Mak M43C Engine Operating Instructions Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Mak M43C Engine Operating Instructions Manual – PDF DOWNLOAD
Engine No.: 68 045
Record No.: 281327
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 responsible service organization.
- The operating instructions do not release the personnel in charge of this engine plant from their duty to take care. The recognized rules of technology are to be observed, taking into account overriding regulations, observance of the general safety measures and locally applicable accident prevention regulations.
- Data or explanations assumed to be the basic knowledge of trained technical and engine room personnel, are not contained. Caterpillar / MaK is not responsible for damage caused by improper operation and maintenance.
TABLE OF CONTENTS:
Mak M43C Engine Operating Instructions Manual – PDF DOWNLOAD
Personnel entrusted with work on the engine/plant must have read the operating instructions and i........................... 6 Technical instructions and/or operations to be strictly observed are marked in the documents with........................... 6 Note refers to special information on appropriate use and work to be carried ou............................................. 6 California / USA............................................................................................................ 6 Proposition 65 Warning...................................................................................................... 6 Diesel engine exhaust and some of its constituents are known to the state of California to cause ........................... 6 Our engine is equipped with a monitoring system and an emergency stop system to prevent damage ca........................... 7 Within the scope of commissioning all mechanical, electric and pneumatic equipment and systems al........................... 7 Participants in this acceptance procedure are the authorized personnel of CATERPILLAR Motoren Kie........................... 7 This important system is subject to recurrent inspections and tests in order to ensure proper fun........................... 7 In the section "Scheduled Maintenance" you will find the respective test frequencies and related ........................... 7 1. Overspeed condition...................................................................................................... 8 2. Lubrication oil (pressure and temperature)............................................................................... 8 3. Engine room monitoring................................................................................................... 8 4. Cooling water - fresh water - HT (pressure and temperature).............................................................. 8 5. Exhaust gas.............................................................................................................. 8 6. Check pneumatic emergency stop system on engine after every emergency stop............................................... 8 7. Fault messages and measuring points...................................................................................... 8 1. Overspeed condition...................................................................................................... 9 1.1 How high was the maximum rpm before emergency stop was triggered?................................................... 9 1.2 Why did engine go into an overspeed condition?...................................................................... 9 • Check if emergency stop safety device is operational.................................................................. 9 • Check free operation of adjustment shaft and joint.................................................................... 9 • Check every single regulator rack of fuel pumps in both directions for proper operation by pull....................... 9 • Checking governor drive............................................................................................... 9 • Verification of possible out of calibration of actuator (if fitted)................................................... 9 1.3 Contact your Caterpillar/ MaK Service........................................................................... 9 2. Lube oil (lube oil pressure, lube oil temperature)....................................................................... 9 2.1 Emergency stop due to lack of lube oil.............................................................................. 9 • Visual inspection of engine........................................................................................... 9 • Lube oil pump drive: - Check gears for damage or loss................................................................. 9 • Check lube oil pressure switch........................................................................................ 9 • Check lube oil filter for metal chips................................................................................. 9 • Check oil sump and piping for leaks and cracks........................................................................ 9 2.2 Contact the Caterpillar/ MaK-Service............................................................................ 9 2.3 Emergency stop due to high lube oil temperature................................................................. 10 • Check temperature sensor.............................................................................................. 10 • Check oil cooler...................................................................................................... 10 • Check cooling water circuit........................................................................................... 10 • Pressurize each cylinder through opened indexing valves with shop air. If there is a rapid pres....................... 10 2.4 Contact the Caterpillar/ MaK Service............................................................................ 10 3. Engine room monitoring Emergency Stop due to excessive oil mist concentration (refer to A3.11............................ 10 • Check engine room monitoring device (operational test), refer to C5.05.11.02.03. nn................................... 10 • Visual inspection of engine and gear train,........................................................................... 10 • of cam shaft trough,.................................................................................................. 10 • of combustion chamber,................................................................................................ 10 • of turbo charger...................................................................................................... 10 3.1 Contact your Caterpillar/ MaK Service........................................................................... 10 4. Cooling water (fresh water - HT, pressure and temperature)............................................................... 10 • Visual inspection of engine........................................................................................... 10 • Check temperature sensors............................................................................................. 10 • Check fresh water cooler.............................................................................................. 11 • Operational test of LT - Cooling water circuit with cooling water pump................................................ 11 4.1 Contact your Caterpillar/ MaK Service........................................................................... 11 5. Exhaust gas Emergency stop due to excessively high exhaust temperature Checks:........................................... 11 • Check exhaust gas temperature sensors................................................................................. 11 • Aftercooler (differential pressure) (refer to A5.05.06.04.02.nn)...................................................... 11 • Fuel pumps and fill level scale on each fuel pump..................................................................... 11 • Injection valves (refer to A5.05.07.08.01.nn)......................................................................... 11 • Turbocharger.......................................................................................................... 11 5.1 Contact your Caterpillar/ MaK Service........................................................................... 11 6. Check pneumatic emergency stop system on engine after every emergency stop............................................... 11 • Check emergency stop pneumatic system on the engine for leaks......................................................... 11 • Stop valve to main start line upstream from start valve must constantly be open during operatio....................... 11 7. Fault messages and measuring points...................................................................................... 12 7.1 General fault messages:............................................................................................. 12 7.2 Plant-specific fault messages:...................................................................................... 12 7.3 Please contact the Caterpillar/ MaK Customer Service................................................................ 12 1. Storage tank......................................................................................................... 52 3. Separator HS1, HS2................................................................................................... 52 4. Day tank HT1......................................................................................................... 53 5. Fuel pressure pump HP1, HP2.......................................................................................... 53 6. Fuel pressure-regulating valve HR1................................................................................... 53 7. Self cleaning fuel filter HF4........................................................................................ 53 8. Mixing tank HT2...................................................................................................... 53 9. Circulating pump HP3, HP4............................................................................................ 54 10. Final preheater HH1................................................................................................. 54 11. Viscosity measurement and control equipment HR2 (Viscometer)........................................................ 54 12. Fine filter HF1..................................................................................................... 54 3.1. Prelubrication LP2 (standby or prelubrication pump)............................................................ 58 3.2. Check the operation of the engine-driven force pump LP1........................................................ 58 3.3. Lube oil automatic filter LF2.................................................................................. 58 3.3.1. Lube oil automatic filter LF2 (flushing with oil or compressed air)...................................... 58 If there are more than 100 flushing per day, the cause of the oil contamination must be detected:....................... 58 3.3.2. Lube oil automatic filter (with permanent oil flushing)...................................................... 59 3.4. Duplex lube oil filter LF1 (with indicator).................................................................... 59 3.5. Strainer filter LF4............................................................................................ 59 Initial operation........................................................................................................... 60 Operational supervision..................................................................................................... 69 1. Turbocharger: Compressor side........................................................................................ 79 1.1 Preface......................................................................................................... 79 1.2 Cleaning procedure.............................................................................................. 79 1.3 Compressor side - cleaning parameters for: ABB turbochargers TPL 76-C33......................................... 80 2. Turbocharger: Turbine side........................................................................................... 81 2.1 Preface................................................................................................................. 81 2.2 Turbine and Nozzle Ring Wet Cleaning Procedure There are two types of wet cleaning: - low loa........................... 82 3. Sequential or parallel cleaning?..................................................................................... 83 3.1 On “inline engines“, there is no difference..................................................................... 83 3.2 Compressor Cleaning (air-side) for “V-type engines“ :........................................................... 83 3.2.1 During compressor cleaning, a certain amount of water is sprayed - sequentially - into each............... 83 3.2.2 The volume of the washing water container is designed for cleaning one turbocharger; it nee............... 83 3.3 Turbine Cleaning (exhaust-side) for „V-type engines“ :.......................................................... 83 3.3.1 During turbine cleaning, the washing water is sprayed into both turbochargers simultaneousl............... 83 3.3.2 The turbine housings are equipped with a device for turbine cleaning. The turbine cleaning ............... 83 4. Specifications and Cleaning Parameters:.............................................................................. 83 4.1 Quality requirements for water for washing turbine and nozzle ring:............................................. 83 4.1.1 Clear freshwater (drinking water) without cleaners or solvents is to be used. The wash wate............... 83 4.2 Water and Air Feed Requirementsfor washing the turbine and nozzle ring:......................................... 83 4.2.1 Before washing the turbine, ensure that there is a constant water pressure of: - p = 2.0 ba............... 83 4.2.2 The water throughput (volume flow) for cleaning turbines is controlled by a diaphragm locat............... 83 4.3 Turbine-side Cleaning Parameters for : ABB turbochargers TPL 76-C33............................................. 84 4.4 Washing device during operation:........................................................................................ 84 4.4.1 All valves are closed, or in their basic position (see A5.05.06.13.01.nn)......................................... 84 4.4.2 During operation, pressurized air is constantly flowing through the lines in order to preve....................... 84 4.5 Notes on the cleaning procedure:.................................................................................... 84 Removal from operation...................................................................................................... 91 Danger of frost............................................................................................................. 96 The following measures are to be implemented after a light or heavy preservation........................................ 106 Running-in.................................................................................................................. 108 Fault tracing............................................................................................................... 110 Emergency operation......................................................................................................... 119 - disassemble the rotor................................................................................................. 121 - obturate the exhaust gas side against bearing housing and air side by means of a blind flange......................... 121 The cooling water supply is to be interrupted only in case there is a considerable leakage at the....................... 121 If there are two turbochargers feeding into one charge air manifold:.................................................... 121 1. Misfire.......................................................................................................... 128 2. Total misfire.................................................................................................... 129 2.1 Twin engine systems / generator systems..................................................................... 129 Safety instructions......................................................................................... 133 During all work or contact with:............................................................................ 133 Regulations and recommendations............................................................................................. 134 1. Engine Lubricating Oil............................................................................................... 145 1.1 Base Oil........................................................................................................ 145 1.2 Additives....................................................................................................... 145 1.2.1 Good detergent and dispersant properties (which for heavy fuel operation equals at least th............... 145 1.2.2 Have an adequate alkalinity in order to be able to neutralize the sulfur acid compositions ............... 145 1.3 Care of lubricating oil......................................................................................... 146 1.3.1 Lubricating oil filtering (By-pass)....................................................................... 146 1.3.2 Lubricating oil filtering (full flow)..................................................................... 146 1.4 Lubricating oil brand recommendations – Limitation of warranty.................................................. 146 1.4.1 List of brands of lubricating oil for Operation with distillate fuel...................................... 147 1.4.2 List of brands of lubricating oil for heavy oil operation................................................. 148 1.5 Lubricating oil changing........................................................................................ 149 1.6 Limits:......................................................................................................... 150 1.6.1 Lubricating oil dilution by fuel.......................................................................... 150 1.6.2 Alkalinity (TBN).......................................................................................... 150 1.6.3 Water content............................................................................................. 150 1.6.4 Contamination............................................................................................. 150 1.7 Lubricating oil for exhaust turbocharger, hydraulic governor and change-over controls........................... 151 1.8 Multi-purpose grease – lithium saponified – consistency number 2 (also suitable for pneumatic................... 152 • Suitable fresh water.................................................................................................. 153 • effective corrosion inhibiting agent.................................................................................. 153 - corrosion inhibiting oil, soluble..................................................................................... 153 - chemical corrosion inhibiting agent (chemicals)....................................................................... 153 • exact dosing of the corrosion inhibiting agent........................................................................ 153 1. Treatment of cooling water with corrosion inhibitors............................................................. 155 01...................................................................................................................... 170 1. Set valve fitting................................................................................................ 186 1.1 Open indicator valves....................................................................................... 186 1.2 Engage the rotor............................................................................................ 186 1.3 Remove the cylinder head (valve) cover, do not damage the gaskets........................................... 186 1.4 Turn the crankshaft until the cylinder to be set reaches ignition TDC....................................... 186 1.5 Release valve bridge of rocker arm (Fig. 1/1). Enlarge clearance „S“ and/or flap back rocker ........................... 187 1.6 Release locknut (Fig. 2/3) and unsrew setting bolt (4) until a contact in „X” without clearan........................... 187 1.7 At this position of the valve bridge screw in setting bolt (4) until contact at „Y” without a........................... 187 1.8 Hold tight setting bolt (4) and tighten locknut (3) with M = 250 Nm................................... 187 1.9 Check absence of clearance at „X“ and „Y“ with feeler gauge of 0.02 mm (W2). Afterwards adjus........................... 187 2. Set valve clearance.................................................................................................. 187 2.1 Measure the clearance (Fig. 1/S) with the feeler gauge. Depress the push rod while measuring ........................... 187 2.2 Correct the clearance “S“............................................................................................... 187 2.2.1 Loosen counternut (5)............................................................................................. 187 2.2.2 Turn the valve adjusting screw (2) until the valve reaches the indicated clearance................................ 187 2.2.3 Retighten the counternut (5) M = 400 Nm to lock the adjusting screw i....................... 187 2.2.4 Check the clearance again after tightening the counternut......................................................... 187 2.2.5 Remove the turning mechanism and close the indicator valves....................................................... 187 2.2.6 Install valve cover............................................................................................... 187 1. Disassembly.......................................................................................................... 188 1.1 Engage the rotor................................................................................................ 188 1.2 Open indicator valves........................................................................................... 188 1.3 Remove valve cover.............................................................................................. 188 1.4 Turn piston to ignition TDC. Intake and exhaust valves are closed, rocker arms subject to no ................... 188 1.5 Remove the four rocker arm nuts with the hydraulic clamping unit................................................ 189 1.5.1 Place the hydraulic clamping elements (W1.1) on the round nuts (1), unscrew threaded bush u............... 189 1.5.2 Connect the clamping elements with the high pressure pump (6) by means of the high pressure............... 189 1.5.3 Close the valve on the high pressure pump and extend both rocker arm bracket bolts evenly a............... 189 1.5.4 Loosen the round nuts with a pin. Turn the round nut back four holes...................................... 189 1.5.5 Depressurize the clamping elements, dismantle the clamping device and remove the round nuts............... 189 Note:....................................................................................................................... 190 1.5.6 Repeat dismantling procedure 1.5.1 to 1.5.5 for the upper round nuts (2).......................................... 190 1.6 Remove rocker arm bracket with intake and exhaust rocker arms....................................................... 190 2. Assembly............................................................................................................. 190 2.1 Clean the contact surface for the rocker arm bracket............................................................ 190 2.2 Blow out the oil outlet with compressed air..................................................................... 190 2.3 Place the rocker arm bracket on the cylinder over the studs and position. The bracket is fast................... 190 2.4 Apply Molykote paste “G-Rapid Plus“ to the threads and contact surface for the nuts and tight................... 190 2.5 Tighten the four rocker arm bracket bolts with the hydraulic clamping unit...................................... 190 2.5.1 Place the hydraulic clamping elements (W1.1) on the round nuts (2) and tighten. Ensure that............... 190 2.5.2 Connect the clamping elements with the high pressure pump by means of the high pressure lin............... 190 2.5.3 Close the valve on the high pressure pump and extend both rocker arm bracket bolts evenly a............... 190 2.5.4 Tighten the round nut firmly with a pin. Check to ensure good action (no stiffness)....................... 190 2.5.5 Check to ensure that the round nut is seated properly. • Reduce pressure by 50 bar. • The r............... 191 2.5.6 Depressurize the clamping elements, dismantle the clamping unit........................................... 191 2.5.7 Repeat installation procedure 2.5.1 to 2.5.6 for lower round nuts (1)..................................... 191 2.6 Set valve clearance (01.01.01.nn)............................................................................... 191 2.7 Diengage the rotor.............................................................................................. 191 2.8 Install valve cover. (Check gasket!)............................................................................ 191 2.9 Close indicator valves.......................................................................................... 191 1. Disassembly.......................................................................................................... 192 1.1 Remove securing rings (Fig. 1/4) and thrust washers (5) from the rocker arm shaft (3)........................... 192 1.2 Remove the intake valve rocker arm (1) and the exhaust valve rocker arm (2) from the rocker a................... 192 2. Clean all parts and check for damage. Blow out oil bores with compressed air and check to ensu....................... 192 3. Check the bearing surfaces of the ball pin (Fig. 2/10) and the adjusting screw (12) for wear a....................... 193 4. Measure the rocker arm bush (Fig.2/ 13) and shaft (Fig. 1/3) and replace the bush when the c....................... 193 5. Assembly............................................................................................................. 193 5.1 Oil the contact surfaces of the intake (Fig. 1/1) and exhaust rocker arms (2) and the rocker ................... 193 5.2 Reinstall the rocker arm bracket and rocker arms on the cylinder cover (01.02.01.nn) and chec................... 193 1. Measure the rocker arm bush (1) and (01.02.02.nn).................................................................... 194 2. Replace.............................................................................................................. 194 2.1 Drive out the bush (1) with the proper copper punch (W1)........................................................ 194 2.2 Oil the new bush lightly and press into rocker arm.............................................................. 194 1. Open the valve cover and note the turning of the valves. The mark “X” on the valve spring plat....................... 195 2. The valve rotor or free-wheel is functioning correctly when the valves rotate evenly in relati....................... 196 2.1 If the valve rotational speed slows to n Å 1 min-1 at the rated engine speed, the valve rotor................... 196 1. Replace the oil scraper rings (O-rings).............................................................................. 197 1.1 Disassemble valve cone, clean valve shaft carefully............................................................. 197 1.2 Remove O-ring (1) from groove with wire hook carefully.......................................................... 197 1.3 Clean the groove................................................................................................ 198 1.4 Oil the new O-ring lightly and place in groove carefully. The ring may not be twisted during ................... 198 2. Measuring the valve guide clearance.................................................................................. 198 2.1 Measure the outer diameter of the valve shaft in the guide area of the bush..................................... 198 2.2 Measure the inner diameter of the guide across the engine block................................................. 198 2.3................................................................................................................. 198 3. Valve guide replacement.............................................................................................. 198 1. Disassembly...................................................................................................... 199 1.1 Loosen the cheese head screws (fig. 2/18) and the connecting flanges (fig. 1/1, 2) together w............... 199 1.2 Pull the sleeves (fig. 2/9) out of the connecting flanges (1, 2)............................................ 200 1.3 Check the O-rings (14). Replace faulty O-rings (14). Insert the O-rings in the grooves using ............... 200 1.4 Remove hexagon screws (Fig. 1/21) and end flange (7)........................................................ 200 1.5 Check gaskets (Fig. 2/13) of the connecting flanges (1, 2) as well as gaskets (13) of the end............... 200 1.6 Remove the cheese head screws (Fig. 3/22) with connecting flange (8)........................................ 201 1.7 Pull the sleeves (10) out of the media block (6)............................................................ 201 1.8 Check the O-rings (15). Replace faulty O-rings (15)......................................................... 201 1.9 Remove lubricating oil pipe (4)............................................................................. 201 1.10 Remove hexagon screws (20, 23) with media block (6)........................................................ 201 1.11 Clean all sealing faces.................................................................................... 201 2. Reassembly....................................................................................................... 202 2.1 Mount the connecting flanges (fig. 2/1 and 2) with inserted sleeves (9). Replace faulty gaske............... 202 2.2 Mount the media block (fig. 3/6). Insert sleeves (10) with new O-rings (15)................................. 202 2.3 Mount lubricating oil pipe (4).............................................................................. 202 2.4 Put the connecting flange (8) onto the sleeves (10) and mount it. Replace faulty gasket (13) ............... 202 2.5 Mount the blank flange (fig. 2/7). Replace faulty gaskets (13) beforehand................................... 202 3. Check operation of the alarm probe for leakage fuel (fig. 3/20).................................................. 202 3.1 Dismantle the alarm probe, refit the connector and submerge the tip of the alarm probe in a m............... 202 3.2 Mount the alarm probe....................................................................................... 202 4. Determine the defective fuel delivery pipe in the event of a "leakage fuel" alarm................................ 202 4.1 Acknowledge the alarm when a "leakage fuel" alarm is given and, beginning with cylinder1, re............... 202 4.2 Check the bore in the connecting flange (1) for leakage fuel. If, for example, leakage fuel i............... 202 4.3 Mount the screw (25) with a new gasket (24)................................................................. 202 1. Open indicator valves, turn piston to ignition-TDC, remove cylinder head cover and pump chambe....................... 203 2. Drain cooling water: Disconnect connection pipe from reserve pump to cooling water manifold pi....................... 203 3. Disconnect and remove connecting flange of the media conduit for the cylinder head to be remov....................... 204 4. Remove rocker arm bracket (01.02.01.nn).............................................................................. 204 5. Remove injection pressure pipe (07.05.01.nn)......................................................................... 204 6. Remove injection valve (07.07.01.nn)................................................................................. 204 7. Remove covering cap between exhaust pipe and cylinder head........................................................... 204 8. Screw hexagon screws (Fig. 2/W5) into cooling water blocks to support the exhaust pipe............................... 204 9. Loosen clamp on exhaust pipe (06.01.01.nn)........................................................................... 204 10. Loosen the six cylinder head screws using the hydraulic torque device............................................... 