.16 Tighten hexagon nuts (5) crosswise with a torque of............................................................251 2.17 Check:.........................................................................................................251 1. Piston inspection (7,500 h)..........................................................................................252 1.1 Open all crankcase covers.......................................................................................252 1.2 Check the running surfaces of the cylinder liners from the crank chamber........................................252 1.3 Draw the piston from the liner with the worst running pattern (02.06.01.nn). Draw the other p...................252 1.4 Remove piston rings only with the piston ring expander (Fig. 1/W1). Record position of ring g...................253 1.5 Clean the piston rings..........................................................................................253 1.6 Check the chromium layer for wear, particularly at the cut and the opposite side. Renew all r...................253 1.7 Clean the piston, ring grooves and oil return holes for the scraper ring........................................253 1.8 Smooth light friction and seazing marks with a fine oily emergy cloth or a fine carborandum s...................253 1.9 Measure the groove width hN (Fig. 2) in the front area of the groove in the longitudinal and ...................253 1.10 Measure the ring thickness hR (Fig. 2) at 4 opposite lying points..............................................253 1.11 Calculate the limit tolerances and check according to the chart for standard piston ring sets..................254 1.12 Insert piston rings with inscription upwards (Fig. 3/X) and with the ring gaps lying alterna...................254 2. Maintenance (30,000 h)...............................................................................................254 2.1 Draw all pistons (02.06.01.nn)..................................................................................254 2.2 Check the state of lubrication and appearance of the running surface of the piston and clean it.................254 2.3 Remove the piston rings with the expander (Fig. 1/W1). Record the position of the ring gaps i...................254 2.4 Clean all ring grooves and check wear of the chromium layer. If the chromium layer is worn aw...................254 2.5 Measure the groove width hN according to operation sequence 1.9.................................................254 2.6 Replace oil scraper ring and all compression rings..............................................................254 2.6.1 Insert piston rings with inscription (Fig. 3/X) upwards and with the ring gaps alternately ...............254 2.7 Fit all pistons (02.10.01.nn)...................................................................................254 1. Turn piston..........................................................................................................255 1.1 Attach crane to lifting gear for piston (Fig. 1/W1), lift piston................................................255 1.2 Mount second lifting gear (W1) to connecting rod boss (1) and attach to second crane............................255 1.3 Turn piston and place it on suitable base.......................................................................255 2. Disassembly (Fig. 1).................................................................................................255 2.1 Mark connecting rod boss (1), piston (2) and piston ring (3) for assemblying on the correct s...................255 2.2 Lift connecting rod boss slightly with crane in order to relieve piston pin.....................................255 2.3 Remove locking rings (4)........................................................................................255 2.4 Push piston pin (3) out of piston bore and piston pin bush without force........................................255 2.5 Check oil bores (6) in connecting rod boss and piston pin bush for free flow....................................256 2.6 Check piston pin surface for cracks and damage..................................................................256 2.7 Measure piston pin, piston pin bush and piston pin bore in piston (02.09.01.nn).................................256 3. Assembly.............................................................................................................256 3.1 Insert one locking ring (4) in the piston bore..................................................................256 3.2 Insert connecting rod boss (1) in the piston so far that piston bore and piston pin bush align..................256 3.3 Lubricate piston pin (3) and push into piston and piston ring bush without canting according ...................256 3.4 Secure piston pin with second locking ring......................................................................256 1. Measure small-end bush...............................................................................................257 1.1 Clean piston pin (Fig. 2/1), small-end bush (2) and piston bosses and measure the sizes A, B,...................257 1.2 Determine axial clearance [piston boss distance (size D) and measure bearing thickness (size ...................257 2. Disassemble small-end bush...........................................................................................259 2.1 When disassembling the small-end bush make sure, the disassembly is carried out with a minimu...................259 3. Assemble the small-end bush..........................................................................................259 3.1 Cool a piston bush by means of CO2 snow to approx. -60 °C and heat the connecting rod boss in...................259 3.2 Insert bush into the connecting rod boss........................................................................259 3.3 After reaching the normal temperature, the dimensional accuracy and the position of the oil b...................259 1. Insert all piston rings with the ring cuts in the longitudinal direction of engine alternating.......................260 2. Loosen the tensioning screw (Fig. 1/1), until the piston mounting device (W9) is released so f.......................260 3. Apply Molykote paste "G-Rapid Plus" to the thread and screw-supporting face of the tensioning .......................260 4. Place the piston mounting device (W9) above the piston ring zone and tighten the tension screw.......................260 5. Check the free motion of rings by turning the piston mounting device(W9)............................................261 6. Mount the lifting device for pistons (Fig.2/W1) on the piston.......................................................261 7. Mount the piston mounting ring (W12).................................................................................261 8. Attach the piston to a crane and lift it.............................................................................261 9. Cautiously insert the piston into the cylinder liner exactly in the cylinder axis....................................261 10. Lower the piston, it must not get jammed in the cylinder liner......................................................261 11. Let sit the piston mounting device (Fig.1/W9) plainly on the piston mounting ring (Fig. 2/W1.......................261 12. Assemble the cylinder liner support (Fig. 2/W8).....................................................................261 13. Mount piston and connecting-rod.....................................................................................262 13.1 Apply Molykote to the threads and contact faces of expansion studs.............................................262 13.2 Attach segments (10) to con-rod shank partition and slightliy tighten tension bolts with rin...................262 13.3 Disassemble the connecting rod support (02.06.01.nn, W5, W6 or W7).............................................262 13.4 Assemble both supports for torque wrenchs (W4) on the camshaft and exhaust side................................262 13.5 Use a torque wrench (W2), change-over ratched (W3) and long socket (A/F22) and tighten all t...................263 13.6 Visual check of tightening torque acc. to angle of rotation approx. 50° + 10°..................................263 13.7 Disassemble both supports for torque wrench (W4)...............................................................263 14. Turn the pistons jointly to TDC with the crane......................................................................263 15. Disassemble the piston mounting device (Fig. 1/W9), the piston mounting ring (Fig. 2/W12) and.......................263 16. Clean the contact face of the cylinder liner (7)....................................................................263 17. Mount new gauging ring..............................................................................................263 18. Assemble the cylinder head (01.11.01.nn)............................................................................263 19. Disassemble the cylinder liner support (Fig. 2/W8), assemble the engine compartment cover and.......................263 1. Dismantle cylinder head (01.06.01.nn) and support piston with the aid of the extraction device.......................264 2. Loosen round nuts (1) with hydraulic device (02.04.01.nn)............................................................264 3. Loosen nuts (1) approx. 20 mm from support on connecting rod bearing cover...........................................264 3.1 Turn crankshaft through an angle of approx. 20° until there is a gap of ...................264 4. Disassembly of the necked-down bolts (5) on the connecting rod blade division on the exhaust s.......................264 4.1 Tie extension (W2) with mounted 22 mm insert (W3) loosely with rope (2) to connecting rod blade.................264 4.2 Position ratchet (W1) with mounted tube (W4) and pull extension (W2) firmly against the conne...................264 4.3 Loosen screws (5)...............................................................................................264 4.4 Remove screws (5) and segment (6)...............................................................................265 4.5 In order to loosen the necked-down bolts (5) on the control side, repeat operation sequences ...................265 4.6 Secure both the cylinder liner and connecting rod in a suitable fashion before disassembly of...................265 4.7 Move connecting rod to bottom dead centre and disassemble (02.06.01.nn).........................................265 1. Check the relief valve from the inside of the crankcase door (Fig. 1/1) for freedom of movemen.......................266 2. If the valve is not free, disassemble the relief valve...............................................................266 3. Check pressure spring (3) and renew if necessary.....................................................................266 4. Check the guide bolt (7) and the valve head (6) and touch them up if necessary.......................................266 5. Check O-ring (4) on the guide bolt and renew if necessary............................................................266 6. When fitting a new O-ring, cover the thread and the shaft of the guide bolt with a smooth mate.......................266 7. Check the seal (5) of the valve head (6) and renew it if necessary (fix it with glue and harde.......................266 8. Assemble the relief valve, fit the splint pin (8) and check the valve head for freedom...............................266 9. Check the seal (9) prior to assembling and renew if necessary........................................................266 1. Check the cylinder liner.............................................................................................267 1.1 Pull piston (02.06.01.nn).......................................................................................267 1.2 Clean the cylinder liner internally (thoroughly cover the crankcase)............................................267 1.3 Measure the cylinder liner with the precision inside micrometer (W2) at the measuring points ...................267 1.4.................................................................................................................267 1.5 Enter the measured values in the table (Fig. 2) and thereafter determine the wear (d1 - refer...................268 1.6 When the wear limit, normally in the area of the top dead center of the piston ring (TDC 1st ...................268 1. Disassemble the cylinder liner.......................................................................................269 1.1 Disassemble the piston (02.06.01.nn). Disassemble the cylinder liner holder (W2)................................269 1.2 Measure the wear................................................................................................269 1.3 Place the upper cross piece half (W1) with threaded rod and ring bolt on the cylinder liner c...................269 1.4 Mount the lower cross piece half (1) and brace the two cross piece halves firmly by means the...................269 1.5 Connect the lifting gear and pull out the cylinder liner in the direction of the cylinder axi...................269 1.6 Remove the O-ring (13) in the cooling water distributor housing (14)............................................269 1.7 Carefully clean the sealing surface and the groove for the O-ring and check for damage..........................269 1.8 Carefully clean the cooling water area on the cylinder liner collar.............................................269 1.9 Clean the cylinder liner support, upper and lower fitting in the cylinder crank-case............................269 1. Clean the inside of the cooling water distributor housing (fig. 1/1).................................................271 2. Fit a new O-ring (4) in the groove on the cooling water distributor housing..........................................271 3. Coat the contact surfaces of the cylinder liner (2) on the cylinder crankcase (3) with sealing.......................271 4. Remove the device (fig. 1/W1) from the drawn cylinder liner..........................................................272 5. Mount the device on the cylinder liner which is to be fitted according to operational sequence.......................272 6. Connect the lifting gear to the ring nut on the device (W1) and insert the cylinder liner in t.......................272 7. Remove the device (W1) from the cylinder liner and fit the piston (02.10.01.nn)......................................272 1. Check for good mounting and leaks of flanged connections, filters, thermostats and pipe clamps.......................273 2. Check the expansion joints for leaks and the suspension of the exhaust piping (06.01.01.nn) be.......................273 3. Check the tight fitting of the suspensions and unions in the charge air manifold.....................................273 4. Retighten the fixing bolts of the brackets of the injection pump control rods and check the lo.......................273 5. Check the monitoring and control equipment for good fitting. Cables and signal pipes must not .......................273 6. Check the foundation bolts and chocks by knocking. Measure the crank web deflection after tigh.......................273 7. Check elastic bedding elements for damages...........................................................................273 1. Check the camshaft bearing clearance.................................................................................274 1.1 Open corresponding inspection glass lid of the camshaft door on the control side................................274 1.2 Measure clearance camshaft bearing / bearing neck...............................................................274 1. Check the running surface of one camshaft bearing and corresponding camshaft section from firs.......................275 1.1 Dismount the valve lifter from camshaft section of the appropriate cylinder and from all cams...................275 1.2 Unscrew the hexagon nuts (Fig.1/1) on the left-hand flange of the camshaft section (3). Turn ...................276 1.3 Unscrew the fixing screw (Fig. 2/11)............................................................................277 1.4 Use a suitable wood block and rubber hammer and beat out camshaft bearing (4) to the right-ha...................277 1.5 Place cardboard or similar material around the bearing journal of the camshaft..................................277 1.6 Use a squared timber and move the camshaft by dimension „s“ to the right up to the limit stop...................277 1.7 Remove the screws (Fig. 1/W2) and the nuts (1)..................................................................277 1.8 Check the camshaft bearing. Replace the camshaft bearing (04.04.01.nn)in the following cases:...................277 1.9 Check the back of the camshaft bearings for wear marks and replace it, if necessary (04.04.01...................277 1.10 Check the running surfaces of the bearing journals of all accessible camshaft sections for s...................277 1.11 Replace the defective camshaft sections and check appertaining camshaft bearings (04.04.01.nn).................277 1.12 Mount the camshaft (04.04.01.nn)...............................................................................277 1.13 Mount the fixing screw (Fig. 2/11). Tighten screw at a torque of...............................................278 2. Check the running surfaces of all camshaft bearings and camshaft sections from first cylinder .......................278 2.1 Unload all valve lifters and lift them (04.04.01.nn)............................................................278 2.2 Loosen the hexagon nuts (Fig.1/1) on the left-hand flange of the camshaft section (3) of the ...................278 2.3 Remove the fixing screws (Fig. 2/11) on the camshaft bearing points.............................................278 2.4 Use a suitable wood block and a rubber hammer and beat out appertaining camshaft bearing (4) ...................278 2.5 Move the camshaft (1.4 to1.7)...................................................................................278 2.6 Support vibration damper and camshaft section of the first cylinder.............................................278 2.7 Check the running surfaces of the bearing journals of all camshaft sections for scoring.........................278 2.8 Replace the defective camshaft sections (04.04.01.nn)...........................................................278 2.9 Mount the camshaft (04.04.01.nn)................................................................................278 2.10 Mount the fixing screw (11). Tighten screw at a torque of M = 60 Nm............................................278 2.11 Disengage the turning device...................................................................................278 2.12 Unload the valve lifter, dismount the supporting device and carry out final work (04.04.01.nn).................278 1. Disassembly..........................................................................................................279 1.1 Open indicator valves and dismount camshaft cover with housing covers and gaskets on the cont...................279 1.2 Dismount all valve lifters of the appropriate cylinder and all valve lifters of the cylinders...................279 1.3 Dismount fuel injection pump of the appropriate cylinder and all fuel injection pumps of the ...................280 1.4 Dismount push-rods from the camshaft section of the appropriate cylinder and from all camshaf...................280 1.5 Disassembly of the last camshaft section........................................................................280 1.5.1 Dismount vibration damper (Fig. 2/10) (04.09.01.nn) and move it to the right-hand side as f...............280 1.5.2 Remove intermediate piece (12)............................................................................280 1.6 Loosen hexagon nuts (Fig. 1/1) on both flanges of the camshaft section (3). Turn free inacces...................280 1.7 Place the round sling (Fig. 3/W1) around the camshaft section (3) between exhaust cam and inj...................281 1.8 Slightly tightened the round sling (W1) with the lifting gear...................................................281 1.9 Remove the fixing screw (11)....................................................................................281 1.10 Use a suitable wood block and a rubber hammer and beat out the right-hand camshaft bearing (...................281 1.11 Place cardboard or similar material around the bearing journal of the camshaft.................................281 1.12 Use a squared timber and move the camshaft by dimension „s“ to the right up to the limit sto...................281 1.13 Secure right part of camshaft with wood wedges to avoid axial movement.........................................282 1.14 Line the camshaft trough with cardboard or similar material....................................................282 1.15 Pull the camshaft section (Fig. 4/3) to the left out of the bearing seats while you lower th...................282 1.16 Remove the camshaft bearing (4) from the lifting gear, check (04.01.02.nn)the camshaft beari...................282 2. Mounting.............................................................................................................283 2.1 Press the parallel pin (Fig. 5/5) into the flange of the camshaft section up to the limit sto...................283 2.2 Lubricate the camshaft bearing (Fig. 1/4) inside and outside and place it on the inlet cam of...................283 2.3 Place the camshaft section (3) in the appropriate camshaft trough on a piece of cardboard or ...................283 2.4 Place the round sling (Fig. 3/W1) around camshaft section between exhaust cam and injection c...................283 2.5 Slowly lift the lifting gear and carefully guide the bearing journal of the camshaft section ...................283 2.6 Use the parallel pin and align the camshaft section with the bore hole in the bearing journal...................284 2.7 Use two opposite studs (Fig. 1/2) and appropriate nuts (1) and screw the camshaft section ont...................284 2.8 Use a squared timber and carefully move the camshaft to the left until the camshaft section i...................284 2.9 Use Molykote and insert all studs (2) and nuts (1). Stiftschrauben (2) in Lagerzapfen (6) ohn...................284 2.10 Insert studs and nuts into the left-hand flange of the camshaft section (if possible) and gr...................284 2.11 Align the location bore hole of the camshaft bearing with the bore hole for the fixing screw...................284 2.12 Push-in the camshaft bearing (4) with a suitable wood block and a rubber hammer. Do not tilt...................284 2.13 Use Molykote and insert the fixing screw (11). Tighten the screw at a torque of................................285 2.14 Insert the