205 10.1 Store hydraulic traction elements (Fig. 3/ W1.1) onto round nuts and tighten. Ensure good ac................... 205 10.2 Store hydraulic traction elements via high pressure hoses (W1.2) to each other. Connect elem................... 205 10.3 Close valve on high pressure pump and extend all 6 cylinder head screws simultaneously and c................... 205 10.4 Loosen round nuts with pin. Turn round nuts back by at least 8 holes........................................... 205 10.5 Relieve traction elements, remove hydraulic device and unscrew round nuts...................................... 205 11. Screw ring screws (Fig. 4/W3) into cylinder head. Fit cylinder head lifting device (W2). Lift....................... 206 12. Lower cylinder head onto wooden surface (two beams, as nozzle protrudes)............................................ 206 1. Remove nozzle sleeve (1)............................................................................................. 207 1.1 Place wrench (W1) so that nozzle sleeve (1) and wrench (W1) are engaged......................................... 207 1.2 Mount the flange (3) (07.07.01.nn).............................................................................. 207 1.3 Attach torque wrench (W2) to wrench (W1) and unscrew nozzle sleeve until the threads of nozzl................... 207 1.4 Remove flange (3)............................................................................................... 208 1.5 Use a brass mandrel (W3) and carefully drive out the nozzle sleeve.............................................. 208 1.6 Remove the O-rings (4 and 5).................................................................................... 208 2. Install nozzle sleeve (1)............................................................................................ 208 2.1 Insert new O-ring (71 x 3,55) with Vaseline in the lower groove (5) without twisting............................ 208 2.2 Insert new O-ring (72,69 x 2,62) with Vaseline in the upper groove (4) without twisting......................... 208 2.3 Coat “Loctite 510“ to the nozzle sleeve threads................................................................. 208 2.4 Slide the nozzle sleeve into the cylinder head.................................................................. 208 2.5 Place the torque wrench on the nozzle sleeve wrench and tighten the nozzle sleeve to ................... 208 1. Unscrew hexagon nut (1).............................................................................................. 209 2. Remove cover (2)..................................................................................................... 209 3. Slacken relief valve (3) by means of a wrench and remove it.......................................................... 210 4. Lubricate the thread of the new relief valve with high-temperature thread paste “Dag 5420 A“ ........................ 210 5. Mount new relief valve (3) with new joint ring (4)................................................................... 210 6. Firmly tighten the relief valve by means of a wrench................................................................. 210 7. Mount cover (2)...................................................................................................... 210 8. Tighten hexagon nut (1) with a torque of M = 50 Nm...................... 210 1. Disassembly...................................................................................................... 212 1.1 Disassemble the cylinder head (01.06.01.nn)................................................................. 212 1.2 Disassemble the rocker arms (01.02.01.nn) and take off valve bridge......................................... 212 1.3 Put the valve spring compressor unit (W1) onto valve spring retainer (2). To this end:...................... 212 1.3.1 Pull pin (10) out of spindle (11)..................................................................... 212 1.3.2 Sleeve (12) must rest above the split spindle end..................................................... 212 1.3.3 Put the split spindle end onto valve cone stem so as to engage........................................ 212 1.3.4 Press sleeve (12) above split spindle end and mount pin (10).......................................... 212 1.4 Remove circlip (5) by means of pliers (W2). Compress valve spring (3) by turning the stem of ............... 212 1.5 Relieve valve spring (3) by turning the stem of device (13) in the other direction.......................... 212 1.6 Remove the valve spring compressor unit (W1). To this end:.................................................. 212 1.6.1 Pull pin (10) out of spindle (11)..................................................................... 212 1.6.2 Sleeve (12) must rest above the split spindle end..................................................... 212 1.6.3 Pull the valve spring compressor unit off the valve cone stem......................................... 212 1.7 Take valve spring retainer (2), valve spring (3) and valve rotator, freewheel or valve spring............... 212 1.8 Pull the valve cone out of the cylinder head................................................................ 213 2. Assembly......................................................................................................... 213 2.1 Check valve guide clearance, replace O-ring (01.05.01.nn)................................................... 213 2.2 Oil the de-burred valve cone well before installation and insert valve cone with a twisting m............... 213 2.3 Installation is completed in the reverse order as disassembly............................................... 213 2.4 After inserting clamping cone halves (4) and assembling circlip (5) by means of pliers (W2) s............... 213 1. Cleaning............................................................................................................. 214 1. Clean the valve stem. Experience has shown that a thorough cleaning, such as an assessment of ....................... 214 2. Inspection........................................................................................................... 214 2.1 Valves can be reused without being reworked when................................................................ 214 2.2 Valves may not be re-used for another interval when............................................................. 216 3. Repair (reworking the sealing surface)............................................................................... 217 3.1 Regrind the sealing surface in accordance with the indicated angle (Fig.3). Do not rework t................... 217 3.2 Observe the instructions of the respective grinding machine manufacturer........................................ 217 3.3 After grinding, measure the distance between the visible edge of the plating “X“ and outer ................... 217 3.4 Outer edge rounded with stone................................................................................... 217 4. Maintenance (Check wear pattern/grinding)............................................................................ 217 4.1 Apply small dots of diamond paste Dp 30/10 - 15 µm to the seating new or reworked valve cone ................... 217 4.2 Slide the oiled valve stem into the guide. Attach the rig (Fig. 5/W1) to the valve head and ................... 218 4.3 If the contact surface does not appear to be in good order, do not regrind any more, but rewo................... 218 4.4 Components which have been ground together (valve cone and seat ring) must be kept together..................... 218 5. Final inspection..................................................................................................... 218 5.1 Check that the reworking limit has not been exceeded............................................................ 218 5.2 Clean the valve cone / seat thoroughly and check the sealing surfaces with an illuminated mag................... 218 1. Inspection........................................................................................................... 220 1.1 Valve rings can be reused without reworking when................................................................ 221 1.2 Valve seat rings may not be reused when......................................................................... 221 2. Cleaning............................................................................................................. 221 3. Repair (reworking the valve seat rings).............................................................................. 221 3.1 Mill valve seat................................................................................................. 221 3.1.1 Clean the valve seat ring carefully in the contact area (3) of the centering disk (4) in or............... 221 3.1.2 Insert the centering disk (4) with the guide punch (5) and tighten with a star handle (6)................. 222 3.1.3 Place the cutting head (2) on the greased guide punch, turn the knurled screw (1) in until ............... 222 3.1.4 Mill the valve seat in a single motion by turning to the right, turn the rig as far as poss............... 222 3.1.5 Before ending the milling procedure, back out the knurled screw (1) slowly while turning th............... 222 3.1.6 Maximum permissible dimension Ø (x) for reworking (Fig. 7):............................................... 222 3.1.7 Remove milling unit. Smooth the sharp edges with a fine emery cloth....................................... 223 4. Contact surface check / grinding..................................................................................... 223 4.1 Apply small dots of diamond paste DP 30/10 - 15 µm to the new or reworked vale shaft with a s................... 223 4.2 Slide the oiled valve shaft into the guide bush. Attach the rig (W1) (01.08.01.nn) to the val................... 223 4.3 If the contact surface does not appear to be in good order, do not grind any more, both seali................... 223 4.4 Components (valve cone and seat ring) which have been ground together must be kept together.................... 223 5. Final inspection..................................................................................................... 223 5.1 Check that the indicated reworking limit has not been exceeded.................................................. 223 5.2 Clean the valve cone / seat thoroughly and check the sealing surfaces with an illuminated mag................... 223 1. Separate valve cones which can no longer be used at the shaft end (Fig.1/1) and bezel the res................... 224 2. Place the valve cone in the valve seat ring and hold in the indicated position, connect the c................... 224 3. Drive the valve seat ring out onto the valve shaft by striking firmly, clean the bore by hand ................... 224 4. Install new seat ring............................................................................................ 225 4.1 Cool seat ring to at least -20 °C, heat cylinder head to 130 °C............................................. 225 4.2 Tap the seat ring completely into the bore with the help of a hammer and valve cone (strike l............... 225 5. Rework valve seat ring lightly with a valve seat grinding machine or valve seat milling unit. ................... 225 6. Install valve cone............................................................................................... 225 1. Remove the rocker arm bracket (01.02.01.nn).......................................................................... 226 2. Remove the cover (1) and O-ring (2) with the help of an M8 bolt...................................................... 226 3. Push down piston (5) and spindle (9) approx. 7 mm using the handle of the hammer. The piston a....................... 226 4. Ensure that the piston (5) and spindle (9) return to the original position quickly and easily........................ 227 5. If the parts do not move freely, lubricate the piston (5) and guide in the cylinder head with ....................... 227 6. Fit cover (1) with new O-ring (3).................................................................................... 227 1. Disassembly...................................................................................................... 228 1.1 Remove the rocker arm bracket (01.02.01.nn)................................................................. 228 1.2 Lay the cylinder head on its side........................................................................... 228 1.3 Remove the cover (1) and O-ring (2) with the help of an M8 bolt............................................. 228 1.4 Remove circlip (12)......................................................................................... 228 1.5 Loosen the hexagon nut (3) while holding the valve shaft (9) with a wrench.................................. 228 1.6 Remove the clamping ring (4), piston (5), spring (6), spring plate (8) and valve shaft(9) wi............... 228 1.7 Clean all parts carefully with gas oil...................................................................... 228 1.8 Check the piston (5), compression ring (10) and valve seat carefully. Smooth scored piston (5............... 228 1.9 Rework starting valve seat with reseating tool (W2)......................................................... 229 1.9.1 Carefully clean valve seat and guide of valve spindle................................................. 229 1.9.2 Loosen adjusting screw (20) on reseating tool (W2). Lightly oil valve canon. Insert reseati........... 229 1.9.3 Tighten adjusting screw (20) until a slight resistance is felt. Then tighten adjusting scre........... 229 1.9.4 Turn reseating tool evenly and slowly without additional pressure. Repeat process until val........... 229 1.9.5 Turn reseating tool evenly and slowly without additional pressure. Repeat process until val........... 229 1.10 If the appearance of the bearing surface is not satisfactory, repeat steps 1.9.1 to1.9.5.................. 229 2. Assembly......................................................................................................... 230 2.1 Apply thin coat of Molykote paste “G-Rapid” to piston (5), distribute ring joints evenly arou............... 230 2.2 Installation is completed in the reverse order as disassembly. Replace O-ring (2). Make sure ............... 230 2.3 Mount circlip (12).......................................................................................... 230 2.4 Check the starter valve for leaks before starting the engine................................................ 230 1. Check gasket between cylinder head, cylinder liner and coolant distributor housing for combust............... 231 2. Check the outside of the cylinder head for leaks......................................................................... 232 2.1 If oil leaks are found, check the valve cover bolts to ensure that they are tight and check ....................... 232 2.2 If leaks are found at the media supply connecting flanges, check all bolts to ensure that the....................... 232 3. Remove valve cover. Inspect the top of the cylinder head................................................................. 232 3.1 Check to ensure that the valves move identically. Irregularities can be seen most easily at l....................... 232 3.2 Check the function of the valve rotor or free-wheel (01.03.01.nn)................................................... 232 3.3 Check valve springs for damage...................................................................................... 232 3.4 Check the oil supply to the valve rockers and rocker arm bearings................................................... 232 1. Clean cylinder block with cold cleaning solution..................................................................... 233 2. Clean intake and outlet ports, underside of cylinder head (not the valve seats!) with a wire b....................... 233 3. Clean coolant intake and outlet ports................................................................................ 233 4. Inspect the underside of the cylinder head carefully for cracks at the valve fittings................................ 233 5. Clean the sealing surface for the injector valve..................................................................... 233 6. Check the intake and outlet bores for media supply for blockage...................................................... 233 7. Check function of leakage sensor for fuel leaks at the connection piece for media supply on th....................... 233 1. Turn pistons to ignition TDC......................................................................................... 235 2. Thoroughly clean sealing and bearing surfaces of cylinder head and cylinder bushing and check ....................... 235 3. Replace the following O rings: Top O ring at cylinder bushing collar (2), at cylinder head(3)....................... 235 4. Carefully place cylinder head with cylinder head lifting device and hoist onto cooling water m....................... 236 5. Align cylinder head. Fit clamp for exhaust pipe and hook in chain links(06.01.01.nn). Grease ....................... 236 6. Tighten the six cylinder head screws simultaneously using the hydraulic tightening device............................ 236 6.1 Store hydraulic traction elements (Fig. 2/ W1.1) onto round nuts and tighten. Ensure good acc................... 237 6.2 Store hydraulic traction elements via high pressure hoses (W1.2) to each other. Connect eleme................... 237 6.3 Close valve on high pressure pump and extend all 6 cylinder head screws simultaneously and co................... 237 6.4 Tighten round nuts with pin firmly. Ensure smooth movement...................................................... 237 6.5 Check the firm contact of the round nut......................................................................... 237 6.6 Relieve hydraulic traction element (W1.1) and remove............................................................ 237 7. Tighten clamp for exhaust pipe. The clamp is held in position by a locking screw from below(0....................... 237 8. Remove hexagon screws (W5) (01.06.01.nn)............................................................................. 237 9. Fit removed connecting flanges of the media conduit with new seals. Ensure proper fitting of d....................... 237 10. Fit removed manometer pipes and fill with cooling water. Vent cooling water return line from ....................... 237 11. Insert push rods into cylinder head................................................................................. 237 12. Fit rocker arm bracket (01.02.01.nn)................................................................................ 237 13. Fit injection pressure pipe (07.05.01.nn)........................................................................... 237 14. Adjust valve clearance (01.01.01.nn) and fit pump chamber cover..................................................... 237 15. Check all connections for tightness after starting the motor........................................................ 237 1. Open indicator valve and engage turning gear..................................................................... 238 2. Open crank case cover approx. 10 min. after shutting down the engine............................................. 238 3. Check crankshaft bearings and big end bearings for even and normal temperatures.................................. 238 4. Visually check screws and nuts................................................................................... 238 5. Check extent of soiling of the engine room (silt deposits, corrosion, bearing metal particles,................... 238 6. Check cylinder liner surface on engine side. Carry out lubrication oil flow check and check oi................... 238 7. Remove camshaft cover. Check screws of camshaft components and the lower valve mechanism for p................... 238 7.1 Turn engine and check bearing surfaces of cams and rollers for scoring, pitting or other damage............. 238 7.2 Check lubricating oil flow for camshaft bearing and valve mechanism......................................... 238 8. Check wheel mechanism (04.08.01.nn).............................................................................. 238 9. Check oil tray and crank case for left-behind tools, cloths etc. Check seals of all crank case................... 238 1. Turn the crankshaft journal to the exhaust side so that the dial gauge is spread apart as far ............... 240 2. Set the scale value 20 on the dial gauge: 1st measurement point (initial position)........................... 240 3. Turn the crankshaft so that the journal turns in the direction of the exhaust side and the dia............... 240 4. Watch the dial gauge and read the values for measurement points 2 - 5. If a value is read befo............... 240 1. Remove piston (02.06.01.nn).......................................................................................... 250 2. Turn the engine so that the connecting rod is horizontal. Both round nuts (2) must be accessible..................... 250 3. Loosen the round nuts (2) with the hydraulic rig..................................................................... 250 3.1 Place and tighten the hydraulic clamping elements (W4) over the round nuts (2). Ensure that t................... 250 3.2 Connect the hydraulic clamping elements (W4) to the high pressure pump (W1) by means of the h................... 250 4. Close the valve (6) on the high pressure pump (W1) and apply force to both connecting rod bolt....................... 250 5. Loosen the round nuts (2) with a pin (W5). Turn the round nuts back 10 holes......................................... 250 6. Open valve of the high-pressure pump (W1), hydraulic jacks are relieved of tension................................... 251 7. Wait until no pressure is left, dismount hydraulic devices (W4)...................................................... 251 8. Turn connecting rod (17) horizontally with the connecting rod shank division to the exhaust side..................... 251 9. Fit mounting and dismounting device (W6) for big end bearing......................................................... 251 9.1 Mount guide rail holder (10) on both sides of the cylinder crankcase............................................ 251 9.2 Suspend guide rail (11)......................................................................................... 251 9.3 Tighten hexagon nuts (12)....................................................................................... 252 9.4 Mount guide rail extension (13) with carriage (14) on camshaft side............................................. 252 10. Screw suspension (18) at big end bearing cap........................................................................ 253 11. Connect suspension (18) with carriage (14).......................................................................... 253 12. Unscrew round nuts (2).............................................................................................. 253 13. Drive big end bearing cap (15) to the camshaft side out of the crankcase. Remove bearing shel....................... 253 14. Fix big end bearing cap (15) at the crane and deposit on suitable support........................................... 253 15. Disassemble big-end bolts (3) and washers (4). Secure connecting rod (17) additionally with s....................... 253 16. Turn connecting rod (17) downward by 180° so that the connecting rod shank division shows to ....................... 254 17. Mount suspension (16) for connecting rod (17) and connect with carriage............................................. 254 18. Dismount connecting rod holder at the counterweight (02.06.01.nn)................................................... 254 19. Drive connecting rod (17) to the camshaft side out of the crankcase. Remove bearing shell(20)...................... 254 20. Sling suspension (16) with suspended connecting rod (17) at the crane. Dismount connection to....................... 254 21. Deposit connecting rod (17) on suitable support..................................................................... 254 22. Evaluate the condition of the big end bearing shells (02.03.03.nn and 02.03.07.nn).................................. 254 1. Bearing shell installation........................................................................................... 255 1.1 Clean and oil crank journals.................................................................................... 255 1.2 Oil the inside and outside of the bearing shells................................................................ 255 1.3 Mount suspension (16) at dismounted connecting rod.............................................................. 256 1.4 Fasten suspension (16) with suspended connecting rod (17) at the crane and lift. Mount connec................... 256 1.5 Remove sling.................................................................................................... 256 1.6 Push connecting rod (17) towards the crank pin up to approx. 20 mm.............................................. 256 1.7 Put upper bearing shell (without holes) on the crank pin and turn below the connecting rod by................... 256 1.8 Press connecting rod (17) carefully against bearing shell (20). The fixing lug of the bearing................... 256 1.9 Mount connecting rod holder at counterweight n (02.06.01.nn). Secure connecting additionally ................... 257 1.10 Dismount suspension (16)....................................................................................... 257 1.11 Turn connecting rod (17) downward by 180° so that the connecting rod shank division shows to................... 257 1.12 Mount suspension (18) at big end bearing cap (15).............................................................. 257 1.13 Fasten big end bearing cap (15) at crane and connect suspension (18) with carriage (14) at g................... 258 1.14 Remove sling................................................................................................... 258 1.15 Push big end bearing cap (15) towards the crank pin up to approx. 160 mm....................................... 258 1.16 Push big end bearing cap (15) forward towards the crank pin up to approx. 100 mm and insert,................... 259 1.17 Push big end bearing cap (15) carefully against bearing shell (19) and bottom end of connect................... 259 1.18 Insert big-end bolts (3) with washer (4). Assemble washer (4) with chamfer pointing towards ................... 260 1.19 Install round nuts (5) and tighten by hand..................................................................... 260 1.20 Remove installation / disassembly unit (W6).................................................................... 260 1.21 Check bearing shell pairs for axial misalignment on the exhaust side. Align shells if necess................... 260 2. Tighten the round nuts (5) with the hydraulicrig.................................................................... 261 2.1 Turn the connecting rod with the connecting rod shank joint by about 15-30 downwards, see in................... 261 2.2 Place the hydraulic clamping element (W4) over the round nut (5) at camshaft side and screw o................... 261 2.3 Connect the hydraulic clamping element (W4) to the high-pressure pump (W1) by means of the hi................... 261 2.4 Close the valve of the high- pressurepump (W1) and extend the big-end bearing bolt at camsha................... 261 2.5 Firmly tighten the round nut (5) at camshaft side with a pin (W5)............................................... 261 2.6 Open the valve of the high-pressure pump (W1), the clamping element is depressurized............................ 261 2.7 Wait until the pressure reduces completely...................................................................... 261 2.8 Place the second clamping element (W4) over the round nut (5) at exhaust gas side and screw o................... 261 2.9 Connect the second hydraulic clamping element (W4) to the high-pressure pump (W1) by means of................... 261 2.10 Close the valve of the high-pressure pump (W1) and extend both big-end bearing bolts steples................... 261 2.11 Firmly tighten the round nuts (5) with a pin (W5). While doing so the nuts must turn smoothl................... 262 2.12 Check to ensure that the round nut is seated properly • Reduce pressure by 50 bar • The roun................... 262 2.13 Open the valve of the high-pressure pump (W1), the clamping elements are depressurized......................... 262 2.14 Wait until the pressure reduces completely..................................................................... 262 3. Mount the piston (02.10.01.nn)....................................................................................... 262 1. Disassembly.......................................................................................................... 263 1.1 Clamp hydraulic jack............................................................................................ 263 1.2 Loosen cover (1) using fork wrench (W1) and disassemble......................................................... 263 1.3 Remove cup spring pack (2)...................................................................................... 263 1.4 Push piston (3) out............................................................................................. 263 1.5 Remove rubber rings (4 and 5) as well as joint rings (6 and 7).................................................. 263 2. Assembly............................................................................................................. 263 2.1 Clean all parts and slightly coat them with Molykote paste "G-Rapid Plus"....................................... 263 2.2 Insert new seals in consideration of the order: Order: At first rubber rings (4 and 5) and th................... 264 2.3 Press piston (3) into the cylinder.............................................................................. 264 2.4 Mount cup spring pack (2)....................................................................................... 264 2.5 Screw cover (1) on using fork wrench (W1) and tighten........................................................... 264 2.6 When the hose coupling has been disassembled mount threaded adapter (8) and high- pressure co................... 264 1. Remove crankshaft bearings........................................................................................... 266 1.1 Open the corresponding crankcase cover on the control and exhaust side.......................................... 266 1.2 Turn the crankshaft to the position which removal can be completed most easily.................................. 266 1.2.1 Turn one of the connecting rods next to the crankshaft bearing to be removed to 90° after c............... 266 1.3 Loosen the round nuts (23) on the lateral uniform strength bolts with the hydraulic rig......................... 266 1.3.1 Remove the protective caps................................................................................ 266 1.3.2 Place hydraulic clamping element (W4) over the round nut (23) and tighten. Ensure that the ............... 266 1.3.3 Connect the hydraulic clamping element (W4) to the high pressure pump (W1) by means of the ............... 266 1.3.4 Close the valve on the high pressure pump (W1) and apply force to uniform strength bolt wit............... 266 1.3.5 Loosen the round nut with a pin. Turn the round nut back 10 holes......................................... 267 1.3.6 Open the valve on the high pressure pump, the hydraulic clamping element is depressurized................. 267 1.3.7 Wait until the pressure drops completely. Remove the hydraulic clamping element........................... 267 1.3.8 Repeat sequence of operations 1.3.2 - 1.3.7 on the opposite side.......................................... 267 1.3.9 Loosen the uniform strength bolts and screw out completely................................................ 267 1.3.10 Loosen the round nuts on the lateral uniform strength bolts on the neighboring bearing(s) ............... 267 1.4 Insert rig...................................................................................................... 267 1.4.1 Lift the rig (W10) into the crankcase collapsed and place in the guide rails of the oil pan............... 267 1.4.2 Connect the hydraulic cylinder of the rig (W10) to the high pressure pump (W1) by means of ............... 268 1.4.3 Bring the carrying arm into position and place the chute (10) between the crankcase and car............... 268 1.4.4 Loosen the round nuts on the crankshaft bearing bolts with the hydraulic rig.............................. 269 1.4.5 Place the hydraulic clamping element (W5) level on the plate above the chute (10). Remove t............... 269 1.4.6 Raise the carrying arm. Place the hydraulic clamping element on the round nut (12) and tigh............... 269 1.4.7 Repeat the installation procedure on the opposite side.................................................... 269 1.4.8 Connect the hydraulic clamping elements (W5) to the high pressure pump (W1) by means of the............... 269 1.4.9 Close the valve on the high pressure pump and subject both crankshaft bearing bolts to a pr............... 269 1.4.10 Loosen the round nuts (12) with a pin. Turn back the round nuts at least 8 holes......................... 