remaining studs and nuts into the right and left-hand bearing flange of the camsh...................285 2.15 Lower the lifting gear and remove the round sling (Fig. 1/W1)..................................................285 2.16 When the last camshaft section is mounted:.....................................................................285 2.16.1 Firmly attach the intermediate piece (Fig. 2/12) to the camshaft section (3). The recess m...............285 2.16.2 2.16.2 Insert the studs (2) into the connection piece between camshaft section and interme...............285 2.16.3 Mount the vibration damper (10) (04.09.01.nn)............................................................285 2.17 Mount the valve mechanisms and fuel injection pump drives......................................................285 2.18 Mount the push-rods............................................................................................285 2.19 Mount the valve lifters and check the valve clearance (01.01.01.nn)............................................285 2.20 Mount the fuel injection pumps (07.02.01.nn)...................................................................285 2.21 Check the lube oil flow through the camshaft...................................................................285 2.22 Mount the housing cover........................................................................................285 2.23 Close the indicating valves....................................................................................285 2.24 Disengage the turning device (12.08.01.nn)....................................................................285 1. Check the tooth profiles and oil nozzles.............................................................................286 1.1 Remove the lid of the gear housing on the controller and exhaust side...........................................286 1.2 Check the tooth profiles of the cam shaft gear wheel (Fig. 1/2), the intermediate wheel (1) a...................286 1.3 Measure the play of the gears between the intermediate wheel and the cam shaft gear wheel (x)...................286 1.4 Setpoints x = 0.20 - 0.37 mm z = 0.28 - 0.44 mm..................................................286 1.5 Check whether the oil nozzles (4,5 and 6) function are tightly fastened.........................................286 2. Measure the axial play of the intermediate wheel (Fig. 2/s) using a feeler gauge or dial gauge.......................287 2.1 Check the seals and install the lids to the gear housing on both the control and the exhaust ...................287 1. Replace the O-ring (Fig. 2/6) of the intermediate wheel axle (Fig. 1/1)..............................................288 1.1 Loosen the hex screws (Fig. 2/3); remove using the resilient sleeves (4) and the tightening p...................288 1.2 Remove the gear space lid of the 1st cylinder...................................................................288 1.3 Press the intermediate wheel axle (1) of the gear space out of the wheel housing to the coupl...................288 1.4 Replace the O-ring (6)..........................................................................................288 1.5 Coat the thread and contact surfaces of the hex screws (3) with Molykote........................................289 1.6 Install the hex screws (3) with the resilient sleeves (4) and the tightening plate (5) and ti...................289 1.7 Press the tightening plate (5) onto the hex screws and tighten the hex screws (3) with a torq...................289 1.8 Check the size of the gap (Fig. 3/X) between the tightening plate and the intermediate wheel ...................289 1. Disassembly..........................................................................................................290 1.1 Loosen the governor linkage from the governor (fig. 1/1), to this end:..........................................290 1.1.1 Arrest the stop lever in stop position....................................................................290 1.1.2 Remove the prevailing torque type nut (1) with spacer sleeve (4), bolt (6) and washer (2).................290 1.1.3 Put aside the spring element (7)..........................................................................290 1.2 Remove hexagon head screws (11) and lift up the governor (10)...................................................290 1.3 Remove hexagon head screws (fig. 2/20) with spacers (21) and hexagon head screws (22)...........................291 1.4 Attach the governor drive housing (23) to a crane by means of a sling and carefully lift up f...................291 1.5 Put the governor drive housing (fig. 2/23) onto a suitable base.................................................291 1.6 Remove gasket (24) and clean the contact face on the engine block...............................................291 1.7 Check the gear flanks of the helical gear wheels (fig. 4/40, 41) for pittings, skewing or bre...................292 1.8 Check the serration of governor drive shaft (43) and governor (fig. 1/10) for wear, if necess...................292 1.9 Check all oil lubrication bores for lubrication of the governor drive shaft and the helical g...................292 2. Reassembly...........................................................................................................293 2.1 Provide the lubricating oil passage sleeve (fig. 3/30) with new O-rings (31)....................................293 2.2 Put gasket (24) onto the engine block...........................................................................293 2.3 Carefully put the governor drive housing (fig. 2/23) onto the engine block by means of a cran...................293 2.4 Insert screws (fig. 2/20) with spacers (21) and screws (22).....................................................293 2.5 Firmly tighten screws (20) and (22) crosswise...................................................................293 2.6 Daub the contact face for the governor with "Dirko 610.020". Put the governor (fig. 1/10) ont...................293 2.7 Insert and firmly tighten screws (fig. 1/11)....................................................................293 2.8 Mount the governor linkage in reversed disassembly sequence. If required readjust the governo...................293 1. Disassambly..........................................................................................................294 1.1 Remove the lateral and end housing lids.........................................................................294 1.2 Loosen the screws (2) and remove them together with the resilient sleeves (3)...................................294 1.3 Lift the vibration damper (1) and the intermediate ring (5) from the adapter(4)................................294 2. Assembly.............................................................................................................295 2.1 Clean and remove grease from the surfaces of the damper (1), the intermediate ring (5) and th...................295 2.2 Lubricate the threads of the screw (2) with Molykote paste “G-Rapid”............................................295 2.3 Push the new damper (1) and the intermediate ring (5) onto the adapter (4) and tighten the sc...................295 2.4 Tighten the screws (2) with a torque of ...................295 2.5 Install the lateral and end housing lids........................................................................295 1. Remove control shaft/injection pumps and control station covers......................................................296 2. Check control shaft and spindle to emergency-off lever and oil bearing areas slightly with lub.......................296 3. Grease the following bearings with multi-purpose grease: - swivel heads of the intermediate sh.......................296 Note:...............................................................................................................296 At V-engines the swivel heads of the intermediate shaft of both control shafts are to be greased....................296 4. Oil all moving bearings of the swivel arm between control shaft and injection pump slightly..........................296 5. Assemble covers......................................................................................................296 1. Secure the engine against unauthorized starting......................................................................297 2. Disconnect pipes and with the governor empty drain the lines, otherwise plug the oil lines (2).......................297 3. Record free length of the limiting screw (3) and unscrew it until piston (5) touches cover (4)......................297 4. Loosen nuts (6) uniformly (caution: spring stress), bring unit to the vertical position, remo.......................297 5. Pour oil, push out piston (5)........................................................................................297 6. Clean all parts, using non-ravelling rags only, check the sealing rings..............................................297 7. Assemble in reverse order, lightly oil the parts. Tighten nuts (6) uniformly. Screw in limitin.......................298 8. Fit starting aid to the engine, mount air (1) and oil pipes (2)......................................................298 9. Filling of the starting aid through the governor oil sump; for this purpose always after a cer.......................298 10. Carry out functional check by starting the engine...................................................................298 1. Functional check.....................................................................................................299 1.1 Check the air connection for leaks..............................................................................299 1.2 Check whether the piston moves easily under air pressure. If the movement is jerky, vent the ...................299 1.3 Check the setting...............................................................................................299 1.3.1 If maximum fuel limitation has been provided, check the setting (see the Acceptance Test Re...............299 1.3.2 Check whether 40 % fuel is admitted when the piston is in the outer dead centre. Adjust by ...............299 1.4 Check whether full fuel is admitted within.....................................................................300 2. Venting..............................................................................................................300 2.1 Slip a transparent hose over vent screw (12) and put the other end into a an oil reservoir ar...................300 2.2 Remove plug (13), spring (14) and piston (15)...................................................................300 2.3 Fill oil in as far as 7 mm below the housing top edge (SAE 20)..................................................300 2.4 Insert the piston. Drive the air out by screwing the plug in....................................................300 2.5 Proceed according to 2.3 and 2.4 until no air escapes any more. Unscrew the plug. Insert the ...................300 2.6 If the cylinder is of the older type, the air must be removed by the throttle screw.............................300 3. Disassembly..........................................................................................................300 3.1 Close the main air valve. Remove the air connection.............................................................300 3.2 Remove the unit from the engine.................................................................................300 3.3 Measure and note down the position of throttle screw (10) and thrust screw (11).................................300 3.4 Disassemble the unit entirely and clean it in spirit............................................................300 3.5 Inspect all parts...............................................................................................300 4. Reassembly...........................................................................................................301 4.1 Renew all gaskets and seals (Fig. 2/1 - 9)......................................................................301 4.2 Assemble the unit observing the following:.....................................................................301 4.2.1 Tighten the socket head cap screws (17) with a torque.....................................................301 4.2.2 Before fitting vent screw (12), plug (13), spring (14), piston (15) and throttle screw (10...............301 4.2.3 Fill oil (SAE 20) in as far as 7 mm below the housing top edge at connection (B)..........................301 4.2.4 Tighten the throttle screw (10) and socket head cap screw (18) with a torque..............................301 4.2.5 Vent the unit according para 2............................................................................301 4.2.6 Adjust the unit and fit it on the engine..................................................................301 4.2.7 Mount air connection......................................................................................301 4.2.8 Open main air shut-off valve..............................................................................301 4.2.9 Check the operation according to para.1..................................................................301 1. Dismount the bushes (1)..............................................................................................302 1.1 Dismount linkage between injection pump control shaft (Fig. 1/7) and hinged lever (8) of cont...................302 1.2 Remove bracket (6) from hinged lever............................................................................302 1.3 Remove bushes (Fig. 2/1) from bracket (6).......................................................................302 2. Mounting of bushes (1)...............................................................................................302 2.1 Insert new bushes (1) in bracket (6)............................................................................302 2.2 Mount bolt (3), washers (4 and 5) and nut (2) to connect the bracket (6) to the hinged lever....................302 2.3 Mount bolt (3), washers (4 and 5) and nut (2) to connect the bracket (6) to the injection pum...................303 1. Drain compressed-air filte.......................................................................................308 1.1 Loosen drain plug (7) and empty filter completely...........................................................308 1.2 Close drain plug............................................................................................308 2. Disassemble compressed-air filter and clean......................................................................308 2.1 Loosen drain plug (7) and drain filter completely...........................................................308 2.2 Close compressed-air feed line and secure...................................................................308 2.3 Relieve compressed-air filter via drain plug................................................................308 2.4 Loosen housing cap (5) and remove, check O-ring (1) and replace if necessary................................308 2.5 Loosen Phillips screw (4), remove with guide (3) and filter element (2).....................................308 2.6 Remove locking ring (8), unscrew drain plug and check O-ring (6), replace if necessary......................308 2.7 Clean all disassembled parts and check for reuse............................................................308 2.8 Assemble compressed-air filter in reverse sequence. Open shut-off valve in the compressed-air...............308 2.9 Close drain plug after a short while........................................................................308 1. Disassemble covering of the exhaust manifold.........................................................................309 2. Check all bolts for tightness........................................................................................309 3. Accumulation of soot, particularly on flanges and expansion joints, indicates an untightness.........................309 4. Replace the defective exhaust pipe as follows:.......................................................................310 4.1 Slacken and remove the adjacent expansion joints (4). Do not load expansion joints by bending...................310 4.2 Slacken the hexagon screw (1) so that both upper parts of tension clamp (3) are still connect...................310 4.3 Slide the upper part of tension clamp, unhook the chain links (2) on both sides from the lowe...................310 4.4 Lift both upper parts of tension clamp jointly, replace defective exhaust pipe..................................310 4.5 Manufacture fitting pieces (x resp. y) to fit the new exhaust pipe..............................................311 4.6 Screw the fitting piece resp. pieces to the new exhaust pipe....................................................311 4.7 Reassemble the exhaust pipe and upper parts of tension clamp....................................................311 4.8 Remove the fitting piece resp., reassemble and screw the expansion joint(s).....................................311 5. Expansion joints with cracks in the bellows are to be replaced, see 4.8..............................................311 6. Mount the covering...................................................................................................311 1. Disassembly......................................................................................................312 1.1 Slacken the ventilation screws (Fig. 1/1) or, with a permanent ventilation engine, make sure ...............312 1.2 Slacken the cooling water supply and discharge lines (4) on the charge air cooler. Dismount c...............312 1.3 Slacken the hexagon screws (10). Unscrew screw plugs (11) and hexagon socket screws (12)....................312 1.4 Pull charge air cooler (9) off the casing(3), sling with hoist and place in an adequate cont...............312 1.5 Clean charge air cooler according to the manufacturer instructions (see book"C")...........................312 1.6 Check casing, drain condensed water by slackening the drain plug (6), if necessary replace ga...............313 2. Reassembly.......................................................................................................313 2.1 To reassemblle, reverse the dismantling sequence............................................................313 2.2 Renew gasket (8)............................................................................................313 2.3 Cautiously fit charge air cooler (9) in the casing (3)......................................................313 2.4 Mount cover plate (13)......................................................................................313 2.5 Firmly tighten hexagon screws (Fig. 2/10)...................................................................313 2.6 Tighten the cheese head screws (12) with a torque of ...............313 2.7 Insert screw plugs (11) together with sealing rings (14) and tighten them firmly............................313 2.8 Screw cooling water supply and discharge lines (Fig. 1/4) to the charge air cooler..........................313 2.9 Firmly tighten drain screws (5), tighten the possibly slackened drain plug (6) and refill the...............313 2.10 Firmly tighten the ventilation screws (1) or, with a permanent ventilation, the correspondin...............313 1. Cleaning procedure - Turbocharger exhaust side.......................................................................315 2. Carrying out.........................................................................................................315 3. Turbocharger cleaning (step 1):......................................................................................316 3.1 Reduce engine output to 20 - 25 % according to an exhaust temperature at turbocharger inlet o...................316 3.2 Operate engine with reduced output until stability of all values is reached (approx. 10 min)....................316 3.3 Connect cleaning pipe (5) with water pipe (detachable tube with shutoff valve)..................................316 3.4 Open drain pipe (check for free water drain). (valve 4).........................................................316 3.5 Open the shutoff valve (3), all cleaning valves (1) are fed in parallel. Proceed with cleanin...................317 3.6 After completion of the cleaning procedure close shutoff valve (3), remove tube (2) with pres...................317 3.7 Dry the exhaust system with reduced output (approx. 25 %) for at least 10 min. Close drain va...................317 3.8 If possible, run up to the reference operating point and take the readings of the reference v...................317 4. Turbocharger cleaning (step 2)::.....................................................................................317 4.1 Reduce engine performance according to application:.............................................................318 4.1.1 Marine main propulsion engine /idle running Engine control panel selector swi...............318 4.2 Operate engine with reduced output until stability of all values is reached (approx. 10 min)....................318 4.3 Connect cleaning pipe (5) with water pipe (detachable tube with shutoff valve (3)...............................318 4.4 Open drain pipe valve (4) (check for free water drain)..........................................................318 4.5 Open the shutoff valve (3), all cleaning valves (1) are fed in parallel. Proceed with cleanin...................318 4.6 Observe water drain until water is clean........................................................................319 4.7 After completion of the cleaning procedure close shutoff valve (3), remove tube (2) with pres...................319 4.8 Dry exhaust system with reduced output (approx. 