269 1.5 Open the valve on the high pressure pump, the hydraulic clamping elements (W5) are depressuri................... 270 1.5.1 Wait until the pressure reduces completely. Remove the hydraulic clamping elements. The hyd............... 270 1.5.2 Remove the clamping element support disk (14) from the carrying arm. Place the spacer block............... 270 1.6 Measure gap, see procedure 2.................................................................................... 270 1.7 Run the carrying arm of the rig (W10) to the crankshaft bearing cover. Bolt the bearing cover................... 271 1.8 Lower the carrying arm carefully to the lower stop with the main bearing cover and lower bear................... 271 1.9 Remove the lower bearing shell.................................................................................. 271 1.10 Place the carrier (W11) into the oil bore in the crankshaft until it stops..................................... 271 1.11 Turn the upper bearing shell and remove........................................................................ 271 1.12 Inspect and evaluate the bearing shells, see 02.03.03.nn and 02.03.07.nn....................................... 272 1.13 Check the wear and wall thickness with a micrometer in the main wear zone at the indicated m................... 272 1.14 The bearing shells must be changed when the wear reaches >0.05 mm. Nominal size = 8.820 - 0................... 272 2. Measure the gap...................................................................................................... 272 2.1 Remove the uniform strength bolts for the respective main bearing on the exhaust and control ................... 272 2.1.1 Loosen both round nuts (12) hydraulically as described in 1.5 and 1.6. Lower the rig...................... 272 2.1.2 Raise the bearing cap with the rig. Tighten the round nuts until the bearing shells barely ............... 273 2.1.3 Measure the gap “K“ between the crankcase and the bearing cover on the exhaust and control ............... 273 1. Install bearing shells............................................................................................... 275 1.1 Oil the running surface of the upper bearing shell thoroughly, dry the back of the bearing an................... 275 1.2 Insert turning mechanism (W12) into the bearing cover. Make sure that the unit seats properly................... 275 1.3 Turn the upper bearing shell into place. Make sure that the bearing shell is centered. The po................... 276 1.4 Raise the rig (W10), remove the round nuts (12). Lower the rig (W10) again and remove the car................... 276 1.5 Oil the running surface of the lower bearing shell, dry the back of the bearing and insert in................... 276 2. Pre-install main bearing bolts....................................................................................... 276 2.1 Raise rig (W10) with the main bearing cover to the upper stop. Be careful not to damage the m................... 276 2.2 Screw round nuts onto main bearing bolts evenly and tighten by hand with pin.................................... 276 2.3 Remove bearing cap mounts on plate.............................................................................. 276 2.4 Lower the rig (W10)............................................................................................. 276 3. Remove the lateral uniform strength bolts............................................................................ 276 3.1 Apply Molykote to the uniform strength bolts, screw in the bolts and tighten to M = 200 Nm.................... 276 3.2 Screw the round nuts (23) onto the uniform strength bolts and tighten by hand................................... 276 3.3 Place the hydraulic clamping elements (W4) over the round nuts (23) on the operating side and................... 276 3.4 Connect the hydraulic clamping elements on the operating side to the high pressure pump (W1) ................... 276 3.5 Close the valve on the high pressure pump and extend the uniform strength bolts with a pressu................... 277 3.6 Tighten the round nut (23) with a pin........................................................................... 277 3.7 Open the valve on the high pressure pump (W1), the clamping elements (W4) are depressurized..................... 277 3.8 Remove hydraulic clamping elements (W4)......................................................................... 277 3.9 Connect the hydraulic clamping elements (W4) on the exhaust side with the high pressure pump ................... 277 3.10 Close the valve on the high pressure pump, extend the uniform strength bolts with a pressure................... 277 3.11 Tighten the round nut (23) with a pin.......................................................................... 277 3.12 Check to ensure that the round nut is seated properly. • Reduce pressure by 50 bar. • The ro................... 277 3.13 Open the valve on the high pressure pump (W1), the clamping elements (W4) are depressurized.................... 277 3.14 Wait until the pressure reduces completely. Remove the clamping elements (W4).................................. 277 3.15 Repeat installation steps 3.8 to 3.14 on the operating side.................................................... 277 3.16 Tighten the round nuts (23) on the lateral uniform strength bolts on the neighboring bearing................... 277 3.17 Screw the protective caps onto the uniform strength bolts...................................................... 277 4. Tightening the main bearing bolts.................................................................................... 277 4.1 Run the carrying arm into position and place the chute (10) between the crankcase and carryin................... 277 4.2 Place the hydraulic clamping element (W5) level on the plate above the chute. Remove the chute.................. 278 4.3 Raise the carrying arm. Place the hydraulic clamping element on the round nut (12) and tighte................... 278 4.4 Repeat the installation procedure on the opposite side.......................................................... 279 4.5 Connect the hydraulic clamping elements (W5) to the high pressure pump (W1) by means of the h................... 279 4.6 Close the valve on the high pressure pump and extend both main bearing bolts with a pressure ................... 279 4.7 Tighten the round nuts (12) with a pin. Check to ensure good action (no stiffness).............................. 279 4.8 Check to ensure that the round nut is seated properly. • Reduce pressure by 50 bar. • The rou................... 279 4.9 Open the valve on the high pressure pump (W1), the clamping elements are depressurized.......................... 279 4.10 Wait until the pressure reduces completely. Remove the hydraulic clamping elements (W5). The................... 279 4.11 Lower the rig until it reaches the lower stop.................................................................. 279 4.12 Remove the rig (W10). The rig is dismantled in the reverse order as installation (see 02.05.................... 279 4.13 Check engine oil flow.......................................................................................... 279 4.14 Close the crankcase covers on the control and exhaust side and the covers under the gear drive................. 279 1. Measure axial clearance “s“.......................................................................................... 281 1.1 Open the cover under the gear drive and the first coupling side crankcase cover on the contro................... 281 1.2 Place a dial gauge on the flywheel with a magnetic retainer and place against crankcase......................... 281 1.3 Slide the crankshaft with a suitable hydraulic unit until it rests firmly against the thrust ................... 281 1.4 Axial clearance “s“:............................................................................................ 281 2. Removing main thrust bearing......................................................................................... 282 2.1 Turn the piston of the 1st cylinder 90° after crankshaft TDC or 90° before crankshaft TDC....................... 282 2.2 Loosen the round nuts (23) on the lateral uniform strength bolts with the hydraulic rig......................... 282 2.2.1 Remove the protective caps................................................................................ 282 2.2.2 Place hydraulic clamping element (W4) over the round nut (23) and tighten. Ensure that the ............... 282 2.2.3 Connect the hydraulic clamping element (W4) to the high pressure pump (W1) by means of the ............... 282 2.2.4 Close the valve on the high pressure pump (W1) and apply force to uniform strength bolt wit............... 282 2.2.5 Loosen the round nut with a pin. Turn the round nut back 10 holes......................................... 282 2.2.6 Open the valve on the high pressure pump, the hydraulic clamping element is depressurized................. 282 2.2.7 Wait until the pressure reduces completely. Remove the hydraulic clamping element......................... 282 2.2.8 Repeat sequence of operations 2.2.2 - 2.2.7 on the opposite side.......................................... 282 2.3 Insert rig...................................................................................................... 283 2.3.1 Lift the rig (W10) into the crankcase collapsed and place in the guide rails of the oil pan............... 283 2.3.2 Connect the hydraulic cylinder in the rig (W10) with the high pressure pump (W1) by means o............... 283 2.3.3 Bring the carrying arm into position and place the chute (10) between the crankcase and car............... 284 2.3.4 Loosen the round nuts on the crankshaft bearing bolts with the hydraulic rig.............................. 284 2.3.5 Place the hydraulic clamping element (W5) level on the plate above the chute (10). Remove t............... 284 2.3.6 Raise the carrying arm. Place the hydraulic clamping element on the round nut (12) and tigh............... 284 2.3.7 Connect the hydraulic clamping elements (W5) with the high pressure pump (W1) by means of t............... 285 2.3.8 Close the valve on the high pressure pump and subject both crankshaft bearing bolts to a pr............... 285 2.3.9 Loosen the round nuts (12) with a pin. Turn the round nuts back 10 holes.................................. 285 2.4 Open the valve on the high pressure pump, the hydraulic clamping elements (W5) are depressuri................... 285 2.5 Wait until the pressure drops completely. Remove the hydraulic clamping elements. The hydraul................... 285 2.6 Remove the clamping element support disk (14) from the carrying arm. Place the spacer block (................... 285 2.7 Measure the gap, see step 3..................................................................................... 285 2.8 Run the carrying arm of the rig (W10) to the crankshaft bearing cover. Bolt the bearing cover................... 286 2.9 Lower the carrying arm with main bearing cover and bottom bearing shell carefully as far as p................... 286 2.10 Screw the lashing eyes (W12) into the bearing cover............................................................ 286 2.11 Secure the bearing cover to the hoists on both sides (exhaust gas side and camshaft side). T................... 287 2.12 Separate the carrying arm of the device (W10) from the bearing cover........................................... 287 2.13 Shift the device (W10) towards cyl. 1, so that there is sufficient clearance below the beari................... 287 2.14 Evenly lower the bearing cover by another 100 mm on both sides by means of the hoists.......................... 287 2.15 Remove both lower thrust bearing segments (1) and replace them if there is a high degree of ................... 287 2.16 Remove the lower bearing shell................................................................................. 287 2.17 Place the carrier (W11) into the oil bore in the crankshaft until it stops..................................... 287 2.18 Turn the upper bearing shell and remove........................................................................ 287 2.19 Inspect and evaluate the bearing shells, see 02.03..03.nn and 02.03..07.nn..................................... 287 2.20 Check the wear and wall thickness in the main wear zone with a micrometer at the indicated m................... 287 2.21 The bearing shells must be changed when the wear reaches >0.05 mm. Nominal size = 8.820 - 0................... 287 3. Measure the gap...................................................................................................... 288 3.1 Loosen both round nuts (12) hydraulically. Lower the rig (see step 2.3)......................................... 288 3.2 Raise the bearing cap with the rig. Tighten the round nuts until the bearing shells barely to................... 288 3.3 Measure the gap “K“ between the crankcase and main bearing cover on the exhaust and control s................... 288 1. Install bearing shells............................................................................................... 290 1.1 Oil the running surface of the upper bearing shell thoroughly, dry the back of the bearing an................... 290 1.2 Insert turning mechanism (W12) into the bearing cover. Make sure that the unit seats properly................... 290 1.3 Turn the upper bearing shell into place. Make sure that the bearing shell is centered. The po................... 291 1.4 Raise the rig (W10), remove the round nuts (12). Lower the rig (W10) again and remove the car................... 291 1.5 Oil the running surface of the lower bearing shell, dry the back of the bearing and insert in................... 291 1.6 Place the lower thrust washer segments (1; only on main thrust bearings ) on the dowel pins (................... 291 2. Pre-install main bearing bolts....................................................................................... 291 2.1 Raise rig (W10) with the main bearing cover to the upper stop. Be careful not to damage the m................... 291 2.2 Screw round nuts onto main bearing bolts evenly and tighten by hand with pin.................................... 291 2.3 Remove bearing cap mounts on plate.............................................................................. 291 2.4 Lower the rig (W10)............................................................................................. 292 3. Tighten the lateral round nuts of the adjacent bearing .............................................................. 292 3.1 Screw the round nuts (23) of the adjacent bearing onto the uniform strength bolts and tighten................... 292 3.2 Place the hydraulic clamping elements (W4) over the round nuts (23) on the operating side and................... 292 3.3 Connect the hydraulic clamping elements on the operating side to the high pressure pump (W1) ................... 292 3.4 Close the valve on the high pressure pump and extend the uniform strength bolts with a pressu................... 292 3.5 Tighten the round nut (23) with a pin........................................................................... 292 3.6 Open the valve on the high pressure pump (W1), the clamping elements (W4) are depressurized..................... 292 3.7 Remove hydraulic clamping elements (W4)......................................................................... 292 3.8 Connect the hydraulic clamping elements (W4) on the exhaust side with the high pressure pump ................... 292 3.9 Close the valve on the high pressure pump, extend the uniform strength bolts with a pressure ................... 292 3.10 Tighten the round nut (23) with a pin.......................................................................... 293 3.11 Check to ensure that the round nut is seated properly. • Reduce pressure by 50 bar. • The ro................... 293 3.12 Open the valve on the high pressure pump (W1), the clamping elements (W4) are depressurized.................... 293 3.13 Wait until the pressure reduces completely. Remove the clamping elements (W4).................................. 293 3.14 Repeat installation steps 3.8 to 3.13 on the operating side.................................................... 293 3.15 Screw the protective caps onto the uniform strength bolts...................................................... 293 4. Tightening the main bearing bolts.................................................................................... 293 4.1 Run the carrying arm into position and place the chute (10) between the crankcase and carryin................... 293 4.2 Place the hydraulic clamping element (W5) level on the plate above the chute. Remove the chute.................. 294 4.3 Raise the carrying arm. Place the hydraulic clamping element on the round nut (12) and tighte................... 294 4.4 Repeat the installation procedure on the opposite side.......................................................... 294 4.5 Connect the hydraulic clamping elements (W5) to the high pressure pump (W1) by means of the h................... 294 4.6 Close the valve on the high pressure pump and extend both main bearing bolts with a pressure ................... 294 4.7 Tighten the round nuts (12) with a pin. Check to ensure good action (no stiffness).............................. 295 4.8 Check to ensure that the round nut is seated properly. • Reduce pressure by 50 bar. • The rou................... 295 4.9 Open the valve on the high pressure pump (W1), the clamping elements are depressurized.......................... 295 4.10 Wait until the pressure reduces completely. Remove the hydraulic clamping elements (W5). The................... 295 4.11 Lower the rig until it reaches the lower stop.................................................................. 295 4.12 Remove the rig (W10). The rig is dismantled in the reverse order as installation (see 02.05.................... 295 4.13 Check engine oil flow.......................................................................................... 295 4.14 Close the crankcase covers on the control and exhaust side and the covers under the gear drive................. 295 1. Open the indicator valves, remove the crankcase cover for the respective cylinder on both sides...................... 297 2. Turn crank journal ca. 20° to the control side from TDC............................................................. 297 3. Remove cylinder head (01.06.01.nn)................................................................................... 297 4. Place cylinder liner retainer (Fig. Y/W9) on coolant distributor housing (1). Tighten the roun....................... 297 5. Clean carbon deposits from the area above TDC for 1st piston ring up to gauging ring. Do not d....................... 297 6. Turn the upper piston edge up to just below the gauging ring (Fig. 2/4).............................................. 297 7. Insert disassembly unit (W10) so that the recess is inside the gauging ring.......................................... 297 8. Tighten the disassembly unit slightly by turning the spindle nut..................................................... 297 9. Press out and remove the gauging ring by turning the engine to raise the piston...................................... 297 10. Remove disassembly unit............................................................................................. 297 11. Rethread the threaded holes (Fig. Z/2; M16, 15 mm deep) in the piston crown......................................... 297 12. Bolt the piston lifting unit (W1) onto the piston crown............................................................. 297 13. Connect the crane to the eye of the lifting unit, turn the piston to TDC together with the cr....................... 297 14. Split the connecting rod shank...................................................................................... 298 14.1 Insert a socket wrench with a square head (Fig. 3/W6) in the hydraulic wrench (W5). Mount th................... 298 14.2 Connect the hydraulic wrench (W5) with the high pressure pump (W3) by means of the high pres................... 299 14.3 Place hydraulic wrench with socket wrench (W6) on the uniform strength bolt (20). Prop the w................... 299 14.4 Close the valve on the high pressure pump (W3) and loosen the uniform strength bolts one aft................... 299 15. Remove the uniform strength bolts (20) with the segments (21)....................................................... 299 16. Open the valve on the high pressure pump (W3). Wait until the pressure abates completely. Rem....................... 299 17. Mount the connecting rod holder (W8) on the counterweight to secure the connecting rod (22)......................... 299 18. Pull the piston carefully and place on a suitable surface........................................................... 299 19. Seal off the oil bore in the connecting rod shank split with a protective cap....................................... 300 1. Turn the piston.................................................................................................. 301 1.1 Attach crane to piston lifting unit (Fig. 1/W1) , lift piston........................................................... 301 1.2 Mount second piston lifting unit (W2) on the big end (1) and attach second crane or sling............................... 301 1.3 Turn the piston carefully and place on suitable surface................................................................. 301 2. Dismantling the piston crown......................................................................................... 301 2.1 Connect piston lifting unit (W1) to crane, remove piston pin (2) (02.08.01.nn).......................................... 301 2.2 Measure piston pin bearing (3) (02.09.01.nn) and evaluate if necessary (02.03.03.nn).................................... 301 2.3 Loosen the hexagon nuts (Fig. 3/5) and remove with piston skirt (12).................................................... 302 2.4 Clean piston crown (8) and piston skirt (12). Make sure that the contact surfaces of piston p........................... 302 2.5 Clean and inspect the oil bores in the piston skirt (Fig. 3/12)......................................................... 303 2.6 Piston assembly......................................................................................................... 303 2.7 Clean the contact surfaces of piston skirt (12) and piston crown (8) and check for unevenness........................... 303 2.8 Clean bores for piston screws (7) and contact surfaces for spacer sleeves (6) in the piston s........................... 303 2.9 Screw piston screws (if removed) into piston crown and tighten to a torque of ........................... 303 2.10 Insert new O-ring (13) untwisted into groove........................................................................... 304 2.11 Put on piston skirt (12), fixation hole and spring dowel pin (11) must match........................................... 304 2.12 Lubricate inside thread and bearing surfaces of the hexagon nuts (5) with Molykote paste............................... 304 2.13 Tighten piston screws (5) crosswise to a torque of M = 170 Nm.......................................................... 304 2.14 Loosen hexagon nuts again.............................................................................................. 304 2.15 Retighten piston screws (7) in the piston crown, torque: M = 40 Nm..................................................... 304 2.16 Tighten hexagon nuts (5) crosswise to a torque of M = 60 Nm and then continue tightening cro........................... 304 2.17 Check: At a torque of M = 115 Nm the hexagon nuts must not turn any further!........................................... 304 2.18 Check by second person: Carry out a visual check to confirm if the hexagon nuts have been tu........................... 304 1. Piston inspection (7.500 h).......................................................................................... 305 1.1 Open all crankcase covers....................................................................................... 305 1.2 Check the running surfaces of all cylinder liners (cylinder liner appearance) from the crankc................... 305 1.3 Remove the piston with the worst running surface (02.06.01.nn). If any piston rings are stuck................... 305 1.4 Piston rings may only be removed with the piston ring pliers (Fig. 1/W1) intended for this pu........................... 306 1.5 Clean the piston rings.................................................................................................. 306 1.6 Check wear in the chrome layer, especially at the gap and on the opposite side. If the chrome........................... 306 1.7 Clean the pistons, ring grooves and oil drain bores for the wiper ring.............................................. 306 1.8 Smooth light scoring and fretting with a fine emery cloth soaked in oil or a fine carborundu....................... 306 1.9 Measure the groove height hN (Fig. 2) in the forward groove area across and along the engine........................ 306 1.10 Measure the ring height hR (Fig. 2) at four opposing points........................................................ 306 1.11 Calculate the clearance limit and check according to the table for standard piston equipment....................... 307 1.12 Insert the rings in the grooves with the labeling up (Fig. 3/X) and with the ring gaps alter........................... 307 2. Maintenance (30,000 h)............................................................................................... 307 2.1 Remove all pistons (02.06.01.nn)........................................................................................ 307 2.2 Check the running surface of the piston and clean the piston........................................................... 307 2.3 Remove the piston rings with the piston ring pliers (Fig. 1/W1). Record the position of the r........................... 307 2.4 Clean all rings and check the wear. If the chrome layer is worn away entirely or in sections,........................... 307 2.5 Measure the groove height hN as defined in 1.9...................................................................... 307 2.6 Replace wiper ring and all compression rings........................................................................ 307 2.6.1 Place the rings in the grooves with the labeling (Fig. 3/X) up and with the ring gaps alter................... 307 2.7 Install all pistons (02.10.01.nn)................................................................................... 307 1. Turn the piston...................................................................................................... 308 1.1 Connect crane to the piston installation unit (W1) and lift the piston.......................................... 308 1.2 Mount second installation unit (W2) on the connecting rod eye (1) and attach second crane or ................... 308 1.3 Turn the piston and place on suitable surface................................................................... 308 2. Disassembly.......................................................................................................... 309 2.1 Mark the connecting rod eye (1), piston (2) and piston pin (3) for proper alignment during re................... 309 2.2 Lift the connecting rod eye slightly with the crane to relive pressure on the piston pin........................ 309 2.3 Remove the circlips (4)......................................................................................... 309 2.4 Remove the piston pin (3) from the piston bore and piston pin bush without applying excessive................... 309 2.5 Check the oil bores (6) in the connecting rod eye and check the piston pin bush to ensure tha................... 309 2.6 Check the piston pin surface for cracks and damage.............................................................. 309 2.7 Measure the piston pin, piston pin bush and piston pin bore (02.09.01.nn)....................................... 309 3. Assembly............................................................................................................. 309 3.1 Insert a circlip (4) into the piston pin bore................................................................... 309 3.2 Slide the connecting rod eye (1) into the piston until the piston pin bore and the piston pin................... 309 3.3 Oil the piston pin (3) and insert into the piston and piston pin bush without tilting; the pi................... 309 3.4 Secure the piston pin with the second circlip................................................................... 309 1. Measure the small end bearing........................................................................................ 310 1.1 Clean the piston pin (Fig. 2/1), small end bearing (2) and piston bosses and measure dimensio................... 310 1.2 Determine the axial clearance [piston boss clearance (D) and bearing width (X)]................................. 310 2. Removal of the small end bearing..................................................................................... 312 2.1 When removing the small end bearing, be sure to use as little force as possible. The small e................... 312 3. Small end bearing installation....................................................................................... 312 3.1 Small end bushing to ca. -60°C in C02 snow and warm connecting rod eye to ca. 80°C in a clean................... 312 3.2 Slide the bushing into the connecting rod eye................................................................... 312 3.3 After the parts have reached normal temperature, the dimensional accuracy and the position of................... 312 1. Insert all piston rings with the gap facing lengthwise respective to the engine; ring gaps mu....................... 313 2. Loosen the clamping bolts (Fig. 1/1) until the piston installation unit (W13) is open wide eno....................... 313 3. Apply Molykote paste "G-Rapid Plus“ to the threads and contact surface of the clamping bolts (1)..................... 313 3.1 Oil the ring area well.......................................................................................... 313 4. Place the piston installation unit (Fig.1/ W13 ) over the piston ring zone and tighten the cl....................... 314 5. Make sure that the rings are not stuck by turning the piston installation unit (W13)................................. 314 6. Attach the piston lifting unit (Fig. 2/W1) to the piston............................................................. 314 7. Mount cylinder liner retainer (W9)................................................................................... 314 8. Mount piston installation ring (W12)................................................................................. 314 9. Attach piston to crane and lift. Oil cylinder liner and piston base well............................................. 314 10. Place the piston into the cylinder liner carefully; the piston must be inserted exactly in li....................... 314 11. Lower the piston, being extremely careful that the cylinder does not catch in the cylinder li....................... 314 12. Place the piston insertion unit (Fig. 1/W13) flat on the piston installation ring (Fig. 2/W12....................... 314 13. Install piston and connecting rod................................................................................... 315 13.1 Apply Molykote to threads and contact surfaces of the uniform strength bolts (Fig. 3/20)....................... 315 13.2 Place segments (21) on the connecting rod split and tighten uniform strength bolts hand tigh................... 315 13.3 Remove connecting rod holder (W8) (02.06.01.nn)................................................................ 315 13.4 Tighten all uniform strength bolts (Fig.4/20) to M = 50 Nm Mark the position of each of the................... 315 13.5 Place socket wrench (Fig. 4/W6) with square head into the hydraulic wrench (W5). Mount suppo................... 316 13.6 Connect the hydraulic wrench (W5) with the high pressure pump (W3) by means of the high pres................... 316 13.7 Place hydraulic wrench with socket wrench (Fig. 4/W6) on the uniform strength bolt (20). Pro................... 316 13.8 Close the valve on the high pressure pump (W3) and tighten all uniform strength bolts (20) o................... 317 13.9 Note the position of the uniform strength bolts (chalk mark), it must be at ................... 317 13.10 Open the valve on the high pressure pump (W3). Wait for the pressure to subside completely ................... 317 14. Turn the piston to TDC together with the crane...................................................................... 317 15. Remove the piston insertion unit (Fig. 1/W13), piston installation ring (Fig. 2/W12) and pist....................... 317 16. Clean the cylinder liner contact surface (3)........................................................................ 317 17. Install new gauging ring............................................................................................ 317 18. Install cylinder head (01.11.01.nn)................................................................................. 