25 %) for at least 10 min. Close drain valve...................319 4.9 If possible, run up to the reference operating point and take the readings of the reference v...................319 1. Disassembly..........................................................................................................320 1.1 Open indicator valves...........................................................................................320 1.2 Remove corresponding camshaft cover on the control side.........................................................320 1.3 Turn the engine so that the rocker (Fig.3/20) of the injection pump drive is on the base cir...................320 1.4 Close the shut-off cocks and drain the fuel distributor pipe (drain cock (Fig. 1/ 4) in the n...................320 1.5 Disassemble the fuel overflow line on the injection pump........................................................320 1.6 Remove the fuel distributor/collecting pipe (07.15.01.nn).......................................................320 1.7 Loosen screwed connection (Fig. 2/16) and disconnect the connection of the injection pump con...................321 1.8 Push the control rod (15) right into the injection pump.........................................................321 1.9 Loosen the pipe clamp (12)......................................................................................321 1.10 Loosen hexagon cap screw (14) and remove with leak fuel drain (13).............................................321 1.11 Loosen bracket (9) for stop cylinder (10) on the injection pump................................................321 1.12 Completely loosen pressure screw (6) and union nut (8). Push union nut upwards, slightly lif...................321 1.13 Loosen nuts (11) evenly and lift the injection pump from the cylinder crankcase................................321 2. Assembly.............................................................................................................322 2.1 Clean the contact surfaces on the injection pump, the spacer plates and the spring plate (21)...................322 2.2 Replace O-rings (22), place the injection pump over the retaining screws........................................322 2.3 Coat the threads and contact surfaces of the nuts (11) with Molykote paste and pull the injec...................322 2.4 Tighten the nuts (11) with a torque of..........................................................................322 2.5 Mount the control air line (Fig. 1/3) in front of the injection pump, pipe clamp (Fig. 2/12) ...................322 2.6 Screw regulating shaft to control rod (15) of the injection pump. Before tightening the screw...................322 2.7 Remove seals from the fuel bores (injection pump, forced fuel pipe).............................................322 2.8 Check O-ring (7) and replace if necessary.......................................................................322 2.9 Insert forced fuel pipe with pressure screw (6) into the cylinder head, turn, lift slightly a...................322 2.10 Tighten union nut (8) and pressure screw (6) by hand. Then tighten with an.....................................322 2.11 Check compressed-air lines for stop cylinder for leakage using compressed air. Check emergen...................322 2.12 Close indicator valves and mount camshaft cover on the control side............................................322 2.13 Open shut-off cocks, fill up fuel system with reserve pump and vent............................................322 1. Checking the pressure keeping valve (Fig. 1/6).......................................................................324 1.1 Place the injection pump next to the nozzle tester (W2).........................................................324 1.2 Screw the pressure pipe (W1) onto the connecting piece (Fig. 1/4) and connect to the test dev...................324 1.3 Pump with tester and increase the pressure gradually up to the opening pressure pÖ and check ...................324 2. Disassembly..........................................................................................................324 2.1 Clean the outside of the injection pump.........................................................................324 2.2 Remove the baffle screws (Fig. 1/7), check (see assembly) and replace if necessary..............................324 2.3 Clamp the pump with the mounting flange (13) upwards............................................................324 2.4 Loosen fillister head screws (18) and remove plate (17) with flange (15)........................................324 2.5 Load the tappet axially in a vice, remove the retainer ring (14) and slowly open the spindle ...................324 2.6 Remove plunger foot plate (20) with tappet (16), tappet spring (11) and pump plunger (12). Ch...................325 2.7 Remove control sleeve (22) with spring plate (21); check the toothing of the control sleeve.....................325 2.8 Remove locking ring (10), pull out retaining pin (9) and control rod (8) and check toothing.....................325 2.9 Clamp injection pump housing (1) with connecting piece (4) facing upwards.......................................325 2.10 Remove fillister head screws (3)...............................................................................325 2.11 Loosen fillister head screws (2) alternately and carefully lift off connecting piece (4). Pa...................325 2.12 Force pump element (25) out of housing (1) with round block of wood............................................325 2.13 Clean all parts with gas oil and a hard brush and blow out with compressed air.................................325 2.14 Replace all O-rings and gaskets................................................................................325 2.15 Unscrew hexagon socket head cap screws (30) and dismount plate (27) to replace rotary shaft ...................325 2.16 After replacement of O-ring (29) and rotary shaft seal (28), insert plate (27) and tighten h...................325 3. Assembly.............................................................................................................326 3.1 Assembling is carried out in reverse sequence of disassembly....................................................326 3.2 Insert the rotary shaft seals (Fig. 2/23, 24) with the lips and the metal spiral facing upwar...................326 3.3 Apply engine oil to the thread and contact surface of the following screws and tighten them c...................326 3.4 Check free movement of the control rod..........................................................................326 1. Disassembly..........................................................................................................327 1.1 Switch off the standby lubricating oil pump of the main engine/switch off the prelubricating ...................327 1.2 Dismantle the cylinder head cover and the fuel delivery pipe (07.02.01.nn)......................................327 1.3 Dismount nuts (Fig 1/1) with extension sleeves (10) and remove flange (3).......................................327 1.4 Screw the fuel injector extractor (fig.2 / W1) firmly onto the adjusting screw (8) of the fu...................328 1.4.1 Screw the threaded rod (20) firmly onto the adjusting screw (8)...........................................328 1.4.2 Mount the device (19) on the threaded rod and studs (2) together with the tortional lock (17).............328 1.4.3 Mount the hexagon nut (18)................................................................................328 1.5 Loosen the fuel injector by tightening the hexagon nut (18) against the device and unscrew it...................328 1.6 Use the extractor to pull out the fuel injector. Dismantle the extractor (fig. 2/ W1)...........................328 1.7 Clean the outside of the fuel injector. Mark it with the cylinder number and carry out the fu...................328 1.8 Clean the injector seat (fig. 1/9) in the injector insert (6) with tool(W2). Clean the inner...................328 2. Reassembly...........................................................................................................328 2.1 Replace the O-rings (7). Make sure the O-rings do not form loops!...............................................328 2.2 Apply a thin film of high-temperature thread paste to the valve seat, nozzle element (fig. 1/...................329 2.3 Apply a thin film of Molykote paste to the stud threads (2), contact surface of the nuts (1) ...................329 2.4 Insert the fuel injector in the sleeve. Pay attention to the position of the positioning pin ...................329 2.5 Mount the flange (fig. 1/3) with the dowel pin (fig. 3/11) facing the exhaust side and the ne...................329 2.6 Mount extension sleeves (10) and tighten nuts (1) by hand uniformly. Make sure flange (3) is ...................329 2.7 Mount the fuel delivery pipe (07.02.01.nn) and the cylinder head cover..........................................329 2.8 Check the lubricating oil and fuel circulations for leakage.....................................................329 1. Remove carbon deposits from the nozzle with a hard brush (no wire brush).............................................331 2. Check the nozzle hole for sharp edges, ovalization, corrosion and damage.............................................331 3. Place the injector with the adapter (Fig.1/W2) in the tester (W1)...................................................331 4. Screw the adapter (W4) into the injector and connect the injector delivery pipe(W3).................................331 5. Increase the pressure gradually until the nozzle opens. Injector opening pressure, see accepta.......................331 5.1 If the opening pressure is not correct, slacken the lock nut (1) and turn the adjusting screw...................331 1. Disassembly..........................................................................................................333 1.1 Slacken nut (Fig. 1/1) and relieve nozzle spring (4) by unscrewing the adjusting screw (2)......................333 1.2 Slacken nozzle nut (6) by turning left and unscrew..............................................................333 1.3 Extract nozzle (8) including nozzle needle without damaging the lapped surfaces. Be aware of ...................333 1.4 locking screw (3) and unscrew adjusting screw (2) , remove spring guide (10), nozzle spring (...................333 1.5 Submit nozzle spring (4) and setbolt (5) to visual inspection...................................................333 1.6 Clean the parts with gasoil.....................................................................................333 1.7 Fit a nozzle needle with gasoil in the nozzle (8) and check, whether the needle falls on the ...................333 1.8 Submit all parts particularly seat and sealing faces to a visual inspection. Replace defectiv...................333 2. Reassembly...........................................................................................................333 2.1 Wipe all sealing surfaces dry with clean, anti-fluff paper......................................................333 2.2 Renew O-ring-type sealing ring (9)..............................................................................333 2.3 Apply a film of lubricating oil to the thread of the fuel injector housin.......................................333 2.4 To assemble, reverse the dismantling sequence. When inserting into the casing (11) align the ...................333 2.5 Degrease and dry locking screw (3) and bore hole................................................................334 2.6 Apply “ Hydraulic sealing compound Loctite 566 “ to the thread of the locking screw (3). Scre...................334 2.7 Tighten the locking screw (3) with a torque of M = 20 Nm........................................................334 2.8 Remove residues of adhesive from housing (11) and locking screw (3).............................................334 2.9 Tighten the nozzle nut (6) with a torque of.....................................................................334 2.10 Check the injector according to 07.08.01.nn and set............................................................334 Procedure:..................................................................................................................336 1. Switch-over procedure (see plate on filter cover)....................................................................336 2. Cleaning.............................................................................................................336 2.1 Clean the filter at operating temperature when..................................................................336 50 % of the red field...................................................................................................336 of the differential pressure gauge (Fig. 1/1) is visible or when the filter alarm is triggered..........................336 2.2 Cleaning the filter when normally soiled........................................................................336 2.2.1 Remove the cover (2) from the isolated filter chamber. Open the sludge drain and drain the ...............336 2.2.2 Remove the filter insert..................................................................................336 2.2.3 Connect the cleaning gun (Fig. 2/W1) to the compressed air line and pressurize............................336 (6 - max. 10 bar).......................................................................................................336 2.2.4 Slide the spray guard (13) onto the nozzle of the cleaning gun completely, slide into the c...................336 2.2.5 Replace the O-ring (5) if necessary. Install the filter insert. Install a new gasket and re...................336 2.2.6 Fill and bleed the filter chamber (see plate on filter cover).................................................336 2.3 Filter cleaning (every 3rd cleaning)............................................................................337 2.3.1 Open the sludge drain and drain the filter chamber........................................................337 2.3.2 Remove the filter insert..................................................................................337 2.3.3 Rinse the filter chamber with gas oil.....................................................................337 2.3.4 Place the filter insert into a container that has been filled with a suitable cleaning flui...............337 2.3.5 Remove the filter insert from the cleaning container and blow out the sieve cartridges (14)...............337 2.3.6 Immerse the filter insert in clean cleaning fluid again, allow to drip off and blow out wit...............337 2.3.7 Check the sieve cartridge for damage......................................................................337 2.3.8 Replace the O-ring (5) if necessary. Place the filter insert into the filter chamber and re...............337 2.3.9 Fill and bleed the filter chamber (see plate on filter cover).............................................337 2.4 Cleaning the sieve cartridge with heavy soiling.................................................................337 2.4.1 Soak the filter insert in cleaning fluid (max. 4 h).......................................................337 2.4.2 Inspect the sieve cartridges and replace the sieve if damage or significant wrinkles are fo...............337 2.4.3 Connect the cleaning gun (W1) to the compressed air line. Air pressure max. 10 bar........................338 2.4.4 Depress the actuating trigger and slide the nozzle of the cleaning gun to the bottom of eve...............338 2.4.5 Remove any caking or other soil with a soft brush.........................................................338 2.4.6 Rinse the sieve cartridges in clean cleaning fluid, blow out and set on suitable surface wi...............338 2.4.7 Hold the sieve up against a bright light and check to see if clean. Repeat the procedure if...............338 3. Replace the O-ring (5) if necessary. Install the filter insert in the filter chamber.............................338 4. Replace the cover (with new gasket)..............................................................................338 5. Fill and bleed the filter chamber (see plate on filter cover)....................................................338 1. Disassembly......................................................................................................339 1.1 Remove the pump space cover.................................................................................339 1.2 Close the shut-off cocks and slacken the screw plug (Fig. 1/1) by about 3 turns to evacuate t...............339 1.3 Slacken the cheese head screws (Fig. 2/2). Move the sleeves (3) with shaft seal (17) and plat...............340 1.4 Pull out the fuel pipes (4).................................................................................340 1.5 To remove the sealing flange (5) on the injection pump of cyl. 1, remove the nozzle leakage p...............340 1.6 Remove the tube (Fig. 3/7)..................................................................................340 1.7 Slacken the cheese head screws (8) until the sealing flange (Fig. 2/5) can be pulled off the ...............340 2. Assembly.........................................................................................................340 2.1 Check the O-ring seals (Fig. 2/10) and the shaft seals (17) on the fuel pipes (4) for damages...............340 2.2 Put sealing flange (5) and lid (12) over the sleeves of the injection pump of cylinder 1....................340 2.3 Tighten the cheese head screws (Fig. 3/8) with a torque of M = 65 Nm Make sure that the cone...............341 2.4 Tighten the cheese head screws (9) with a torque of M = 60 Nm...............................................341 2.5 Mount the tube (7). Firmly tighten the banjo bolts (16).....................................................341 2.6 Mount the nozzle leakage pipe (Fig. 1/6)....................................................................341 2.7 Insert the fuel pipes (Fig. 2/4). Shift the sleeves (3) with shaft seal (17) and plate (18) t...............341 2.8 Daub the cheese head screws (2) with Molykote paste "G-Rapid Plus" and tighten them with a to...............341 2.9 Open the shut-off cocks and firmly tighten the screw plug (Fig. 1/1) with a torque of ...............341 2.10 Replenish the fuel system by means of the stand-by pump and vent it........................................341 2.11 Mount the pump space cover. ...............................................................................341 1. Disassembly..........................................................................................................342 1.1 Drain lubricating oil system....................................................................................342 1.2 Remove suction (Fig. 1/4) and pressure line (2).................................................................342 1.3 Loosen hexagon nuts (1) and pull lubricating oil pump (3) with gearwheel (6) out of cylinder ...................343 1.4 Loosen hexagon cap screw (8) and pull gearwheel (6) off drive gearwheel shaft (Fig. 2/10) wit...................343 1.5 Check tooth profiles for wear (pitting, slanting run, splintering)..............................................343 1.6 Slacken screws (16,18). Remove relief valve (21) and end cover (17) from pump casing (20).......................343 1.7 Disassemble driving gear wheel shaft (10) and impeller shaft (19) ..............................................343 1.8 Check the bushes (11 and 14), bearing areas of the drive and intermediate gearwheel shafts fo...................343 2. Assembly.............................................................................................................344 2.1 Mount lubricating oil pump in reverse sequence..................................................................344 2.2 Before mounting the gearwheel, check the contact reflection between gearwheel cone (Fig.1/6)...................344 2.3 Clean, free from grease and dry gearwheel cone and drive gearwheel shaft cone...................................344 2.4 Put gearwheel (Fig. 1/6) on drive gearwheel shaft cone, measure distance S (Fig. 1/X) and mak...................344 2.5 Heat gearwheel in oil bath to approx. 110 °C to 120 °C above the temperature of the drive gea...................344 2.6 Check the distance S, it must be smaller by 0.58 - 0.63 mm than in cold condition...............................344 2.7 Coat the thread and contact surface of the hexagon cap screw (Fig. 1/8) and disk (7) with Mol...................344 2.8 Clean the contact surfaces of the pump flange (Fig. 2/21) and the pump carrier plate (Fig. 1/...................344 2.9 Carefully insert the lubricating oil pump (3) with gearwheel (6) into the cylinder crankcase ...................344 2.10 Mount suction (4) and pressure lines (2) with new seals........................................................344 2.11 Fill in new lubricating oil (lubricating oil quality, see A4.05.08.nn) up to the respective ...................344 2.12 Fill up lubricating oil system and take lubricating oil prelubricating pump into service. Ve...................344 2.13 Check oil supply of the gearwheels.............................................................................344 1. Change the filter over (see the plate on the filter cover)...........................................................345 2. Cleaning.............................................................................................................345 2.1 Clean the filter when it is still warm from operation and.......................................................345 2.2 Cleaning the filter with built-in cartridges....................................................................346 2.2.1 Remove the cover (2) from the shut-off filter chamber. Remove contaminated liquid by openin...............346 2.2.2 Remove filter insert......................................................................................346 2.2.3 Connect cleaning pistol (Fig. 2/W1) to compressed-air supply and load. (6 - max. 10 bar)..................346 2.2.4 Shift the spouting guard (13) to the stop on the pistol nozzle, put it into the cartridge o...............346 2.2.5 Replace seals and mount cover.............................................................................346 2.2.6 Fill the filter chamber and vent it (see the plate on the filter cover)...................................346 2.3 Cleaning the filter with cartridges removed (every 3rd cleaning)................................................346 2.3.1 Open sludge drain and empty filter chamber................................................................346 2.3.2 Remove filter insert......................................................................................346 2.3.3 Flush the filter chamber with gas oil.....................................................................346 2.3.4 Put the filter insert in a container filled with a suitable cleansing liquid. The cleansing...............347 2.3.5 Take the filter insert out of the cleansing container and blow out cartridges (14) with the...............347 2.3.6 Submerge filter insert again in clean cleansing liquid, let it drip off and then blow it ou...............347 2.3.7 Intermittent check of cartridges for damage (operation sequence 2.4)......................................347 2.3.8 Place filter insert in filter chamber, mount cover, replace seals if necessary............................347 2.3.9 Fill filter chamber and vent (see plate on filter cover)..................................................347 2.4 Cleaning of cartridges in the case of persistent fouling........................................................347 2.4.1 Soak filter insert in cleansing liquid (max. 4 h).........................................................347 2.4.2 Loosen base plate and carefully