317 19. Remove cylinder liner retainer (Fig. 2/W9), replace crankcase cover and close indicator valves...................... 317 1. Disassembly of balance weight........................................................................................ 319 1.1 Turn crankshaft to position according to (Fig. 3)............................................................... 319 1.2 Mount the mounting and removal device for balance weights (Fig. 4/W7)........................................... 319 1.3 Attach the lugs (20) of device (W7) via shackles and slings to hoists. Pull the hoists so tha................... 319 1.4 Loosen both round nuts (Fig. 3/1) of the studs (2) by means of the hydraulic device set......................... 319 1.5 Place hydraulic element (W4) over the round nut (1) and tighten it. Make sure the slits (Fig.................... 319 1.6 Connect the hydraulic element (Fig. 3/ W4) via the high-pressure hose (W2) to the high-pressu................... 319 1.6.1 Close valve (10) of the high-pressure pump (W1) and stretch the stud steplessly with a pres............... 319 1.6.2 Loosen round nut (Fig. 2/1) with pin (W3). Turn back round nut at least 8 holes........................... 319 1.6.3 Open valve (Fig. 3/10) of the high-pressure pump (W1), the hydraulic element will be relieved............. 320 1.6.4 Wait until the pressure has dropped completely, and then remove the hydraulic element (W4)................ 320 1.6.5 Loosen the second round nut (1), see sequence of operations 1.4.1 to 1.4.6................................ 320 1.6.6 Remove the round nuts completely.......................................................................... 320 1.7 Lower device (Fig. 4/W7) with the hoists slowly and evenly on both sides until the balance we................... 320 1.8 Move the balance weight slowly out of the crankcase and place it on a suitable base............................. 320 1.9 Remove the mounting and removal device for balance weights (W7)................................................. 320 1.10 Screw hexagon nuts (W8) onto the studs (Fig. 2/2) and lock with a second nut................................... 320 1.11 Loosen studs and screw out of the crankshaft................................................................... 320 2. Reassembly of balance weight......................................................................................... 320 2.1 Turn crankshaft to position according to (Fig. 3) .............................................................. 320 2.2 Clean the contact surfaces on balance weight and crankshaft..................................................... 320 2.3 Apply a thin coat of Molykote paste to the studs (2) and insert in crankshaft................................... 321 2.4 Tighten the studs by means of locked hexagon nuts (W8) with a torque of ................... 321 2.5 Disassemble the hexagon nuts (W8)............................................................................... 321 2.6 Mount the mounting and removal device for balance weights (Fig. 4/W7)........................................... 321 2.7 Lower the device with balance weight slowly into the crankcase by means of hoists............................... 321 2.8 Tension the slings slowly and put balance weight on crankshaft via the studs.................................... 321 2.9 Screw the round nuts (Fig. 3/1) onto the studs (2) so as to be fingertight...................................... 321 3. Tighten the round nuts (1) of the studs (2) with the hydraulic device set............................................ 321 3.1 Place hydraulic element (W4) above the first round nut (1) and tighten it. Make sure the slit................... 321 3.2 Connect the hydraulic element (Fig. 3/W4) via the high-pressure hose (W2) to the high- pressu................... 322 3.3 Close valve (10) of the high-pressure pump (W1) and stretch the first stud (2) steplessly wit................... 322 3.4 Firmly tighten round nut (1) with pin (Fig. 1/W3)............................................................... 322 3.5 Open valve (10) of the high-pressure pump (W1), the hydraulic element will be relieved.......................... 322 3.6 Wait until the pressure has dropped completely, and then remove the hydraulic element (W4)...................... 322 3.7 Place hydraulic element (W4) onto the second round nut (1) according to sequence of operation................... 322 3.8 Close valve (10) of the high-pressure pump (W1) and stretch the second stud (2) steplessly wi................... 322 3.9 Firmly tighten round nut (1) with pin (Fig. 2/W3)............................................................... 322 3.10 Decrease hydraulic pressure by p = 50 bar. It must not be possible to loosen the roun................... 322 3.11 Relieve the hydraulic element according to sequence of operations 3.5 and 3.6.................................. 322 1. Locking of the resilient mounting.................................................................................... 323 1.1 Disassemble nuts and washers (Fig. 1/20, 21 and 22)............................................................. 323 1.2 Disassemble spring dowel pin (23)............................................................................... 323 1.3 Screw down locking ring (24) so that it abuts against pipe (25). To this end an auxiliary bor................... 323 1.4 Apply a thin coat of oil to the foundation bolts. Place washer (22) onto side stopper (26) an................... 323 2. Disassemble cylinder head (01.06.01.nn).............................................................................. 323 3. Disassemble the push-rods for inlet and exhaust valve. Put up the cam followers for inlet and ....................... 325 4. Insert retaining device for cam follower (Fig. 3/W1) of the injection pump drive into the engi....................... 325 4.1 Screw in the hexagon head screw (2) until there is clearance S between the cam follower and t................... 325 5. Draw piston (02.06.01.nn)............................................................................................ 325 5.1 Disassemble cylinder liner retainer............................................................................. 325 6. Disassemble big-end bearing and big- end bearing cap as well as connecting rod (02.04.01.nn)......................... 325 6.1 Place connecting rod onto a suitable base....................................................................... 325 6.2 Disassemble one balance weight of the damaged running gear (02.11.00.nn)........................................ 325 7. Obturate the oil bore in the crank pin of the damaged running gear by means of plug (Fig. 4/W2....................... 326 7.1 Tighten prevailing torque type nut (13) by hand................................................................. 326 8. Disassemble the control air pipe (Fig. 5/30) of the corresponding injection pump. Obturate con....................... 326 9. Mount cylinder head (01.11.01.nn).................................................................................... 326 10. Mount crankcase cover on camshaft and exhaust side.................................................................. 326 11. Start the engine under emergency operation (A3.12.02.nn). Continuously check the foundation b....................... 326 12. Repairing a damaged engine.......................................................................................... 327 12.1 Disassemble cylinder head, plug in the crank pin (Fig. 4/10), retaining device for cam follo................... 327 12.2 Deactivating the locking of the resilient mounting............................................................. 327 12.3 Exchange / repair any damaged parts............................................................................ 327 12.4 Mount connecting rod, connecting rod bearing with bearing cap (02.04.02.nn), piston (02.10.0................... 327 12.5 Mount crankcase cover on camshaft and exhaust side............................................................. 327 12.6 Put the engine into service (A3.05.00.nn)...................................................................... 327 1. Check the relief valve manually for freedom from inside of the crankcase door (1). Thereto rem....................... 328 2. Disassembly.......................................................................................................... 328 2.1 Remove hexagon screws (9) of the explosion relief valve and the crankcase door(1).............................. 328 2.2 Remove the explosion relief valve completely from crankcase door (1)............................................ 328 2.3 Screw off the nuts (2) with the spring ring (3) from the countersunk screws (4)................................. 328 2.4 Lift off the deflection plate (5), the pressure spring (6) and the valve plate (7).............................. 328 2.5 Remove the two countersunk screws (4)........................................................................... 328 2.6 Remove the six spacer tubes (8) with retaining washers.......................................................... 328 2.7 Take the rubber ring (10) out of the seat ring.................................................................. 328 2.8 Clean all parts with gas oil.................................................................................... 328 2.9 Check all parts and renew if necessary.......................................................................... 328 3. Reassembly........................................................................................................... 329 3.1 Reassembly is done in reverse order of disassembly.............................................................. 329 3.2 Tighten connecting bolts (9) using a torque of ................... 329 3.3 Check the explosion relief valve for proper function by manual operation after assembly......................... 329 3.4 When mounting the explosion relief valve to the crankcase door be sure that the sealing betwe................... 329 1. Remove coolant distributor housing................................................................................... 330 1.1 Remove mounting bolts (Fig. 2/1) on the coolant block........................................................... 330 1.2 Loosen the sleeves (2) from the starting air channel and slide into opposite distributor hous................... 331 1.3 Remove the distributor housing mounting bolts (3). Screw the eye bolts (Fig. 3/W1) into the c................... 331 1.4 Replace O-ring (4) on the charge air passage and O-ring (5) on the valve lifter passage in th................... 331 2. Install coolant distributor housing.................................................................................. 332 2.1 Set coolant distributor housing (6) into place on the crankcase with a crane. Replace coolant................... 332 2.2 Tighten coolant distributor housing mounting bolts (3).......................................................... 332 2.3 Slide sleeves (2) for starting air channel into place and secure................................................ 332 2.4 Apply a light coat of Molykote to the coolant block mounting bolts (1), slide into place and ................... 332 2.5 Remove eye bolts (Fig. 3/W1).................................................................................... 332 2.6 Remove cylinder liner retainer (W2)............................................................................. 332 1. Check cylinder liner................................................................................................. 333 1.1 Remove gauging ring and remove piston........................................................................... 333 1.2 Clean the inside of the cylinder liner, cover the crankcase well............................................... 333 1.3 Measure the cylinder liner with the fine gauge inside micrometer (W2) at the points indicated................... 333 1.4................................................................................................................. 333 1.5 Enter the values measured into the table (Fig. 2) and calculate the wear values (d1 - referen................... 334 1.6 When the wear limit has been reached, normally at the point at which the top piston ring reve................... 334 1. Remove cylinder liner................................................................................................ 335 1.1 Remove piston (02.06.01.nn). Remove cylinder liner retainer (W2)................................................ 335 1.2 Measure wear (03.03.01.nn)...................................................................................... 335 1.3 Insert rig (W1) with threaded rod and swivel cross arm (1) into the cylinder liner.............................. 335 1.4 Fasten clamping plate (2) and swivel cross arm (1) securely with the nut (3).................................... 335 1.5 Attach lifting unit to eye bolt (4) and pull cylinder liner out along cylinder axis and place................... 335 1.6 Remove the O-ring (13) in the coolant distributor housing (14).................................................. 335 1.7 Clean the sealing surface and O-ring groove thoroughly and check for damage..................................... 336 1.8 Clean coolant area on the cylinder liner collar thoroughly...................................................... 336 1.9 Clean cylinder liner collar seat, upper and lower fitting bore in crankcase thoroughly.......................... 336 1. Clean the inside of the coolant distributor housing (Fig. 1/1)....................................................... 337 2. Place new O-ring (4) into the groove in the coolant distributor housing.............................................. 337 3. Clean the cylinder liner contact surfaces(2) on the crankcase (3)................................................... 337 4. Connect hoisting unit to the eye bolt on the rig (Fig. 1/W1) and lower the cylinder liner into....................... 338 5. Mount rig onto the cylinder liner to be installed in accordance with steps 1.3 and 1.4 of the ....................... 338 6. Remove the rig (W1) from the cylinder liner and install piston (02.10.01.nn)......................................... 338 1. Check the tightness and seal of the engine connecting flange, filter, control unit and the lin....................... 339 2. Check the compensators for leaks and check the exhaust line (06.01.01.nn) behind the exhaust t....................... 339 3. Check the brackets and connecting pieces of the charge air line for tightness and leaks.............................. 339 4. Tighten the mounting bolts in the bearing blocks of the fuel pump regulating rod and check th....................... 339 5. Check the control and monitoring equipment to ensure secure fit. Cables and impulse lines may....................... 339 6. Check foundation bolts and fitted pieces by tapping. Check web deflection after tightening lo....................... 339 7. Check elastic bearing elements for damage............................................................................ 339 1. Check camshaft bearing clearance..................................................................................... 340 1.1 Remove the corresponding sight hole cover on the control side of the camshaft cover............................. 340 1.2 Check camshaft bearing /bearing journal clearance............................................................... 340 1. Check the running surface of one camshaft bearing and the corresponding camshaft section after....................... 341 1.1 Remove all rocker arms from the corresponding cylinder and the rocker arms of all cylinders l................... 341 1.2 Remove the injection pump of the cylinder to be checked and all cylinders located to the righ................... 341 1.3 Raise and secure the rocker arms of the cylinder to be checked and all cylinders to the right................... 341 1.4 Loosen the hex head bolts (Fig.1/1) on the left flange of the camshaft section (3). Turn the ................... 342 1.5 Remove retaining bolt (Fig. 2/11)............................................................................... 343 1.6 Drive the camshaft bearing (4) out to the right with a suitable wood block and rubber mallet.................... 343 1.7 Place cardboard or similar material around the camshaft bearing journal......................................... 343 1.8 Slide the camshaft to the right until it stops (distance “s“) with a strip of wood. Distance ................... 343 1.9 Remove bolts (Fig. 1/W1)........................................................................................ 343 1.10 Check crankshaft bearing. Replace (04.04.01.nn) if:............................................................ 344 1.11 Check the camshaft bearing for scuffing on the back of the bearing and replace if necessary ................... 344 1.12 Check the running surfaces of the bearing journals of all available crankshaft sections for ................... 344 1.13 Replace defective camshaft sections and check the corresponding bearings (04.04.01.nn)......................... 344 1.14 Install camshaft (04.04.01.nn)................................................................................. 344 1.15 Install bearing and align with positioning bore................................................................ 344 1.16 Install retaining bolt (Fig. 2/11). Tighten bolt to............................................................ 344 2. Check the running surface of all camshaft bearings and camshaft sections after the 1st cylinder...................... 344 2.1 Release and raise all rocker arms (04.04.01.nn)................................................................. 344 2.2 Loosen the hex head bolts (Fig.1/1) on the left flange of the camshaft section (3) of the 1st................... 344 2.3 Remove the retaining bolts (Fig. 2/11) on the camshaft bearings one after the other............................. 344 2.4 Drive out the camshaft bearings (4) to the right with a suitable wood block and rubber mallet................... 344 2.5 Slide the camshaft to the side (1.4 to 1.7)..................................................................... 345 2.6 Prop up the oscillation damper and the camshaft section above the 1st cylinder.................................. 345 2.7 Check the running surfaces of the bearing journals of all camshaft sections for scoring......................... 345 2.8 Replace defective camshaft sections (04.04.01.nn)............................................................... 345 2.9 Install camshaft (04.04.01.nn).................................................................................. 345 2.10 Install retaining bolt (11). Tighten bolt to M =130Nm........................................................ 345 2.11 Disengage the rotor............................................................................................ 345 2.12 Install rocker arms and complete all remaining work (04.04.01.nn).............................................. 345 1. Disassembly:......................................................................................................... 346 1.1 Engage barring device........................................................................................... 346 1.2 Disassemble corresponding rocker arm bracket (01.02.01.nn)...................................................... 346 1.3 Mark and disassemble push-rods (7). Push-rods may not be interchanged........................................... 346 1.4 Disassemble corresponding camshaft cover........................................................................ 346 1.5 Disassemble corresponding injection pump (07.02.01.nn).......................................................... 346 1.6 Disassemble injection pump drive................................................................................ 346 1.7 Loosen circlips (8) of oil pipes (9) and shift towards the centre of the pipe................................... 346 1.8 Remove oil pipes (9)............................................................................................ 347 1.9 Remove clamping screw (10) and both lower fastening screws (11)................................................. 347 1.10 Bring into position support (W1.1) and firmly mount to cam follower bracket.................................... 347 1.11 Bring into position arms (W1.5) and tension them by means of tubular hexagon box wrench (W1.8)................. 347 1.12 In case of disassembly and assembly at cylinder 1 mount support (W1.6). Here the camshaft co................... 348 1.13 Mount guide rail (W1.2). Firmly tighten the nuts only after having aligned all parts of the ................... 348 1.14 Put on carriage (W1.4). By means of setscrew (15) adjust height if necessary so that the scr................... 349 1.15 Screw together carriage (W1.4) and support (W1.1). Use screws (W1.7)........................................... 349 1.16 Remover upper fastening screws (12) of the cam follower bracket................................................ 349 1.17 Bring into position bracket with hoist (W1.3).................................................................. 349 1.18 Engage hoist in support (W1.1) and tension it.................................................................. 350 1.19 Roll out valve drive completely on the carriage................................................................ 350 1.20 Separate support (W1.1) from carriage (W1.4) by removing screws (W1.7)......................................... 350 1.21 Disassemble carriage (W1.4).................................................................................... 350 1.22 Disassemble guide rail (W1.2).................................................................................. 350 1.23 Lower complete valve drive with hoist and deposit on a suitable base support................................... 350 1.24 Remove support (W1.1).......................................................................................... 350 2. Assembly:............................................................................................................ 351 2.1 Bring into position support (W1.1) and firmly mount to cam follower bracket..................................... 351 2.2 Bring into position arms (W1.5) and tension them by means of tubular hexagon box wrench (W1.8).................. 351 2.3 Raise complete valve drive with hoist up to limit stop.......................................................... 351 2.4 Mount guide rail (W1.2)......................................................................................... 351 2.5 Mount carriage (W1.4)........................................................................................... 351 2.6 Deposit valve drive on carriage (W1.4).......................................................................... 351 2.7 Separate connection to hoist.................................................................................... 351 2.8 Screw together carriage (W1.4) and support (W1.1). Use screws (W1.7)............................................ 351 2.9 Carefully roll valve drive into camshaft casing................................................................. 351 2.10 Make sure there is sufficient clearance for inlet and exhaust cam followers. Possible correc................... 351 2.11 Insert spacer sheets (13)...................................................................................... 351 2.12 Insert the two upper fastening screws (12) of the valve drive with extension sleeves (14) an................... 351 2.13 Lower cam follower and disassemble arms (W1.5)................................................................. 351 2.14 Separate carriage (W1.4) and support (W1.1).................................................................... 351 2.15 Disassemble carriage........................................................................................... 351 2.16 Disassemble guide rail (W1.2).................................................................................. 351 2.17 Disassemble bracket with hoist (W1.3).......................................................................... 351 2.18 Remove support (W1.1).......................................................................................... 352 2.19 Lubricate threads and contact faces of screws (10, 11, 12) with Molykote Paste "G Rapid Plus".................. 352 2.20 Insert the two lower fastening screws (11) with extension sleeves (14) and slightly tighten ................... 352 2.21 Tighten fastening screws (11, 12) "crosswise" gradually until a torque of M = 455 Nm is reac................... 352 2.22 Assemble clamping screw (10) and tighten to a torque of M = 455 Nm............................................. 352 2.23 Slightly lubricate new O-rings (16) with Vaseline and insert into the oil pipe grooves untwi................... 352 2.24 Insert oil pipes (9) into the cam follower shaft and assemble circlips (8)..................................... 352 2.25 Insert push-rods according to their marking.................................................................... 352 2.26 Assembly injection pump drive.................................................................................. 352 2.27 Assemble injection pump (07.02.01.nn) ......................................................................... 352 2.28 Assemble push-rods (7)......................................................................................... 352 2.29 Assemble rocker arm bracket (01.02.01.nn)...................................................................... 352 2.30 Check valve clearance (01.01.01.nn) ........................................................................... 352 2.31 Assemble valve cover........................................................................................... 352 2.32 Start prelubrication pump and check oil pipes (9) for leaks.................................................... 352 2.33 Assemble camshaft cover........................................................................................ 352 1. Disassembly.......................................................................................................... 353 1.1 Open the indicator valves and remove the camshaft cover with housing covers and gaskets on th................... 353 1.2 Remove all rocker arms for the corresponding cylinder and the rocker arms of all cylinders lo................... 353 1.3 Remove the injection pump of the corresponding cylinder and for all cylinders to the right of................... 354 1.4 Remove the lifters and the camshaft section for the corresponding cylinder and all camshaft s................... 354 1.5 When removing the last camshaft section:........................................................................ 355 1.5.1 Remove the oscillation damper (Fig.2/ 10) (04.09.01.nn) and slide to the right as far as p............... 355 1.5.2 Remove the intermediate piece (12)........................................................................ 355 1.6 Place the sling (Fig. 3/W1) around the camshaft section (3) between the exhaust cam and injec................... 355 1.7 Tighten the sling (W1) with the lifting unit.................................................................... 355 1.8 Remove the retaining bolt (11).................................................................................. 355 1.9 Drive the right camshaft bearing (Fig. 1/4) out of the camshaft section with a suitable wood ................... 356 1.10 Loosen the hex head bolts (Fig. 1/1) on both camshaft section (3) flanges. Turn the enginet................... 356 1.11 Place cardboard or similar material around the camshaft bearing journal........................................ 356 1.12 Slide the camshaft to the right until it stops (distance “s“) with a strip of wood. Secure t................... 356 1.13 Secure the right end of the camshaft with wooden wedges........................................................ 357 1.14 Fill the camshaft trough with cardboard or a similar material.................................................. 357 1.15 Pull the camshaft section (Fig. 4/3) out of the bearing block to the left while lowering the................... 357 1.16 Remove camshaft bearing (4) and inspect (04.01.02.nn), replace if necessary.................................... 357 2. Assembly............................................................................................................. 357 2.1 Press the straight pin (Fig. 5/5) into the flange until it stops in accordance with the numbe................... 357 2.2 Oil the inside and outside of the camshaft bearing (Fig. 1/4) thoroughly and place on intake ................... 358 2.3 Place camshaft section (3) facing the coupling side in the corresponding camshaft trough on c................... 358 2.4 Place the sling (Fig. 3/W1) around the camshaft section between the exhaust cam and the injec................... 358 2.5 Raise the lifting unit slowly and slide the camshaft section bearing journal into the bearing................... 358 2.6 Align the camshaft section with the straight pin towards the bore in the bearing journal or i................... 358 2.7 Attach the camshaft section to the right camshaft section flange by tightening two opposing h................... 358 2.8 Slide the camshaft section carefully to the left with a wood strip until the straight pin (5)................... 358 2.9 Apply Molykote to all hex head bolts (1)........................................................................ 358 2.10 Place the hex head bolts in the left camshaft section flange (as many as possible) and gradu................... 358 2.11 Align the retaining bore in the camshaft bearing with the bore for the retaining bolt (11) i................... 358 2.12 Drive the camshaft bearing (4) into place evenly with a suitable wood block and rubber malle................... 358 2.13 Apply Molykote to the retaining bolt (11) and install. Tighten the bolt to..................................... 358 2.14 Lower the lifting unit and remove the sling (Fig. 1/W1)........................................................ 359 2.15 Screw the remaining hex head bolts into the right and left camshaft section flanges by hand.................... 359 2.16 After installing the last camshaft section:.................................................................... 359 2.16.1 Place the intermediate piece (Fig. 2/12) on the camshaft section (3) securely. The recess ............... 359 2.16.2 Insert the hex head bolts (1) into the connection between the camshaft section and the int............... 359 2.16.3 Install the oscillation damper (10 ) (04.09.01.nn)....................................................... 360 2.17 Install valve actuators and the injection pump drives.......................................................... 359 2.18 Install the lifters............................................................................................ 360 2.19 Install the rocker arms and check valve clearance (01.01.01.nn)................................................ 360 2.20 Install injection pump (07.02.01.nn)........................................................................... 360 2.21 Check oil flow through camshaft................................................................................ 360 2.22 Mount housing cover............................................................................................ 360 2.23 Close indicator valves......................................................................................... 360 2.24 Remove turning unit (12.08.01.nn).............................................................................. 360 1. Checking the tooth profiles and oil nozzles...................................................................... 361 1.1 Remove the timing cover from the control and exhaust side................................................... 361 1.2 Check the tooth profiles on the camshaft gear (Fig.1/2), step gear (1) and crankshaft gear (............... 362 1.3 Measure the tooth clearance between the step gear and the camshaft gear (2) and between the s............... 362 1.4 Check the function and seat of the oil nozzles (4 and 5).................................................... 362 2. Measure the axial clearance of the step gear (Fig. 2/s) with a feeler gauge or dial gauge. Nom........................... 363 2.1 Check the gaskets and install the timing gear cover on the exhaust and control side................................. 363 1. Replace the O-ring (Fig. 2/6) on the step gear shaft (2)............................................................. 365 1.1 Loosen the hex head bolts (7 and 8) and remove with sleeves (5) and locking plates (3 and 4).................... 365 1.2 Remove the crankcase cover for the 1st cylinder................................................................. 365 1.3 Press the step gear shaft (2) out of the gear housing towards the coupling only far enough th................... 365 1.4 Replace the O-ring (6) and slide the gear shaft back into place................................................. 365 Attention: Do not damage the O-ring (6)..................................................................................... 