remove protective jacket from filter insert...............................347 2.4.3 Remove cartridges (14) with the drift (Fig. 3/W2) downwards and tilt them out. Remove the O...............347 2.4.4 Inspect the cartridges and replace them if damaged or if the gauze is badly crinkled......................347 2.4.5 Connect cleaning pistol (Fig. 2/W1) to compressed-air supply. Air pressure max. 10 bar....................347 2.4.6 Introduce the cleaning pistol into the cartridge, pull the trigger and move down to the bot...............348 2.4.7 Remove sticking dirt with a soft brush....................................................................348 2.4.8 Rinse the cartridges in clean cleaning fluid, blow them out and let them dry with the openi...............348 2.4.9 Put a strong light behind the gauze and check the cleaning operation. Repeat it if necessary..............348 2.4.10 Install cartridges in reverse sequence as described under 2.4.3. O-ring between element pl...............348 3. Check the seal between the element plate and filter housing and replace if necessary.................................348 4. Mount filter insert in filter chamber................................................................................348 5. Fit cover (replace seal).............................................................................................348 6. Fill the filter chamber and vent it (see the plate on the filter cover)..............................................348 1. Disassembly......................................................................................................349 1.1 Loosen the cheese head screws (8) evenly to relieve the pressure spring (3).................................349 1.2 Remove and dismantle the control valve (1)..................................................................349 1.2.1 Loosen the hexagon nut (18) and completely unscrew the spindle (19) by turning it counter- ...........349 1.2.2 Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush...........349 1.2.3 Remove the locking ring (9) and take out the piston (11) with washer (15) and pressure spri...........349 1.2.4 Remove the screw plug (26) of the pilot control unit (A-A) with the sealing ring (25), wash...........349 1.3 Clean all parts with gas oil and check them.................................................................350 1.4 Check the free passage of the control oil bore (12) in the pressure control valve and in the ...............350 1.5 Check the valve seats, balls, piston seating as well as the slide faces and grind them if nec...............350 2. Reassembly.......................................................................................................351 2.1 Check the O-ring (7) and sealing ring (14) and replace them if necessary....................................351 2.2 Assembly is effected in the reverse sequence of disassembly. Pay attention to the free moveme...............351 2.3 Check the lubricating oil pressure at the pressure gauge on the control panel and adjust it i...............351 3. Adjustment.......................................................................................................351 3.1 Pressure to be set (see engine data A1.05)..................................................................351 3.2 Loosen the hexagon nut (18).................................................................................351 3.3 Secure the setting with the hexagon nut (18)................................................................351 1. Carry out steps 1.1 and 1.2 simultaneously for approx. 5 min.............................................352 1.1 Start the stand-by pump.............................................................................352 1.2 Turn the engine by means of the barring gear........................................................352 1. Disassembly..........................................................................................................353 1.1 Drain cooling water; loosen connecting pipeline from the reserve pump to the cooling water di...................353 1.2 Remove pipelines from the cooling water pump....................................................................353 1.3 Loosen hexagon cap screws (Fig. 1/2) and pull cooling water pump (1) with gearwheel (3) out o...................353 1.4 Remove O-ring (6)...............................................................................................353 1.5 Fix shaft (Fig. 2/23) in bore (u) with pin (10 mm)..............................................................353 1.6 Loosen hexagon cap screw (Fig. 1/4) and remove with disk (5)....................................................353 1.7 Pull off gearwheel (3) from shaft (Fig. 2/ 23) with extractor...................................................353 1.8 Check tooth profile for wear (pitting, slanting run, splintering)...............................................353 1.9 Loosen hexagon nuts (25), extract bearing housing (16) with seal plate (28) and running wheel...................354 1.10 Loosen nut on running wheel (30) and remove with running wheel disk (29). Pull running wheel...................354 1.11 Remove gasket set (10).........................................................................................354 1.12 Loosen hexagon nuts (14) and remove sealing plate (28) from bearing housing (16) and pull of...................354 1.13 Loosen screws (21), disassemble end cover (18) with thrust washer (19) and thrust collar(20)..................354 1.14 Force shaft (23) out of bearing housing (16) with suitable tool, remove oil seal (24)..........................354 2. Inspection...........................................................................................................354 2.1 Visual inspection of running wheel (11), replace if there are signs of severe cavitation........................354 2.2 Inspect front and rear bearing (17 and 22) as well as shaft for wear and corrosion, replace i...................354 2.3 Inspect all parts and the outlet openings (v, w), clean if necessary............................................354 3. Assembly.............................................................................................................355 3.1 Assembling is effected in the reverse sequence, taking notice of the following points:..........................355 3.2 Replace oil seal (24), gasket set (10) and O-ring (27). Mount centrifugal disk (15).............................355 3.3 Apply a ring of silicone sealing compound "Dirco-Grau" around the oil bore (y) of the bearing...................355 3.4 Insert screws (21) with screw lock "Loctite 270" and tighten....................................................355 3.5 Before mounting the running wheel (Fig. 2/11), inspect contact reflection between running whe...................355 3.6 Before mounting the gearwheel (Fig. 1/3), inspect contact reflection between gear wheel cone ...................355 3.7 Clean and dry running wheel, gearwheel and shaft cones after having removed grease..............................355 3.8 Mount running wheel (Fig. 2/11) and running wheel disk (29), coat thread of the running wheel...................355 3.9 Fix shaft with pin and tighten running wheel nut with a torque of...............................................355 3.10 Mount gearwheel (Fig. 1/3) on drive gearwheel shaft cone, measure distance (s) and note........................355 3.11 Heat up gearwheel to approx. 90 °C to 100 °C above the temperature of the shaft and mount fi...................355 3.12 Check distance measurement (s), it must be 0.43 - 0.48 mm smaller than in the condition........................355 3.13 Coat the thread and contact surface of the hexagon cap screw (4) and disk (5) with Molykote ...................355 3.14 Replace O-ring (6), carefully insert cooling water pump with gearwheel (3) into cylinder cra...................355 3.15 Mount pipelines and connecting lines of the reserve pump to the cooling water distribution l...................355 3.16 Check lubricating oil supply of gearwheels, also check for leakage.............................................355 1. Disassembly..........................................................................................................356 1.1 Remove air pipes from the swivelling screw fittings (Fig. 1/1) and muffs (5)....................................356 1.2 Loosen cover (4), remove and take out control disk (2) with shaft (3)...........................................356 1.3 Loosen fillister head screws (11) and pull off starting air distributor housing(10)............................356 1.4 Clean all parts, blow out with compressed air, inspect and replace defective parts..............................356 2. Assembly.............................................................................................................357 2.1 Reassembly is effected in reverse sequence......................................................................357 2.2 Threads and contact surfaces of the loosened hexagon cap screws (8) are to be coated with Mol...................357 2.3 Install starting air distributor with shaft (3) and carrier (7). The housing (10) must lie fl...................357 2.4 Threads and contact surfaces of the hexagon cap screws (11) are to be coated with Molykote an...................357 2.5 Check setting according to 3. and tighten cover (4).............................................................357 2.6 Fix compressed-air pipelines with new seals upon completion of assembly, start engine numerou...................357 3. Setting the starting air distributor.................................................................................357 3.1 Turn the piston of the 1st cylinder to ignition position........................................................357 3.2 Disk slot (Fig. 2/20) of the control disk(2) must cut the bore of the 1st cylinder (Fig. 2/c...................357 3.2.1 If necessary, loosen hexagon nut (14) (attention: lefthand thread), coat thread of the shaf...............357 3.2.2 Set control disk with disk slot according to 3.2 and tighten hexagon nut by hand..........................357 3.2.3 Clamp shaft in vice with soft blocks, fix control disk and tighten nut with torque........................357 3.3 Recheck the position of the disk and shaft and mount starting air distributor according to 2....................357 1. Activate the emergency stop facility (machine control room)..........................................................358 2. Check the position of the control rods...............................................................................358 3. Check the stop cylinder (3). To do so, press the control rod (2) into the injection pump by ap.......................358 4. Press the "Reset" button on the safety system........................................................................358 1. Connecting the adjusting device..................................................................................359 1.1 Turn cock (Fig. 1/1) of the pressure line to test position (downwards)......................................359 1.2 Remove plug (2) (G1/8") (depressurizing the line, soaking up fluid with a rag) and connect ad...............359 1.3 Pneumatic connection (Fig. 2)...............................................................................360 1.4 Electrical connection (Fig. 3)..............................................................................360 2. Inspection.......................................................................................................360 2.1 Vent pressure switch via adjusting device...................................................................360 2.2 Check the switch point with the precision pressure gauge of the adjusting device and test lamps.............360 2.3 Slowly vent the pressure switch, thereby observing the switch point on the precision pressure...............360 3. Correction of the adjustment.....................................................................................361 3.1 Remove lead seal............................................................................................361 3.2 Loosen housing cover (Fig. 4/20) of the pressure switch.....................................................361 3.3 Set switch point to required value according to measurement points list with a hexagon spanne...............361 4. Removal of the adjusting device..................................................................................361 4.1 Loosen the cable connections and pneumatic connection of the test device....................................361 4.2 Seal test connection with plug and turn cock (Fig. 1/1) to operating position...............................361 4.3 Screw on housing cover and seal with lead seal..............................................................361 1. Note the rpm switch point setting. Loosen the pointer locking plate (2) and set the pointer (1...................362 2. Turn the pointer carefully to the left towards 0 rpm. When reaching the engine speed, the outp...................362 3. Set the pointer again at the original rpm switch point and lock it...............................................362 4. The automatic cut-out F 1.1 and F 2.1 on the plug-in card A1 in the rpm switch installation mu...................362 5. Voltage check at the plug-in socket contacts of the plug-in frame................................................362 5.1 Supply (24 V DC at contact z16 and z20, contact z20 positive)...............................................362 5.2 PICK UP IMPULSE (dependent upon engine speed up to 1500 Hz at contact b14 and d14)..........................363 1. Disassembly..........................................................................................................364 1.1 Drain lubricating oil/cooling water lines.......................................................................364 1.2 Unscrew hexagon nuts (2) of housing cover (6)...................................................................364 1.3 Remove cover (6) with O-ring (1)................................................................................364 1.4 Turn out thermostatic element (5) fromvalve housing (7)........................................................364 1.5 Wash parts in gas oil and blow them clean.......................................................................364 1.6 Wipe clean thermostat housing with lint-free cloth and check for corrosion and deposits.........................364 2. Functional check of thermostatic element.............................................................................365 2.1 Put thermostatic element (Fig. 1/5) into a water bath of temperature of approx. 15 K aboveth...................365 2.2 The thermostatic element (5) must open steadiliy................................................................365 3. Assembly.............................................................................................................365 3.1 Repalce O-rings (1 and 9) and gasket (8)........................................................................365 3.2 Assembly is done in reverse order of disassembly................................................................365 3.3 Top up lubricating oil/cooling water system and check thermostat for leakages...................................365 Maintenance and trouble shooting: refer to manual C.....................................................................366 1. Dismantling......................................................................................................368 1.1 Dismantle fuel feed pump (07.13.01.nn)), lubricant pump(08.03.02.nn)and cooling water pump (0...............368 1.2 Dismantle lubricant piping and pump bearer plate (4), completely removing all silicon sealant...............368 1.3 Drain the oil: • Turn oil flow boring to lower position (30). • For full drainage turn the da...............368 1.4 Mark the position of the damper to the crankshaft...........................................................368 1.5 Remove the antifatigue screws and fastening screws (1) (12).................................................368 1.6 Dismantle the pump wheel carrier (15) and pump gear wheel (14)..............................................368 1.7 Remove fastening screws (13)................................................................................368 1.8 Remove the oscillation damper and forcing screw from the crankshaft and dismantle...........................368 1.9 Dismantle side plates (18); forcing may be carried out through tapping bore holes...........................368 1.10 Remove O rings (20 and 21).................................................................................368 1.11 Clean all parts thoroughly. Check oil flow bores and oil feed bores are clear..............................368 1.12 Measure gap (Fig. 2/"s" ) between spring ends and groove flanks of the interior using a feel...............369 1.13 Apply an adequate quantity of "Loctite 275" to both sides of the cup spring (Fig. 1/22). Tig...............369 2. Apply Molykote "Typ 60 G" across the inner side of the side plates (18)..........................................370 3. Insert new greased O rings (20 and 21)...........................................................................370 4. Set the side plates so that the oil flow bore holes are positioned between the oil feed bore h...................370 5. Assembly of oscillation damper:..................................................................................370 5.1 Bleed the air from the oscillation damper:..................................................................370 5.2 Further assembly procedure takes place in reverse order from dismantling procedure.. Apply Mo...............370 5.3 Apply "Dirco-Grau" silicon sealant to the pump bearer plate (4) , position over the tapered p...............370 5.4 Assemble fuel feed pump (07.13.01.nn), lubricant pump(08.03.02.nn), cooling water pump (09.07...............370 1. Operating the turning device.................................................................................371 1.1 Engaging the turning device.............................................................................371 1.1.1 Move blockinglever (1) to position “V“ and hold...................................................371 1.1.2 Move lever (2) to position“ X“, so that the gearwheel of the turning device engages complet.......371 1.1.3 Let off blockinglever and make sure that the blockinglever engages in position “Z“................371 1.1.4 Turn the engine...................................................................................371 1.2 Disengaging the turning device..........................................................................372 1.2.1 Move blockinglever (1) to position “V“ and hold...................................................372 1.2.2 Move lever (2) to position“ Y “, so that the gearwheel of the turning device is disengaged .......372 1.2.3 Let off blockinglever and make sure that the blockinglever is engaged in position “Z“.............372 2. Maintenance..................................................................................................373 2.1 Oil level check.........................................................................................373 2.1.1 Check oil level at the oil level glas (10) and fill in gear oil ( e.g. Shell Omala Oil 460 .......373 2.2 Lubricating / greasing of shaft and gearwheel...........................................................373 2.2.1 Grease the notch on the output shaft (9) and the gearwheel (3) with bearing grease by means.......373 2.2.2 Coat toothing of gearwheel thinly with bearing grease.............................................373 2.3 Oil change..............................................................................................373 2.3.1 Remove screw plug (5) on the driving gear of the turning device...................................373 2.3.2 Drain the oil from the driving gear of the turning device.........................................373 2.3.3 Mount the screw plug (5) with new gasket (6)......................................................373 2.3.4 Remove screw plug (7)ont the driving gear of the turning device...................................373 2.3.5 Fill in new oil (e.g. Shell Omala Oil 460 ; ca.7,5 l) up to the oil level mark (10)...............373 2.3.6 Mount the screw plug (7) with new gasket (8)......................................................373 Please select target document for B1.05.10.n.861n ??:.......................................................................709 • B1.05.10.9.8610 NN....................................................................................................709 • B1.05.10.9.8618 DD....................................................................................................709 Please select target document for B1.05.10.n.861n ??:.......................................................................710 • B1.05.10.9.8610 NN....................................................................................................710 • B1.05.10.9.8618 DD....................................................................................................710 Please select target document for B1.05.06.9.725n ??:.......................................................................711 • B1.05.06.9.7250 VV....................................................................................................711 • B1.05.06.9.7259 ZM....................................................................................................711 • B1.05.06.9.7259 ZS....................................................................................................711 Please select target document for B1.05.06.9.7259 ??:.......................................................................712 • B1.05.06.9.7259 ZM....................................................................................................712 • B1.05.06.9.7259 ZS....................................................................................................712 Please select target document for B1.05.06.9.7259 ??:.......................................................................713 • B1.05.06.9.7259 ZM....................................................................................................713 • B1.05.06.9.7259 ZS....................................................................................................713 Please select target document for B1.05.11.1.4877 ??:.......................................................................714 • B1.05.11.1.4877 GG....................................................................................................714 • B1.05.11.1.4877 MM....................................................................................................714
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