366 1.5 Apply Molykote to the contact surfaces and threads of the hex head bolts (7 and 8).................................. 366 1.6 Mount hex head bolts (7) and hex head bolts (8) with sleeves(5) and locking plates (3 and 4)....................... 366 1.7 Tighten hex head bolts (7 and 8) to M = 190 Nm.................................................... 366 1. Disassembly.......................................................................................................... 367 1.1 Detach governor floater linkages from governor (Fig. 1/10) This is achieved by:................................. 367 1.1.1 Locking stop lever in stop position....................................................................... 367 1.1.2 Removing locking nut (1) with distance bushing (4), bolt (6) and washer (2)............................... 367 1.1.3 Removing spring link (7).................................................................................. 367 1.2 Removing hexagonal screws (11) and lifting governor (10)........................................................ 367 1.3 Removing hexagonal screws (Fig. 2/20) with resilient sleeves (21)............................................... 368 1.4 Lightly attach governor drive housing (23) with sling to hoist and carefully lift out of cyli................... 368 1.5 Deposit governor drive housing (23) onto suitable surface....................................................... 368 1.6 Clean bearing surfaces on engine block.......................................................................... 368 1.7 Check tooth profiles of hypoid gears (Fig. 3/40, 41) for pitting, off-track running or blow- ................... 369 1.8 Check channel toothing of governor drive shaft (43) and governor (Fig. 1/10) for wear, clean ................... 369 1.9 Check all oil lubrication holes for lubricating the governor drive gear and the hypoid gears ................... 369 2. Assembly............................................................................................................. 370 2.1 Provide lubricating oil passage sleeve (Fig. 2/30) with new O-rings (31)........................................ 370 2.2 Place governor drive housing (23) carefully onto engine block by means of a crane. During thi................... 370 2.3 Insert screws (Fig. 2/20) with resilient sleeves (21)........................................................... 370 2.4 Tighten screws (20) crosswise................................................................................... 370 2.5 Brush bearing surface of governor with “Dirko 610.020“. Put governor (Fig. 1/10) onto bearing................... 370 2.6 Insert screws (Fig. 1/11) and tighten firmly.................................................................... 370 2.7 Fit governor floater linkages in reverse order to removal. If necessary, carry out readjustme................... 370 1. Disassembly...................................................................................................... 371 1.1 Remove lateral and face casing covers....................................................................... 371 1.2 Release screws (2) and remove together with extension sleeves (3)........................................... 371 1.3 Lift the vibration damper (1) off the intermediate piece (4). Remove distance ring (5)...................... 371 2. Reassembly....................................................................................................... 371 2.1 Clean contact face of damper (1) and intermediate piece (4) (fat free)...................................... 371 2.2 Lubricate the thread of screw (2) with Molykote-Paste "G-Rapid"............................................. 371 2.3 Mount distance ring (5)..................................................................................... 372 2.4 Push new damper (1) onto intermediate piece (4) and screw in screws (2) with extension sleeves.............. 372 2.5 Tighten screws (2) with a torque of ............... 372 2.6 Mount lateral and face casing covers........................................................................ 372 1. Remove the control shaft, injection pump and operator stand covers................................................... 373 2. Check the control shaft and shaft to emergency stop lever in the operating console and oil lig....................... 373 3. Grease the following bearings with multi-purpose grease: • Jointed heads on the connecting rod....................... 373 4. Oil all movable bearings on the jointed lever between the control shaft and injection pump lig....................... 373 5. Reinstall cover...................................................................................................... 373 1. Close the main shut-off valve on the air receiver.................................................................... 375 1.1 Vent the air pipes on the engine................................................................................ 375 1.2 Disassemble all pipework and cable connections from the starting valve.......................................... 375 2. Unscrew the screws (Fig. 1/1) and disassemble the starting valve from the engine..................................... 375 3. Disassemble the protective cover (Fig. 2/2).......................................................................... 376 3.1 Disassemble the silencer (3) and remove the solenoid (4)........................................................ 376 3.2 Disassemble the armature (5) by slackening the screw connection (6). Pay attention to the spr................... 376 3.3 Slacken the screw connection (8) and pull out the emergency actuation knob (9). Pay attention................... 376 3.4 Disassemble screw connection (11) and nut (12).................................................................. 376 3.5 Disassemble piston (13) by means of the fork wrench (W1)........................................................ 376 3.6 Unscrew the hexagon socket screws (16) and disassemble flange (17). Pay attention to the spri................... 376 3.7 Remove the spindle (14) completely from the casing.............................................................. 376 4. Clean the casing by means of gas oil. Check the sliding surfaces for rust formation, ifnecess....................... 376 5. Renew all O-rings, piston guide ring (19) and other sealing rings. Grease the sliding surfaces....................... 377 5.1 Insert a new, completely assembled spindle (14)................................................................. 377 5.2 Assemble all valve parts in inverse disassembly order........................................................... 377 5.3 Assemble the emergency actuation knob (9) with a new spring (10) and a new O-ring (20).......................... 377 5.4 Put the finish assembled valve onto the engine. Firmly tighten the screws (Fig. 1/1)............................ 377 5.5 Mount all pipe and cable connections............................................................................ 377 5.6 Mount the protective cover (Fig. 2/2)........................................................................... 377 6. Open the main shut-off valve on the air receiver..................................................................... 377 7. Carry out a functional and leakage test with starting air............................................................ 377 1. Remove bushings (1).................................................................................................. 378 1.1 Disassemble the connection between the injection pump control rod (Fig.1/7) and jointed leve................... 378 1.2 Remove the bracket (6) from the jointed lever................................................................... 378 1.3 Remove the bushings (Fig. 2/1) from the bracket (6)............................................................. 378 2. Install bushings (1)................................................................................................. 378 2.1 Place new bushings (1) into the bracket(6)..................................................................... 378 2.2 Connect the bracket (6) to the jointed shaft by installing the pin(3), the sliders (4 and 5)................... 378 2.3 Connect the bracket (6) to the injection pump control rod by installing the pin (3), the slid................... 379 1. Drain compressed-air filte........................................................................................... 381 1.1 Loosen drain plug (7) and empty filter completely............................................................... 381 1.2 Close drain plug................................................................................................ 381 2. Disassemble compressed-air filter and clean.......................................................................... 381 2.1 Loosen drain plug (7) and drain filter completely............................................................... 381 2.2 Close compressed-air feed line and secure....................................................................... 381 2.3 Relieve compressed-air filter via drain plug.................................................................... 381 2.4 Loosen housing cap (5) and remove, check O-ring (1) and replace if necessary.................................... 381 2.5 Loosen Phillips screw (4), remove with guide (3) and filter element (2)......................................... 381 2.6 Remove locking ring (8), unscrew drain plug and check O-ring (6), replace if necessary.......................... 381 2.7 Clean all disassembled parts and check for reuse................................................................ 381 2.8 Assemble compressed-air filter in reverse sequence. Open shut-off valve in the compressed-air................... 381 2.9 Close drain plug after a short while............................................................................ 381 1. Remove the exhaust line shroud....................................................................................... 382 2. Check all bolted connections to make sure that they are tight........................................................ 382 3. Carbon, which can especially be found at flange connections and compensators, is a sign of leaks..................... 383 4. Replace any defective exhaust lines as follows:...................................................................... 383 4.1 Loosen and remove adjacent compensators (4). Compensators may not be subjected to bending or ................... 383 4.2 Loosen the hex head bolts (1) far enough that the upper sections of the clamps (3) are still ................... 383 4.3 Slide the upper sections of the clamps aside, remove the chain links (2) from the lower clamp................... 383 4.4 Lift both upper clamp sections simultaneously, replace defective exhaust line................................... 383 4.5 Prepare fitted pieces (x or y) for the installation of the new exhaust line. Fitted piece len................... 383 4.6 Bolt fitted piece or pieces to new exhaust line................................................................. 384 4.7 Mount exhaust gas pipe with new seal (5) and clamp tops......................................................... 384 4.8 Remove fitted piece or pieces, install compensator(s) and bolt securely into place. - Note th................... 384 4.9 Tighten screws (6) with a torque of M = 13................... 384 4.10 Tighten screws (7) with a torque of M = 2................... 384 5. Replace any compensators with cracks in the bellows, see 4.8......................................................... 384 6. Install shroud....................................................................................................... 384 1. Disassembly.......................................................................................................... 385 1.1 Loosen the bleeder bolts, or for engines with continual bleeding, ensure that the correspondi................... 385 1.2 Remove the coolant feed and return lines(4) from the charge air cooler.......................................... 385 1.3 Remove hexagon screws (Fig. 2/28) with washers (37)............................................................. 386 1.4 Pull the charge air cooler (9) out of the housing (3), suspend with hoist and lower into suit................... 386 1.5 Clean the charge air cooler in accordance with the manufacturer's instructions (see BookC)..................... 386 1.6 Inspect the housing, drain all condensation by opening the drain line........................................... 386 2. Assembly............................................................................................................. 387 2.1 Install charge air cooler in the reverse order as disassembly................................................... 387 2.2 Insert new O-ring (8) into O-ring sheet (9)..................................................................... 387 2.3 Slide charge air cooler (2) into the housing (3) carefully...................................................... 387 2.4 Insert hexagon screws (28) with washers (37).................................................................... 387 2.5 Tighten hexagon screws (28) one after the other to a torque of M = 130 Nm....................................... 387 2.6 Attach coolant supply and return lines (4) to the charge air cooler............................................. 387 2.7 Tighten drain bolts (5) and fill engine completely with coolant................................................. 387 2.8 Tighten bleeder bolts or the corresponding cock valves tightly.................................................. 387 1. Disassembly.......................................................................................................... 388 1.1 Loosen the bleeder bolts, or for engines with continual bleeding, ensure that the correspondi................... 388 1.2 Remove the coolant feed and return lines(4) from the charge air cooler.......................................... 388 1.3 Remove hexagon screws (Fig. 2/28) with washers (37)............................................................. 389 1.4 Pull the charge air cooler (9) out of the housing (3) on exhaust gas side until the flange co................... 389 1.5 Clean the charge air cooler in accordance with the manufacturer's instructions (see BookC)..................... 389 1.6 Inspect the housing, drain all condensation by opening the drain line........................................... 389 2. Assembly............................................................................................................. 390 2.1 Install charge air cooler in the reverse order as disassembly. Be careful on the alignment of................... 390 2.2 Insert new O-ring (Fig. 2/8) into O-ring sheet (9).............................................................. 390 2.3 Slide charge air cooler (2) into the housing (3) carefully...................................................... 390 2.4 Insert hexagon screws (28) with washers (37).................................................................... 390 2.5 Tighten hexagon screws (28) one after the other to a torque of M = 130 Nm....................................... 390 2.6 Attach coolant supply and return lines (Fig. 1/4) to the charge air cooler...................................... 390 2.7 Tighten drain bolts (5) and fill engine completely with coolant................................................. 390 2.8 Tighten bleeder bolts or the corresponding cock valves tightly.................................................. 390 1. Remove cap (1) from water container (2).............................................................................. 392 1.1 Fill water container (2) with clean water....................................................................... 392 1.2 Return cap (1) to its position and tighten...................................................................... 392 2. Push valve handle (3) against the spring and hold for approx. 10 seconds until the entire wate....................... 393 Prerequisites: - wet cleaning............................................................................................... 395 Notes on the cleaning procedure:............................................................................................ 396 Cleaning procedure.......................................................................................................... 397 Note........................................................................................................................ 397 Sequence:................................................................................................................... 397 1. Wait for 10 to 15 minutes until after the exhaust gas temperature has stabilized and is below ....................... 397 2. Control valve (1) on the control panel is locked in the “Operation (air)“position.................................... 397 3. Shut-off valve (4) is closed......................................................................................... 397 4. Connecting the water supply to shut-off valve (4) before pressure meter (5). Check if the wate....................... 397 5. Open drain valve (3)................................................................................................. 398 6. Open shut-off valve (4); pressure meter (5) should indicate a pressure of p = 2,0 ± 0, 2 bar ........................ 398 7. Pull up on control valve (1) on the control panel and hold for 10 minutes............................................ 398 8. Check if exhaust gas temperature after turbocharger decreases........................................................ 398 9. Closing shut-off valve (4)........................................................................................... 398 10. Return control valve (1) on the control panel to its “Operation (air)“position...................................... 398 11. After approx. 5 minutes, close drain valve (3), completing this cleaning procedure.................................. 398 12. Disconnect the water supply completely, including shut-off valve (4) and pressure meter (5) f....................... 398 13. If necessary, the cleaning procedure may be repeated................................................................ 398 14. If the engine will not be operated for an extended period of time, the drying air may be turn....................... 398 1. Disassembly.......................................................................................................... 400 1.1 Open the indicator valves....................................................................................... 400 1.2 Remove corresponding camshaft casing cover on camshaft side..................................................... 400 1.3 Remove the high-pressure injection pipe (07.05.01.nn) .......................................................... 400 1.4 Mount the injection pump lifting device (Fig. 1/W1). To this end use the threaded holes for f................... 400 1.5 Turn the engine so that the cam follower (2) of the corresponding injection pump drive is on ................... 400 1.6 Close the shut-off valves....................................................................................... 401 1.7 Drain the fuel distributing/collecting line on the fuel duplex filter........................................... 401 1.8 Remove the lubricating oil leakage line (Fig. 2/10), fuel leakage line (Fig. 3/20, 21) and co................... 401 1.9 Remove the fuel distributing/collecting line (07.15.01.nn)...................................................... 401 1.10 Disassemble the connection (Fig. 5/40) between injection pump control rack (41) and control ................... 402 1.11 Push the control rack (41) as far as possible into the injection pump.......................................... 403 1.12 Put on the torque wrench (W2) and evenly slacken the nuts (5). Hydraulic pressure ................... 403 1.13 Attach the injection pump (6) with lifting device (W1) to a crane and lift from the engine b................... 403 1.14 Remove the sleeve (Fig. 5/50) with O-rings (51)................................................................ 403 2. Assembly............................................................................................................. 404 2.1 Clean the contact surfaces of the injection pump (Fig. 1/6) and the spacer plates (7)........................... 404 2.2 Clean the contact surfaces of the pressure spring (3) and the pushrod (8) on the tappet body ................... 404 2.3 Mount sleeve (Fig. 6/50) with new O-rings (51).................................................................. 404 2.4 Renew O-ring (Fig. 1/4) and put the injection pump over the fastening screws. Insert pushrod ................... 404 2.5 Lubricate thread and contact surfaces of the nuts (5) with Molykote paste and tighten the inj................... 404 2.6 Put on the torque wrench (W2) and tighten the nuts (5) one after the other with a hydraulic p................... 404 2.7 Screw together hinged lever (Fig. 5/42) and control rack (41) of the injection pump. Before a................... 404 2.8 Mount lubricating oil leakage line (Fig. 2/10), fuel leakage line (Fig. 3/20, 21) and control................... 404 2.9 Mount the high-pressure injection pipe (07.05.01.nn)............................................................ 404 2.10 Mount the fuel distributing/collecting line (07.15.01.nn)...................................................... 404 2.11 Mount the screws of the fuel filter lines (admission and return)............................................... 404 2.12 Check the control air pipe (Fig. 4/30) for the stop piston for leakage by means of compresse................... 405 2.13 Check stop piston / emergency stop device for correct function (10.03.01.nn)................................... 405 2.14 Mount the camshaft casing cover on camshaft side............................................................... 405 2.15 Open the shut-off valves....................................................................................... 405 2.16 Fill the fuel system by means of the stand-by pump and have it circulate the fuel for about ................... 405 2.17 Close the indicator valves..................................................................................... 405 1. Check the pressure valve..................................................................................... 407 1.1 Place the injection pump next to the injector testing unit (W2) with the help of a crane................ 407 1.2 Mount adapter (W6) on valve support (Fig. 1/20) and connect to testing unit (W2) via pressure........... 407 1.3 Pump to raise pressure to opening pressure pO and see if the pressure valve maintains the set........... 407 2. Disassembly.................................................................................................. 408 2.1 Clean the outside of the injection pump................................................................. 408 2.2 Remove deflector bolts (Fig. 1/6)....................................................................... 408 2.3 Check defector bolts for cavitation in the deflector surface, replace deflector bolts if nece........... 408 2.4 Clamp the injection pump with the valve support (20) down............................................... 408 2.5 Release and dismantle two opposite screws (Fig. 3/36)................................................... 408 2.6 Replace by longer screws (W5). (Assembly aid)........................................................... 408 2.7 Slowly dismantle the remaining screws (36).............................................................. 408 2.8 Slowly dismantle the assembly aid screws (W5)........................................................... 408 2.9 Carefully lift the bottom pump housing (4) by means of a crane, until the slotted disk (26) o........... 408 2.10 Take the slotted disk (26) sideways out of the foot of the pump plunger (50)........................... 408 2.11 Remove the pump spring and check for corrosion......................................................... 409 2.11.1 Remove the control sleeve (5) with spring plate (7).............................................. 409 2.11.2 Check the toothing in the control housing for damage............................................ 409 2.11.3 Loosen guide bolt (11), remove control rod (Fig. 2/10) and check control rod toothing for....... 409 2.12 Remove stop piston (15):............................................................................... 409 2.12.1 Loosen cap screws (44), remove stop (16) and cap screws.......................................... 409 2.12.2 Remove stop piston and control rod spring (Fig. 2/18)............................................ 409 2.13 Place the injection pump in the clamp with the vale support (Fig. 1/20) up............................. 409 2.14 Loosen and remove the cap screws (33) - inner screw hole circle - cross-wise........................... 409 2.15 Loosen and remove the cap screws (33) - outer screw hole circle - cross-wise and lift the va........... 409 2.16 Drive the pump element (1) out of the housing with a suitable wooden dowel............................. 409 2.17 Clean all parts with gas oil and a stiff brush and blow out with compressed air........................ 409 2.18 Replace all O-rings and gaskets........................................................................ 409 2.19 Remove the pressure piece (24) completely with the cap screws (27), slotted disks (26) and s........... 409 2.20 Reinstall the complete pressure piece after replacing the gaskets...................................... 409 3. Assembly..................................................................................................... 410 3.1 The pump is assembled in the reverse order as disassembly.............................................. 410 3.1.1 Apply engine oil to the threads and contact surfaces of the following bolts and tighten to ....... 410 3.1.2 Check the action of the control rod (10); must be smooth.......................................... 410 1. Remove deflector bolts........................................................................................... 411 1.1 Check deflector bolts (6) for cavitation (Y) of the deflection surfaces (X)................................. 411 1.2 Maximum permissible wear value s = 4 mm..................................................................... 411 1.3 To check this use the depth gauge of the caliper gauge...................................................... 412 1.4 When the above wear value is reached, replace deflector bolts (6) with new ones............................. 412 2. Mount deflector bolts............................................................................................ 412 2.1 Lightly lubricate thread and contact faces of the deflector bolts with engine lubricating oil............... 412 2.2 Tighten new deflector bolts (6) by hand..................................................................... 412 2.3 After that, tighten deflector bolts to a torque of ............... 412 1. Disassembly...................................................................................................... 413 1.1 Close shut-off valves of the fuel line...................................................................... 413 1.2 Empty the fuel distributing and collecting pipe on the fuel duplex filter................................... 413 1.3 Remove the fuel injector delivery pipe of the corresponding injection pump (07.05.01.nn).................... 413 1.4 Remove cheese head srews (1 und 2).......................................................................... 414 1.5 Remove valve support (3). Pay attention to dowel pins (5)................................................... 414 1.6 Remove pressure valve (4)................................................................................... 414 2. Assembly......................................................................................................... 414 2.1 Insert new pressure valve (4) into valve support (3)........................................................ 414 2.2 Replace O-ring (6).......................................................................................... 414 2.3 Put valve support (3) onto injection pump. Pay attention to dowel pins (5).................................. 414 2.4 Lubricate threads and contact faces of cheese head screws (1 und 2) with engine lubricating oil............. 414 2.5 Tighten cheese head screws (1) crosswise to a torque of M = 190 Nm.......................................... 414 2.6 Tighten cheese head screws (2) crosswise to a torque of M = 190 Nm.......................................... 414 2.7 Replace O-ring (7).......................................................................................... 414 2.8 Mount fuel injector delivery pipe (07.05.01.nn)............................................................. 414 2.9 Open shut-off valves of the fuel line....................................................................... 414 1. Disassembly...................................................................................................... 416 1.1 Valve cover is removed...................................................................................... 416 1.2 Disassemble the fillister head screws (Fig. 2/1) with cover (3) and O-ring (2).............................. 417 1.3 Loosen the clamping screw (4) (about 5 turns)............................................................... 417 1.4 Loosen the pressure screw (6) and disassemble it............................................................ 417 1.5 Take the transverse thrust piece (15) out of the receptacle (14)............................................ 417 1.6 Screw the cap screw (8) out of the cylinder head/injection nozzle holder (20)............................... 417 1.7 Take the complete radial thrust piece (13) with cap screw (8) out of the cylinder head throug............... 417 1.8 Disassemble the spring ring (10) from the cylinder head and take out the sleeve (12)........................ 417 1.9 Remove the fillister head screws (16) and carefully draw the receptacle (14) off the injectio............... 417 2. Reassembly....................................................................................................... 418 2.1 Renew the O-rings (2, 5, 7, 9, 11).......................................................................... 418 2.2 Daub the O-rings and sealing faces with "Molykote".......................................................... 418 2.3 All high-pressure surfaces must be free of dirt and damages................................................. 418 2.4 Daub the threads of cap screw (8), pressure screw (6), and clamping screw (4) slightly with "............... 418 2.5 Insert the sleeve (12) into the cylinder head and lock by means of the spring ring (10)..................... 418 2.6 Put the receptacle (14) onto the injection pump connection (17) and tighten the fillister hea............... 418 2.7 Introduce the complete radial thrust piece (13) with cap screw (8) through the receptacle (14............... 418 2.8 Screw the cap screw (8) into injection nozzle holder (Fig. 1/20) with a torque of M = 250 Nm................ 418 2.9 Insert the transverse thrust piece (15) into the receptacle (14)............................................ 418 2.10 Screw the pressure screw (6) and the clamping screw (4) evenly and alternately by hand into ............... 418 2.11 Tighten the pressure screw (6) and the clamping screw (4) alternately and step by step start............... 419 2.12 Tighten the fillister head screws (16)..................................................................... 419 2.13 Tighten cover (3) and O-ring (2) by means of fillister head screws (1)..................................... 419 2.14 Check the injection system for leakage and reassemble the valve cover...................................... 419 1. Disassembly...................................................................................................... 420 1.1 Remove the valve cover...................................................................................... 420 1.2 Loosen hexagon nuts (Fig. 1/1), remove extension sleeves (12) and flange (3)................................ 420 1.3 Reassemble extension sleeves (12)........................................................................... 420 1.4 Bolt the injector valve pulling unit (Fig. 2/W1) securely to the adjuasting screw (Fig. 1/8) ............... 420 1.4.1 Put in place the complete unit........................................................................ 421 1.4.2 Loosen the hexagon head bolts (Fig. 2/ 20) a bit and firmly screw the threaded pieces (21) ........... 421 1.4.3 Firmly tighten the hexagon head bolts (20)............................................................ 421 1.4.4 Firmly screw the threaded rod (22) onto the adjusting screw (Fig. 1/8)................................ 421 1.4.5 Place the torsional lock (Fig. 2/23) on the hexagon of the threaded rod (22).......................... 421 1.5 Disassemble high-pressure injection pipe (07.05.01.nn)...................................................... 421 1.6 Loosen the injector valve by turning the threaded sleeve (24) by means of wrench (25) and scr............... 421 1.7 Remove hexagon head bolts (Fig. 2/20)....................................................................... 421 1.8 Pull out injector valve with pulling unit................................................................... 421 1.9 Remove the pulling unit completely and reassemble it........................................................ 421 1.10 Clean the injector valve externally, mark it with the cylinder number and carry out a functi............... 421 1.11 Clean the injector seat (Fig. 1/9) in the sleeve (6) by scraping with tool (W2). Clean the i............... 421 2. Assembly......................................................................................................... 421 2.1 Replace O-rings (7)......................................................................................... 421 2.2 Apply a thin coat of high temperature thread paste to the injector seat, injector element (Fi............... 422 2.3 Apply a thin coat of Molykote paste to the threads fo the studs (2), contact surfaces of the ............... 422 2.4 Place injector valve in sleeve, note the position of the locking pin (Fig. 5/10)............................ 422 2.5 Install flange (Fig. 1/3) with the dowel pin (Fig. 5/11) to the exhaust side and the ring sho............... 422 2.6 Install the sleeves (Fig. 1/12)............................................................................. 422 2.7 Tighten the hex head nuts (1) evenly by hand. Make sure that the flange (3) rests flush on th............... 422 2.8 Install injector line (07.05.01.nn)......................................................................... 422 2.9 Tighten the nuts (1) to M = 60 Nm in two steps.............................................................. 422 2.10 Check fuel line for leaks.................................................................................. 422 2.11 Install cylinder head cover................................................................................ 422 1. Remove carbon deposits from the nozzle with a hard brush (no wire brush)......................................... 424 2. Check the nozzle hole for sharp edges, ovalization, corrosion and damage......................................... 424 3. Place the injector with the adapter (W2) in the tester (W1)...................................................... 424 4. Connect the injector delivery pipe(W3).......................................................................... 424 5. Increase the pressure gradually until the nozzle opens. Injector opening pressure, see accepta................... 424 5.1 If the opening pressure is not correct, slacken the lock nut (1) and turn the adjusting screw............... 424 1. Disassembly.................................................................................................. 426 1.1 Insert fuel injector (Fig. 1/13) into retainer (W1). In doing so fit tightly into insert (W3)........... 426 1.2 Mount flange (2) with hexagon screws (1) and tighten the hexagon head screws............................ 426 1.3 Slacken nut (3) and relieve nozzle spring (4) by unscrewing the setting screw (11)...................... 426 1.4 Put hexagon spanner (W4) on the key face (Fig. 1/16) of insert (W3) and slacken nozzle nut (F........... 426 1.5 Take off hexagon spanner (W4) and remove nozzle nut..................................................... 426 1.6 Take out nozzle element (Fig. 2/8) including nozzle needle (12) without damaging the lapped s........... 426 1.7 Slacken hexagon head screws (Fig. 1/1) and remove with flange (2)....................................... 426 1.8 Take fuel injector out of retainer (W1)................................................................. 426 1.9 Remove adjusting screw (Fig. 2/11), remove spring guide (10), injector spring (4) and pressur........................... 427 1.10 Inspect injector spring (4) and pressure pin (5)....................................................................... 427 1.11 Clean all parts with gas oil........................................................................................... 427 1.12 Place injector needle (12) into nozzle (8) with gas oil and check to see if the needle sinks........................... 427 1.13 All parts, especially injector needle and sealing surfaces, must be inspected. Replace any d........................... 427 2. Assembly............................................................................................................. 427 2.1 Dry all sealing surfaces with lint free paper........................................................................... 427 2.2 Install new O-rings (9) and (14) with Molykote paste.................................................................... 427 2.3 The fuel injector is installed in the reverse order as disassembly...................................................... 427 2.4 Apply high temperature paste to the outer threads of the fuel injector (13)............................................. 427 2.5 Place fuel injector in retainer (Fig. 3/W1)............................................................................. 427 2.6 Mount flange (2) with hexagon head screws (1) and tighten the screws.................................................... 427 2.7 Put on complete nozzle element (Fig. 2/8+12). Observe position of the pins (7)...................................... 428 2.8 Unscrew nozzle nut (6) and tighten by hand.......................................................................... 428 2.9 Put torque wrench (Fig. 3/W2) on nozzle nut (Fig. 2/6) and tighten with a pressure of p = 465....................... 428 2.10 Slacken hexagon head screws (Fig. 3/1) and remove with flange (2).................................................. 428 2.11 Take fuel injector out of retainer (W1)............................................................................ 428 2.12 Check / adjust fuel injector according to 07.08.01.nn ............................................................. 428 1. Change the filter over (see the plate on the filter cover)........................................................... 429 2. Cleaning............................................................................................................. 429 2.1 Clean the filter when it is still warm from operation and....................................................... 429 2.2 Cleaning the filter with built-in cartridges.................................................................... 430 2.2.1 Remove the cover (2) from the shut-off filter chamber. Remove contaminated liquid by openin............... 430 2.2.2 Remove filter insert...................................................................................... 430 2.2.3 Connect cleaning pistol (Fig. 2/W1) to compressed-air supply and load. (6 - max. 10 bar).................. 430 2.2.4 Shift the spouting guard (13) to the stop on the pistol nozzle, put it into the cartridge o............... 430 2.2.5 Replace seals and mount cover............................................................................. 430 2.2.6 Fill the filter chamber and vent it (see the plate on the filter cover)................................... 430 2.3 Cleaning the filter with cartridges removed (every 3rd cleaning)................................................ 430 2.3.1 Open sludge drain and empty filter chamber................................................................ 430 2.3.2 Remove filter insert...................................................................................... 430 2.3.3 Flush the filter chamber with gas oil..................................................................... 430 2.3.4 Put the filter insert in a container filled with a suitable cleansing liquid. The cleansing............... 431 2.3.5 Take the filter insert out of the cleansing container and blow out cartridges (14) with the............... 431 2.3.6 Submerge filter insert again in clean cleansing liquid, let it drip off and then blow it ou............... 431 2.3.7 Intermittent check of cartridges for damage (operation sequence 2.4)...................................... 431 2.3.8 Place filter insert in filter chamber, mount cover, replace seals if necessary............................ 431 2.3.9 Fill filter chamber and vent (see plate on filter cover).................................................. 431 2.4 Cleaning of cartridges in the case of persistent fouling........................................................ 431 2.4.1 Soak filter insert in cleansing liquid (max. 4 h)......................................................... 431 2.4.2 Loosen base plate and carefully remove protective jacket from filter insert............................... 431 2.4.3 Remove cartridges (14) with the drift (Fig. 3/W2) downwards and tilt them out. Remove the O............... 431 2.4.4 Inspect the cartridges and replace them if damaged or if the gauze is badly crinkled...................... 431 2.4.5 Connect cleaning pistol (Fig. 2/W1) to compressed-air supply. Air pressure max. 10 bar.................... 431 2.4.6 Introduce the cleaning pistol into the cartridge, pull the trigger and move down to the bot............... 432 2.4.7 Remove sticking dirt with a soft brush.................................................................... 432 2.4.8 Rinse the cartridges in clean cleaning fluid, blow them out and let them dry with the openi............... 432 2.4.9 Put a strong light behind the gauze and check the cleaning operation. Repeat it if necessary.............. 432 2.4.10 Install cartridges in reverse sequence as described under 2.4.3. O-ring between element pl............... 432 3. Check the seal between the element plate and filter housing and replace if necessary................................. 432 4. Mount filter insert in filter chamber................................................................................ 432 5. Fit cover (replace seal)............................................................................................. 432 6. Fill the filter chamber and vent it (see the plate on the filter cover).............................................. 432 1. Disassembly.......................................................................................................... 433 1.1 Remove pump area shroud......................................................................................... 433 1.2 Close shut-off valve............................................................................................ 433 1.3 Drain fuel distributor line by means of the leakage line........................................................ 433 1.4 Remove the fuel leakage line (Fig. 1/1) at the flange........................................................... 433 1.5 Remove the fuel line at the flange (Fig. 2/4)................................................................... 434 1.6 Loosen the locking rings (6) and slide towards the middle of the line........................................... 434 1.7 Slide the fuel line (Fig. 1/5) to the side with a 55mm open jawed wrench and then remove........................ 434 1.8 Loosen hex head bolts (Fig. 2/10)............................................................................... 434 1.9 Remove the hex head bolts and pull the flange (2) from the injection pump bushings (3).......................... 434 1.10 Remove the bushings (3) with the O-rings (7) and support ring (11)............................................. 434 1.11 Remove fuel lines (supply and return).......................................................................... 435 1.12 Loosen cap screws (9).......................................................................................... 435 1.13 Remove cap screws and pull the flange (4) from the injection pump bushing (3). Remove O-ring................... 435 1.14 Remove the bushings (3) with the O-rings (7) and support ring (11)............................................. 435 2. Assembly............................................................................................................. 435 2.1 Check the O-rings (7) and (8) on the injection pumps for damage. Replace if necessary........................... 435 2.2 Insert bushings (3) with O-rings (7) and support ring (11) into the injection pump / flange..................... 435 2.3 Apply Molykote to hex head bolts (10)........................................................................... 435 2.4 Install flange (2) with hex head bolts.......................................................................... 435 2.5 Tighten bolts to M = 130 Nm..................................................................................... 435 2.6 Insert bushings (3) with O-rings (7) and (8) and support ring (11) into the injection pump / ................... 435 2.7 Mount flange with cap screws (9)................................................................................ 435 2.8 Tighten cap screws to M = 130 Nm................................................................................ 435 2.9 Insert O-rings (12). Install fuel lines (supply and return)..................................................... 435 2.10 Insert fuel line with O-rings (8), support ring (11) and locking rings (6)..................................... 435 2.11 Turn locking rings firmly into locked position................................................................. 435 2.12 Mount fuel leakage line (Fig. 1/1) on flange (2)............................................................... 435 2.13 Open shut-off valve............................................................................................ 435 2.14 Fill fuel system with reserve pump and bleed air from system by circulating fuel with reserv................... 435 2.15 Install pump area shroud....................................................................................... 435 1. Disassembly.......................................................................................................... 436 1.1 Drain lube oil system........................................................................................... 436 1.2 Remove suction (Fig. 1/4) and pressure lines (2)................................................................ 436 1.3 Loosen hex nuts (1) and pull lube oil pump (3) with gear (6) from the cylinder crank case. Wa................... 436 1.4 Loosen hex bolt (7) and pull gear (6) from the drive gear shaft (Fig. 2/10) using puller........................ 437 1.5 Check tooth faces for wear (pitting, unevenness, spalling)...................................................... 437 1.6 Loosen bolts (16,18). Remove cover (21) und cover (17) from pump housing (20)................................... 437 1.7 Remove drive gear (10) and impeller shaft (19).................................................................. 437 1.8 Check bushes (11, 14, and 15), bearing areas of drive and impeller gear shafts for wear and r................... 437 2. Assembly:............................................................................................................ 438 2.1 Assemble lube oil pump by reversing above steps................................................................. 438 2.2 Mount cover (21). Tighten hex bolts (18) to a torque of M = 410 Nm.............................................. 438 2.3 Mount cover flange (17). Tighten hex bolts (16) to a torque of M = 206 Nm...................................... 438 2.4 Before mounting gears, check wear pattern between gear cone (Fig. 1/6) and drive gear shaft c................... 438 2.5 Clean, degrease and dry gear cone and drive gear cone shaft..................................................... 438 2.6 Place gear (Fig. 1/6) on drive gear shaft cone, measure dimension S (Fig. 1/X) and note down.................... 438 2.7 Heat gear by approx. 110 C to 120 C above the temperature of the drive gear shaft and shrin................... 438 2.8 Then immediately mount hex bolt (7) with washer (8) and tighten to a torque of ................... 438 2.9 After the connection has cooled down to room temperature, loosen hex bolt (7). Then coat thre................... 438 2.10 Check distance S; it should be smaller than measured under 2.6 by 0.57 - 0.67 mm (sliding tr................... 439 2.11 Clean pump flange surface (Fig. 2/17) and pump support surface (Fig. 1/5) and coat with seal................... 439 2.12 Carefully insert lube oil pump (3) with gear (6) into the cylinder crankcase (tooth faces of................... 439 2.13 Install resilient sleeves. Coat hex nuts (1) and bolt threads with „G-Rapid Plus“ Molykote p................... 439 2.14 Install suction (4) and pressure (2) lines using new seals..................................................... 439 2.15 Fill with new lube oil (for lube oil quality see A4.05.08.nn) to the mark on the circulating................... 439 2.16 Refill lube oil system and start lube oil prelube pump. Purge air from system. Check system ................... 439 2.17 Check lube oil supply to gears................................................................................. 439 1. Change the filter over (see the plate on the filter cover)........................................................... 440 2. Cleaning............................................................................................................. 440 2.1 Clean the filter when it is still warm from operation and....................................................... 440 2.2 Cleaning the filter with built-in cartridges.................................................................... 441 2.2.1 Remove the cover (2) from the shut-off filter chamber. Remove contaminated liquid by openin............... 441 2.2.2 Remove filter insert...................................................................................... 441 2.2.3 Connect cleaning pistol (Fig. 2/W1) to compressed-air supply and load. (6 - max. 10 bar).................. 441 2.2.4 Shift the spouting guard (13) to the stop on the pistol nozzle, put it into the cartridge o............... 441 2.2.5 Replace seals and mount cover............................................................................. 441 2.2.6 Fill the filter chamber and vent it (see the plate on the filter cover)................................... 441 2.3 Cleaning the filter with cartridges removed (every 3rd cleaning)................................................ 441 2.3.1 Open sludge drain and empty filter chamber................................................................ 441 2.3.2 Remove filter insert...................................................................................... 441 2.3.3 Flush the filter chamber with gas oil..................................................................... 441 2.3.4 Put the filter insert in a container filled with a suitable cleansing liquid. The cleansing............... 442 2.3.5 Take the filter insert out of the cleansing container and blow out cartridges (14) with the............... 442 2.3.6 Submerge filter insert again in clean cleansing liquid, let it drip off and then blow it ou............... 442 2.3.7 Intermittent check of cartridges for damage (operation sequence 2.4)...................................... 442 2.3.8 Place filter insert in filter chamber, mount cover, replace seals if necessary............................ 442 2.3.9 Fill filter chamber and vent (see plate on filter cover).................................................. 442 2.4 Cleaning of cartridges in the case of persistent fouling........................................................ 442 2.4.1 Soak filter insert in cleansing liquid (max. 4 h)......................................................... 442 2.4.2 Loosen base plate and carefully remove protective jacket from filter insert............................... 442 2.4.3 Remove cartridges (14) with the drift (Fig. 3/W2) downwards and tilt them out. Remove the O............... 442 2.4.4 Inspect the cartridges and replace them if damaged or if the gauze is badly crinkled...................... 442 2.4.5 Connect cleaning pistol (Fig. 2/W1) to compressed-air supply. Air pressure max. 10 bar.................... 442 2.4.6 Introduce the cleaning pistol into the cartridge, pull the trigger and move down to the bot............... 443 2.4.7 Remove sticking dirt with a soft brush.................................................................... 443 2.4.8 Rinse the cartridges in clean cleaning fluid, blow them out and let them dry with the openi............... 443 2.4.9 Put a strong light behind the gauze and check the cleaning operation. Repeat it if necessary.............. 443 2.4.10 Install cartridges in reverse sequence as described under 2.4.3. O-ring between element pl............... 443 3. Check the seal between the element plate and filter housing and replace if necessary................................. 443 4. Mount filter insert in filter chamber................................................................................ 443 5. Fit cover (replace seal)............................................................................................. 443 6. Fill the filter chamber and vent it (see the plate on the filter cover).............................................. 443 1. Disassembly.......................................................................................................... 444 1.1 Loosen the cheese head screws (8) evenly to relieve the pressure spring (3)..................................... 444 1.2 Remove and dismantle the control valve (1)...................................................................... 444 1.2.1 Loosen the hexagon nut (18) and completely unscrew the spindle (19) by turning it counter- ............... 444 1.2.2 Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush............... 444 1.2.3 Remove the locking ring (9) and take out the piston (11) with washer (15) and pressure spri............... 444 1.2.4 Remove the screw plug (26) of the pilot control unit (A-A) with the sealing ring (25), wash............... 444 1.3 Clean all parts with gas oil and check them..................................................................... 445 1.4 Check the free passage of the control oil bore (12) in the pressure control valve and in the ................... 445 1.5 Check the valve seats, balls, piston seating as well as the slide faces and grind them if nec................... 445 2. Reassembly........................................................................................................... 446 2.1 Check the O-rings (2 and 7) and sealing ring (14) and replace them if necessary................................. 446 2.2 Assembly is effected in the reverse sequence of disassembly. Pay attention to the free moveme................... 446 2.3 Check the lubricating oil pressure at the pressure gauge on the control panel and adjust it i................... 446 3. Adjustment........................................................................................................... 446 3.1 Pressure to be set (see engine data A1.05)...................................................................... 446 3.2 Loosen the hexagon nut (18)..................................................................................... 446 3.3 Secure the setting with the hexagon nut (18).................................................................... 446 1. Carry out steps 1.1 and 1.2 simultaneously for approx. 5 min................................................. 447 1.1 Start the stand-by pump................................................................................. 447 1.2 Turn the engine by means of the barring gear............................................................ 447 1. Actuate emergency stop............................................................................................... 448 2. Check the position of the control rods............................................................................... 448 3. Check the stop piston (3) in the injection pump, press the control rod (2) into the injection ....................... 448 4. Actuate the "Reset“ button on the safety system...................................................................... 448 5. (Fig. 2/T3) Measuring point 6105 (function of the safety system) in the maintenance unit (C5.0....................... 449 5.1 Venting by loosening screw (13). If the shutdown air pressure is decreased below the switchin................... 449 6. Check the emergency stop by actuating the emergency stop lever (Fig. 3/20) on the control stand...................... 449 1. Note the rpm switch point setting. Loosen the pointer locking plate (2) and set the pointer (1....................... 450 2. Turn the pointer carefully to the left towards 0 rpm. When reaching the engine speed, the outp....................... 450 3. Set the pointer again at the original rpm switch point and lock it................................................... 450 4. The automatic cut-out F 1.1 and F 2.1 on the plug-in card A1 in the rpm switch installation mu....................... 450 5. Voltage check at the plug-in socket contacts of the plug-in frame.................................................... 450 5.1 Supply (24 V DC at contact z16 and z20, contact z20 positive)................................................... 450 5.2 PICK UP IMPULSE (dependent upon engine speed up to 1500 Hz at contact b14 and d14).............................. 451 1. Disassembly.......................................................................................................... 452 1.1 Drain lubricating oil/cooling water lines....................................................................... 452 1.2 Unscrew hexagon nuts (2) of housing cover (6)................................................................... 452 1.3 Remove cover (6) with O-ring (1)................................................................................ 452 1.4 Turn out thermostatic element (5) fromvalve housing (7)........................................................ 452 1.5 Wash parts in gas oil and blow them clean....................................................................... 452 1.6 Wipe clean thermostat housing with lint-free cloth and check for corrosion and deposits......................... 452 2. Functional check of thermostatic element............................................................................. 453 2.1 Put thermostatic element (Fig. 1/5) into a water bath of temperature of approx. 15 K aboveth................... 453 2.2 The thermostatic element (5) must open steadiliy................................................................ 453 3. Assembly............................................................................................................. 453 3.1 Repalce O-rings (1 and 9) and gasket (8)........................................................................ 453 3.2 Assembly is done in reverse order of disassembly................................................................ 453 3.3 Top up lubricating oil/cooling water system and check thermostat for leakages................................... 453 Maintenance and trouble shooting: refer to manual C..................................................................... 454 1. Dismantling...................................................................................................... 456 1.1 Dismantle the lubricant pump (08.03.02.nn).................................................................. 456 1.2 Dismantle lubricant piping and pump bearer plate (4), completely removing all silicon sealant............... 456 1.3 Drain the oil: • Turn oil flow boring to lower position (30). • For full drainage turn the da............... 456 1.4 Mark the position of the damper to the crankshaft........................................................... 456 1.5 Remove the antifatigue screws and fastening screws (1) (12)................................................. 456 1.6 Dismantle the pump wheel carrier (15) and pump gear wheel (14).............................................. 456 1.7 Remove fastening screws (13)................................................................................ 456 1.8 Remove the oscillation damper and forcing screw from the crankshaft and dismantle........................... 456 1.9 Dismantle side plates (18); forcing may be carried out through tapping bore holes........................... 456 1.10 Remove O rings (20 and 21)................................................................................. 456 1.11 Clean all parts thoroughly. Check oil flow bores and oil feed bores are clear.............................. 456 1.12 Measure gap (Fig. 2/"s" ) between spring ends and groove flanks of the interior using a feel............... 457 1.13 Apply an adequate quantity of "Loctite 275" to both sides of the cup spring (Fig. 1/22). Tig............... 457 2. Apply Molykote "Typ 60 G" across the inner side of the side plates (18).......................................... 458 3. Insert new greased O rings (20 and 21)........................................................................... 458 4. Set the side plates so that the oil flow bore holes are positioned between the oil feed bore h................... 458 5. Assembly of oscillation damper:.................................................................................. 458 5.1 Check the run-out tolerances of the vibration damper (Fig. 1)............................................... 458 5.2 Bleed the air from the oscillation damper:.................................................................. 458 5.3 Further assembly procedure takes place in reverse order from dismantling procedure.. Apply Mo............... 458 5.4 Apply "Dirco-Grau" silicon sealant to the pump bearer plate (4) , position over the tapered p............... 458 5.5 Assemble the lubricant pump (08.03.02.nn), check systems for sealing and check lubricant supp............... 458 1. Operating the turning device................................................................................. 460 1.1 Engaging the turning device............................................................................. 460 1.1.1 Move blockinglever (1) to position “V“ and hold................................................... 460 1.1.2 Move lever (2) to position“ X“, so that the gearwheel of the turning device engages complet....... 460 1.1.3 Let off blockinglever and make sure that the blockinglever engages in position “Z“................ 460 1.1.4 Turn the engine................................................................................... 460 1.2 Disengaging the turning device.......................................................................... 461 1.2.1 Move blockinglever (1) to position “V“ and hold................................................... 461 1.2.2 Move lever (2) to position“ Y “, so that the gearwheel of the turning device is disengaged ....... 461 1.2.3 Let off blockinglever and make sure that the blockinglever is engaged in position “Z“............. 461 2. Maintenance.................................................................................................. 462 2.1 Oil level check......................................................................................... 462 2.1.1 Check oil level at the oil level glas (10) and fill in gear oil ( e.g. Shell Omala Oil 460 ....... 462 2.2 Lubricating / greasing of shaft and gearwheel........................................................... 462 2.2.1 Grease the notch on the output shaft (9) and the gearwheel (3) with bearing grease by means....... 462 2.2.2 Coat toothing of gearwheel thinly with bearing grease............................................. 462 2.3 Oil change.............................................................................................. 462 2.3.1 Remove screw plug (5) on the driving gear of the turning device................................... 462 2.3.2 Drain the oil from the driving gear of the turning device......................................... 462 2.3.3 Mount the screw plug (5) with new gasket (6)...................................................... 462 2.3.4 Remove the vent socket (7) on the gear of the turning device...................................... 462 2.3.5 Fill in new oil (e.g. Shell Omala Oil 460 ; ca.9 l) up to the oil level mark (10)................. 462 2.3.6 Mount vent socket (7)............................................................................. 462 List of Measuring Points.................................................................................................... 906 -........................................................................................................................... 906 List of Measuring Points Engine............................................................................................. 919 Sensors and Actuators....................................................................................................... 919 Woodward Governor UG40DI.................................................................................................... 923 Checks and Tips............................................................................................................. 923 Governor.................................................................................................................... 927 UG40-Di..................................................................................................................... 927 Booster Servomotor.......................................................................................................... 994 -........................................................................................................................... 994 Oil - Regulations...........................................................................................................1031 (Woodward)..................................................................................................................1031 Three-position Controller...................................................................................................1056 Console Mounting............................................................................................................1056 Oil Detector for Cooling Water System.......................................................................................1122 BG0.00.6-93.22.00-03........................................................................................................1122 Electrical Equipment........................................................................................................1125 -...........................................................................................................................1125 Circuit diagram Motor.......................................................................................................1389 -...........................................................................................................................1389 Description.................................................................................................................1440 Engine Monitoring Devices...................................................................................................1440 Equipment List Engine.......................................................................................................1465 -...........................................................................................................................1465 Charge air preheating.......................................................................................................1471 -...........................................................................................................................1471 RPM Switch Unit.............................................................................................................1475 -...........................................................................................................................1475 Safety System...............................................................................................................1493 Description.................................................................................................................1493 Machinery control room......................................................................................................1518 -...........................................................................................................................1518 Engine Adjusting Valve......................................................................................................1524 -...........................................................................................................................1524 Turbocharger................................................................................................................1534 TPL76-C33 281251............................................................................................................1534 Charge Air Cooler...........................................................................................................1648 -...........................................................................................................................1648 Fuel Pump...................................................................................................................1665 -...........................................................................................................................1665 Plate Heat Exchangers.......................................................................................................2073 Description.................................................................................................................2073 Back-Flushing-Filter........................................................................................................2138 Automatic...................................................................................................................2138 Engine Adjusting Valve......................................................................................................2168 -...........................................................................................................................2168 Oil Mist Detector...........................................................................................................2178 -...........................................................................................................................2178 Engine Adjusting Valve......................................................................................................2327 -...........................................................................................................................2327 Engine Adjusting Valve......................................................................................................2337 -...........................................................................................................................2337 Please select target document for A3.06.06.nn:..............................................................................2347 • A3.06.06.02...........................................................................................................2347 • A3.06.06.04...........................................................................................................2347 • A3.06.06.31...........................................................................................................2347 Please select target document for A3.06.06.nn:..............................................................................2348 • A3.06.06.02...........................................................................................................2348 • A3.06.06.04...........................................................................................................2348 • A3.06.06.31...........................................................................................................2348 Please select target document for B1.05.06.43725n ??:.......................................................................2349 • B1.05.06.437250 KK....................................................................................................2349 • B1.05.06.437254 EE....................................................................................................2349 • B1.05.06.437259 ZR....................................................................................................2349 Please select target document for B1.05.07.438540 ??:.......................................................................2350 • B1.05.07.438540 MM....................................................................................................2350 • B1.05.07.438540 PP....................................................................................................2350 Please select target document for B1.05.07.438540 ??:.......................................................................2351 • B1.05.07.438540 MM....................................................................................................2351 • B1.05.07.438540 PP....................................................................................................2351 K A6.05.90.10.02 (PDF).pdf.................................................................................................. 0 Überprüfung der HochdruckkupplungsnippelChecki�........................................................................ 541 Normal verformter Dichtkonus am Gewindeadapter. Montagedrehmoment 50 Nm............................................. 542 Normally deformed sealing taper on the threaded adapter. Installation torque 50 Nm.................................. 542 Plastisch stark verformter Dichtkonus am Gewindea................................................................... 542 Montagedrehmoment 100 Nm............................................................................................ 542 Seriously deformed sealing taper on thread adapter. Here, the thread adapter and the nipple must be replaced........ 542 Einspannen der Hochdruckschlauchleitung in einem ................................................................... 543 Normal verformter Dichtkonus am Gewindeadapter. Montagedrehmoment 50 Nm............................................. 543 Plastisch stark verformter Dichtkonus am Gewindea................................................................... 543 Montagedrehmoment 100 Nm............................................................................................ 543 K C5.05.02.01.05.32 (PDF).pdf............................................................................................... 0 2 Load Reductions...................................................................................................... 911 3 Start Pumps / Functions.............................................................................................. 912 4 Safety relevant Alarms.............................................................................................. 913 5 Alarms............................................................................................................... 913 K C5.05.06.10.20.96 (PDF).pdf............................................................................................... 0 Preliminary remarks.....................................................................................................1539 Foreword............................................................................................................1539 Layout and function.................................................................................................1540 Correct application.................................................................................................1542 Essential information...............................................................................................1543 Abbreviations and symbols...........................................................................................1546 Turbocharger rating plate...........................................................................................1547 Safety..................................................................................................................1549 Basic safety instructions...........................................................................................1549 General safety instructions.........................................................................................1550 Special safety instructions.........................................................................................1551 Safety instructions and hazard protection...........................................................................1554 Commissioning...........................................................................................................1559 Oil supply..........................................................................................................1559 Inspection work.....................................................................................................1561 Inspection before commissioning.................................................................................1561 Inspection after commissioning..................................................................................1562 Inspection after 100 service hours..............................................................................1562 Putting into operation after laying up..............................................................................1563 Operation...............................................................................................................1565 Servicing work......................................................................................................1565 Servicing operations every 25 to 50 hours.......................................................................1565 Entries in the machine logbook..................................................................................1566 Servicing work according to the engine manufacturer's instru....................................................1566 Servicing work every 8,000 - 12,000 hours.......................................................................1567 Servicing work every 35,000 hours...............................................................................1567 Monitoring..........................................................................................................1568 Speed measurement...............................................................................................1568 U-tube manometer................................................................................................1570 Surging of turbocharger.............................................................................................1572 Contact with rotating parts.........................................................................................1573 Maintenance.............................................................................................................1575 Outline of cleaning work............................................................................................1575 Cleaning the filter silencer during operation.......................................................................1576 Cleaning the compressor during operation............................................................................1580 Wet cleaning of the compressor..................................................................................1581 Wet cleaning with water vessel (XC4) on filter silencer.........................................................1582 Wet cleaning with external pressurised water container (XC3)....................................................1583 Cleaning turbine blades and nozzle ring in operation................................................................1585 Wet cleaning of turbine and nozzle ring.........................................................................1586 Operation of wet cleaning the turbine and nozzle ring.......................................................1588 Troubleshooting.........................................................................................................1591 Possible remedies for failures......................................................................................1591 Exhaust temperature too high....................................................................................1591 Charge-air pressure too low.....................................................................................1592 Charge-air pressure too high....................................................................................1593 Vibrations......................................................................................................1593 Noises during run-out...........................................................................................1593 Run-out time too short..........................................................................................1594 Sluggish start-up...............................................................................................1594 Lubricating oil pressure too low................................................................................1594 Constant surging of the turbocharger............................................................................1595 Removal and installation................................................................................................1597 Turbocharger weights................................................................................................1597 Remove the turbocharger.............................................................................................1598 Installing the turbocharger.........................................................................................1600 Disassembly and assembly................................................................................................1601 Module weights......................................................................................................1601 Removing and fitting the filter silencer or air suction bran........................................................1604 Axial clearance.....................................................................................................1605 Removing cartridge group............................................................................................1606 Dismantling and installing the turbine diffuser and nozzle r........................................................1612 Installing the cartridge group......................................................................................1617 Turbine-end removal / fitting of nozzle ring........................................................................1623 Table of tightening torques.........................................................................................1625 Taking out of operation temporarily.....................................................................................1627 Possibilities for emergency repair..................................................................................1627 Blocking the rotor..................................................................................................1628 Lock rotor with polygon connection..............................................................................1629 Further measures and information for operation with a turboc....................................................1631 Fitting the cover plate.............................................................................................1632 Further measures and information for operation with a turboc....................................................1635 Blocking the inlets and outlets.....................................................................................1636 Bypass the turbocharger.............................................................................................1637 Mothballing the turbocharger............................................................................................1639 Taking out of operation for up to 12 months.........................................................................1639 Taking out of operation for more than 12 months.....................................................................1640 Reserve and spare parts.................................................................................................1641 Ordering spare parts................................................................................................1641 List of part numbers................................................................................................1643 General view of turbocharger........................................................................................1645 General view of cartridge group.....................................................................................1646 K C5.05.07.07.20.72 (PDF).pdf............................................................................................... 0 E1855177_L3NG_e_rev5.pdf................................................................................................ 0 Technical Documentation E 185 5177..................................................................................1668 Allowable displacements coupling E 185 5270.........................................................................1686 N&R for filling pump E 185 5504.....................................................................................1687 K C5.05.07.14.01.61 (PDF).pdf............................................................................................... 0 DOCUMENTATION...........................................................................................................1704 Directory...........................................................................................................1705 1. ORDER INDEPENDENT SECTION....................................................................................1707 1.1 General note on the module..............................................................................1707 1.1.1 Concerning this documentation.....................................................................1707 1.1.2 Copyright.........................................................................................1708 1.1.3 Use of the module in accordance with directions...................................................1709 1.2 Safety information......................................................................................1709 1.2.1 Explanation of symbols............................................................................1709 1.2.2 Work safety information...........................................................................1710 1.3 Transportation of the module............................................................................1712 1.3.1 Dismantling level of the module...................................................................1712 1.3.2 Use of the module.................................................................................1713 1.3.3 Intermediate storage of the module................................................................1714 1.3.4 Scope of supply of the entire module..............................................................1714 1.4 Assembly instructions...................................................................................1715 1.4.1 Installation conditions for the module............................................................1715 1.4.2 Information for the assembly of the module........................................................1715 1.4.3 Information for the dismantling of the module.....................................................1716 1.5 Maintenance, inspection and repair work.................................................................1717 1.5.1 Information on maintenance and inspection.........................................................1717 1.5.2 Information on maintenance........................................................................1718 1.6 Maintenance of replacement parts and customer Service...................................................1718 1.6.1 Replacement part and customer service addresses...................................................1718 2. ORDER DEPENDENT SECTION OF THE MODULE........................................................................1719 2.1. Technical specifications of the module.................................................................1719 2.1.1. Characteristic values of the module..............................................................1719 2.1.2 Component overview of the module..................................................................1723 2.1.3 Space requirement of the fuel oil module..........................................................1727 2.1.4 Lubricating point list of the module..............................................................1728 2.1.5 Operative range of the module.....................................................................1728 2.2 General view of the module..............................................................................1729 2.2.1 Flow diagram......................................................................................1730 2.3 Initial operation of the module.........................................................................1731 2.3.1 Preparatory measures and putting into service.....................................................1731 2.3.2 Putting the module out of service.................................................................1733 2.3.3 Measures during danger of frost...................................................................1734 3. APPENDIX.....................................................................................................1736 3.1 Standards and guidelines................................................................................1736 3.2 Main components.........................................................................................1737 Supply/Booster Pump.....................................................................................1739 Contents............................................................................................1739 List of components..............................................................................1740 Exploded view...................................................................................1741 Ordering code/Service intervals.................................................................1742 Sectional view..................................................................................1743 Useful tools/Shaft seal-assembly drawing........................................................1744 Dismantling/reassembly..........................................................................1745 Pressure relief valve/SealGuard.................................................................1749 Thermal oil control valve...............................................................................1751 Duplex filter...........................................................................................1755 Contents............................................................................................1756 1.Type sheet....................................................................................1757 2.Spare part drawing and spare parts list.......................................................1759 3.Desription and operating instructions for the duplex filter...................................1761 4.Description and operating instructions for the filter element cleaning........................1764 5.Data sheet for the differential pressure indicator (to order).................................1765 6.Spare parts drawing for the differential pressure indicator (to order)........................1766 Pressure control system.................................................................................1767 Contents............................................................................................1768 Safety..........................................................................................1769 Adress of manufacturer..........................................................................1769 The Documentation...............................................................................1770 Installation of the Pressure limiting valve.....................................................1770 Constructions and spares........................................................................1771 Comissioning....................................................................................1771 Valve construction..............................................................................1772 Characteristics.................................................................................1773 Characteristics curves..........................................................................1774 Type key........................................................................................1775 Dimensions......................................................................................1776 Accessories.....................................................................................1777 Flowmeter...............................................................................................1779 Contents............................................................................................1780 1.Plant design..................................................................................1781 2.Mounting......................................................................................1783 3.Electrical connections........................................................................1784 4.Operating start...............................................................................1786 5.Operating instructions........................................................................1787 6.Maintenance...................................................................................1789 7.Guarantee, liability..........................................................................1789 8.Dimensional sketches..........................................................................1790 Heater .................................................................................................1803 Contents............................................................................................1804 General Description.............................................................................1804 Installation Space Requirements.................................................................1805 Space allowance.............................................................................1805 Installation surface........................................................................1805 Storage.........................................................................................1805 Damp and humidity...........................................................................1805 Hydrostatic testing.........................................................................1805 Extended storage............................................................................1805 Mounting and Installation.......................................................................1805 Connecting the Heat Exchanger...................................................................1806 Preparation and pipe connection of the heat exchanger.......................................1806 Operation.......................................................................................1806 Commissioning...............................................................................1806 Initial adjustments.........................................................................1806 Initial start-up............................................................................1806 Output......................................................................................1807 Conservation during shut down periods...........................................................1807 Maintenance and Cleaning........................................................................1807 Regular cleaning periods....................................................................1807 Cleaning of tubes...........................................................................1807 Heavy contamination.........................................................................1807 Checking the safety valves..................................................................1807 Dismantling and reassembling of the tube section................................................1808 Spare parts.....................................................................................1808 3/2 way change over valve...............................................................................1810 Actuators...........................................................................................1810 Limit switch box....................................................................................1814 5/2-way solenoid valve..............................................................................1822 Drawing.............................................................................................1824 Cooler C1...............................................................................................1825 Table of contents...................................................................................1826 Glossary........................................................................................1827 1 Introduction..................................................................................1828 2 Installation and start-up.....................................................................1829 3 Maintenance...................................................................................1831 4 Trouble shooting & repairs....................................................................1837 5 Spare parts & tools...........................................................................1838 Viscosity control system................................................................................1842 TABLE OF CONTENTS...................................................................................1843 1. GENERAL......................................................................................1845 2. INTRODUCTION.................................................................................1846 2.1 To record important serial numbers......................................................1846 3. SYSTEM DISCRIPTION...........................................................................1847 3.1 Principle of operation..................................................................1847 3.2 System description......................................................................1848 4. TECHNICAL SPECIFICATION......................................................................1849 4.1 Viscotherm sensor.......................................................................1849 4.2 Differential pressure transmitter and valve manifold....................................1850 5. WARNINGS.....................................................................................1851 6. INSTALLATION.................................................................................1852 6.1 Electric motor..........................................................................1852 6.2 Dp-transmitter..........................................................................1853 7. OPERATION....................................................................................1854 7.1 Initial start-up........................................................................1854 7.2 Routine start-up........................................................................1855 7.3 Shut-down...............................................................................1855 8. MAINTENANCE..................................................................................1856 8.1 General.................................................................................1856 8.2 Monthly zero check of dp-transmitter....................................................1857 8.3 To clean measuring capillary............................................................1858 8.4 To replace electric motor of viscotherm sensor..........................................1859 8.5 Other maintenance / repair..............................................................1859 9. TROUBLESHOOTING..............................................................................1860 9.1 Viscosity signal too low................................................................1860 9.2 Viscosity signal too high...............................................................1860 9.3 Viscosity signal remains at maximum value...............................................1861 9.4 No viscosity signal.....................................................................1861 10. MAINTENANCE RECORD..........................................................................1862 11. PART LISTS..................................................................................1863 11.1 Spare parts kits.......................................................................1863 11.2 Viscotherm sensor parts................................................................1865 Automaticfilter 6.60....................................................................................1866 Contents............................................................................................1867 1.Type sheet....................................................................................1868 2.General information on the automatic filter...................................................1870 3.Filter installation...........................................................................1871 4.Comissioning..................................................................................1874 5.Filtration phase..............................................................................1875 6.Back-flushing operation.......................................................................1877 7. Description of the EL.-control system........................................................1880 8.Circuit diagram...............................................................................1894 9.Equipment list for EL.-control system.........................................................1893 10.Servicing....................................................................................1895 11.Servicing tools..............................................................................1897 12.Cleaning agents for candle elements..........................................................1898 13.Manuel cleaning..............................................................................1900 14.Maintenance instructions bypass filter.......................................................1902 15.Spare part drawing for type 6.60 and 6.60.1..................................................1903 16.Spare part list for type 6.60.1..............................................................1905 17.Type sheet for DPI with electrical contacts..................................................1917 18.Spare part drawing for the DPI...............................................................1918 Manual of control cabinet...............................................................................1919 Viscosity control...................................................................................1919 Pump control........................................................................................1924 Control panel.......................................................................................1929 Compensation tank.......................................................................................1931 3.3 Other components........................................................................................1737 Ball valve..............................................................................................1932 1.General...........................................................................................1933 2.Safety instructions...............................................................................1933 3.Transport.........................................................................................1933 4.Storage...........................................................................................1934 5.Functioning.......................................................................................1934 6.Installation......................................................................................1934 7.Initial operation.................................................................................1935 8.Maintenance.......................................................................................1935 9.Troubleshooting...................................................................................1935 Drawing.............................................................................................1936 Safety valve............................................................................................1939 1 Contents..........................................................................................1941 2 General...........................................................................................1941 3 Testing/marking...................................................................................1941 4 Pressure..........................................................................................1942 5 Function of the safety valve......................................................................1942 6 Functional tightness of the safety valve..........................................................1943 7 Medium............................................................................................1943 8 Temperature of the medium and environmental temperature...........................................1944 9 Choice of spring..................................................................................1944 10 Safety valves with bellows.......................................................................1945 11 Safety valves built into installations...........................................................1945 11.1 Open bonnet................................................................................1945 11.2 Regular lifting operation..................................................................1945 11.3 Forces acting on the safety valve..........................................................1945 11.4 Connections................................................................................1945 11.5 Orientation of safety valves...............................................................1946 11.6 Flow-through...............................................................................1946 11.7 Condensation...............................................................................1946 11.8 Transfer of vibrations from the installation...............................................1946 11.9 Discharge pipe.............................................................................1947 11.10 Unfavourable environmental conditions.....................................................1947 11.11 Leaks caused by impurity..................................................................1947 11.12 Protection during storage and transportation..............................................1947 11.13 Corrosion protection......................................................................1947 11.14 Maintenance...............................................................................1947 11.15 Identification of safety valves...........................................................1947 11.16 Lever safety valves.......................................................................1947 12 Setting instructions for spring loaded safety valves.............................................1948 12.1 Lifting device H3..........................................................................1948 12.2 Lifting device H4..........................................................................1948 12.3 Spring replacement.........................................................................1948 13 Handling.........................................................................................1949 14 Supplementary loading system.....................................................................1949 15 Combined Safety Valve and Bursting Disc..........................................................1950 16 Unexpected conditions............................................................................1950 17 Product overview.................................................................................1950 Declaration of Confomity-Safety Valves..............................................................1952 Declaration of Confomity-Change-over Valves 310.....................................................1953 Declaration of Conformity-Pressure-Reducer 612......................................................1954 Thermometer.............................................................................................1957 Non return valve........................................................................................1961 Content.............................................................................................1961 1. Declaration of Conformity in acc. to PED 97/23/EC............................................1963 2. General notes................................................................................1965 3. Intended Use.................................................................................1965 4. Safety Instructions..........................................................................1965 5. Transport and Storage........................................................................1966 6. Categorisation in acc. to PED 97/23/EC.......................................................1967 7. Specification................................................................................1968 8. Installation.................................................................................1970 9. Initial Operation, Shut down, Maintenance, Elimination of Failures...........................1973 10. Spare Parts.................................................................................1974 11. Further Information.........................................................................1974 Pressure gauge..........................................................................................1975 Pressure gauge snubber..................................................................................1977 Pressure gauge valve....................................................................................1978 Float switch............................................................................................1980 1.Function description..............................................................................1980 2.Installation......................................................................................1980 3.Contact protection................................................................................1981 4.Mounting..........................................................................................1982 5.Maintenance.......................................................................................1982 Dimensions..........................................................................................1983 Technical data......................................................................................1984 Pressure Transmitter for OEM Applications...............................................................1985 Content.............................................................................................1986 1.General information...........................................................................1987 2.Safety Instructions...........................................................................1987 3.Installation..................................................................................1989 4.Technical Data................................................................................1991 5.Wiring........................................................................................1992 6.Service.......................................................................................1992 7.Accessories...................................................................................1993 8.Data sheet....................................................................................1994 Shut off valve..........................................................................................1998 Contents............................................................................................1998 1.0 General information on operating instructions...............................................1999 2.0 Notes on possible dangers...................................................................1999 3.0 Storage and transport.......................................................................1999 4.0 Description.................................................................................2000 5.0 Installation................................................................................2002 6.0 Putting the valve into operation............................................................2004 7.0 Care and maintenance........................................................................2005 8.0 Troubleshooting.............................................................................2007 9.0 Troubleshooting table.......................................................................2008 10.0 Dismantling the valve or the top part......................................................2009 11.0 Warranty / Guarantee.......................................................................2009 12.0 EC declaration of conformity...............................................................2010 data sheet......................................................................................2011 Butterfly valve.........................................................................................2013 Contents............................................................................................2013 1.0 General Information on Operating Instructions...............................................2014 2.0 Notes on Possible Dangers...................................................................2014 3.0 Handling....................................................................................2015 4.0 Descriptions................................................................................2015 5.0 Installation................................................................................2018 6.0 Notes on Dangers During Installation, Operation and Maintenance.............................2020 7.0 Putting the Valve into Operation............................................................2021 8.0 Care and Maintenance........................................................................2021 9.0 Troubleshooting.............................................................................2021 10.0 Troubleshooting Table......................................................................2022 11.0 Dismantling the Valve......................................................................2023 12.0 Warranty...................................................................................2023 13.0 EC declaration of conformity / Manufacturers declaration...................................2024 Data sheet......................................................................................2025 Ball valve V1-316.......................................................................................2027 PT 100..................................................................................................2028 Dimensions..........................................................................................2030 Electrical connection...............................................................................2031 3.4 Electrical bill of materials and diagrams...............................................................1738 Main control cabinet....................................................................................2036 3.5 Diagram.................................................................................................1738 General arrangement drawing.............................................................................2071 Flow diagram............................................................................................2072 K C5.05.08.08.04.01 (PDF).pdf............................................................................................... 0 Plate Heat Exchangers...................................................................................................2074 Table of contents...................................................................................................2076 1 Preface........................................................................................................... 0 2 PHE safety........................................................................................................ 0 2.1 General safety.............................................................................................. 0 2.2 Incorrect operating conditions.............................................................................. 0 2.3 Permitted PHE operators..................................................................................... 0 2.4 Residual dangers............................................................................................ 0 3 Operating instructions............................................................................................ 0 3.1 Operating instructions...................................................................................... 0 3.1.1 User notes............................................................................................ 0 Drawings and figures.................................................................................... 0 Operator of the PHE..................................................................................... 0 PHE setter.............................................................................................. 0 3.1.2 Safety notes in the text.............................................................................. 0 4 Manager’s obligations............................................................................................. 0 5 Functional description............................................................................................ 0 6 Intended purpose.................................................................................................. 0 7 Overview and description of the PHE............................................................................... 0 7.1 Basic structure............................................................................................. 0 7.2 Identification.............................................................................................. 0 7.3 Frames...................................................................................................... 0 7.4 HE plates................................................................................................... 0 7.4.1 Chevron pattern....................................................................................... 0 7.4.2 Free Flow design...................................................................................... 0 7.4.3 Plate evaporator design............................................................................... 0 7.5 HE plate gaskets............................................................................................ 0 8 Delivery, transport, and installation of the PHE.................................................................. 0 8.1 Delivery.................................................................................................... 0 8.2 Setting up the lying PHE.................................................................................... 0 8.3 Transport................................................................................................... 0 8.3.1 Suspended with shackles at the fixed plate and with sling attachment at the carrying beam............. 0 8.3.2 Suspended at transport eyes........................................................................... 0 8.3.3 Suspended with sling attachment at the tightening bolt................................................ 0 8.4 Installation of the PHE..................................................................................... 0 8.4.1 Space requirements.................................................................................... 0 8.4.2 Pipe assembly......................................................................................... 0 8.5 PHE disposal................................................................................................ 0 9 Operation, start-up, and shutdown................................................................................. 0 9.1 Start-up.................................................................................................... 0 9.2 Operation................................................................................................... 0 9.3 Shutdown of the PHE......................................................................................... 0 9.3.1 Short-term shutdown................................................................................... 0 9.3.2 Long-term shutdown.................................................................................... 0 10 Maintenance and repair........................................................................................... 0 10.1 Preparatory precautions.................................................................................... 0 10.2 Opening the PHE and removing the HE plates................................................................. 0 10.2.1 Opening a PHE with a CD frame........................................................................ 0 10.2.2 Opening a PHE with B frame........................................................................... 0 10.3 Mounting the HE plates and closing the PHE................................................................. 0 10.4 Cleaning the PHE........................................................................................... 0 10.4.1 Cleaning the HE plates of the closed PHE............................................................. 0 CIP process............................................................................................. 0 Backflushing............................................................................................ 0 10.4.2 Cleaning the HE plates of an open PHE................................................................ 0 Manually cleaning the HE plates......................................................................... 0 Chemically cleaning the HE plates....................................................................... 0 10.5 Replacing HE gaskets....................................................................................... 0 10.6 Replacing port rings....................................................................................... 0 10.7 Maintaining the PHE frame.................................................................................. 0 11 Troubleshooting.................................................................................................. 0 11.1 Impaired PHE performance................................................................................... 0 11.2 PHE leakages............................................................................................... 0 12 Technical terms.................................................................................................. 0 K C5.05.08.12.03.20 (PDF).pdf............................................................................................... 0 If operating an engine on diesel oil....................................................................................2156 K C5.05.12.13.00.73 (PDF).pdf............................................................................................... 0 E&B_RATO-S_G1210-G7020_BR2100-2401_englisch.pdf......................................................................... 0 General safety instructions.........................................................................................2296 Symbol for industrial safety....................................................................................2296 Attention remark................................................................................................2296 Design of the flexible part.........................................................................................2298 Installation of the coupling........................................................................................2299 Assembly for series 2100, 2110, 2200, 2210, 2300, and 2400 s....................................................2299 Assembly for series 2100, 2110, 2200, 2210, 2300 and 2400 do....................................................2300 Assembly for series 2101, 2111, 2201, 2211, 2301 and 2401 si....................................................2301 Commissioning.......................................................................................................2301 Maintenance.........................................................................................................2302 Operating performance considering the mechanical properties ....................................................2302 Operating performace considering the chemical properties of ....................................................2302 Replacement of the flexible part....................................................................................2303 Disassembly of the flexible part................................................................................2303 Assembly of the flexible part...................................................................................2303 Service and spare parts.............................................................................................2303 Ausr_Beurt_Coat_Englisch.pdf............................................................................................ 0 COATING 113 e_2.pdf................................................................................................. 0 COATING 113 e_2.pdf............................................................................................. 0 Surface Protection COATING 113.............................................................................. 0 VULKAN RATO- S/R/DS Couplings........................................................................... 0 IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND COMPANY COM................................................ 0 COMPOSITION / INFORMATION ON INGREDIENTS.................................................................... 0 HAZARD IDENTIFICATION....................................................................................... 0 FIRST AID MEASURES.......................................................................................... 0 FIRE-FIGHTING MEASURES...................................................................................... 0 ACCIDENTAL RELEASE MEASURES................................................................................. 0 HANDLING AND STORAGE........................................................................................ 0 EXPOSURE CONTROLS AND PERSONAL PROTECTION................................................................... 0 PHYSICAL AND CHEMICAL PROPERTIES............................................................................ 0 STABILITY AND REACTIVITY.................................................................................... 0 TOXICOLOGICAL INFORMATION................................................................................... 0 ECOLOGICAL INFORMATION...................................................................................... 0 ADVICE ON DISPOSAL.......................................................................................... 0 TRANSPORT INFORMATION....................................................................................... 0 REGULATORY INFORMATION...................................................................................... 0 OTHER INFORMATION........................................................................................... 0 COATING 113 e_3.pdf................................................................................................. 0 Surface Protection COATING 113..................................................................................2320 VULKAN RATO- S/R/DS Couplings...............................................................................2320 IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND COMPANY COM....................................................2322 COMPOSITION / INFORMATION ON INGREDIENTS........................................................................2322 HAZARD IDENTIFICATION...........................................................................................2322 FIRST AID MEASURES..............................................................................................2322 FIRE-FIGHTING MEASURES..........................................................................................2323 ACCIDENTAL RELEASE MEASURES.....................................................................................2323 HANDLING AND STORAGE............................................................................................2323 EXPOSURE CONTROLS AND PERSONAL PROTECTION.......................................................................2323 PHYSICAL AND CHEMICAL PROPERTIES................................................................................2323 STABILITY AND REACTIVITY........................................................................................2324 TOXICOLOGICAL INFORMATION.......................................................................................2324 ECOLOGICAL INFORMATION..........................................................................................2324 ADVICE ON DISPOSAL..............................................................................................2325 TRANSPORT INFORMATION...........................................................................................2325 REGULATORY INFORMATION..........................................................................................2325 OTHER INFORMATION...............................................................................................2326 Beurteilungskriterien für RATO_S_R_englisch1.pdf.................................................................... 0 Criteria for the inspection of.................................................................................. 0 VULKAN-RATO-S/R couplings................................................................................... 0 Beurteilungskriterien für RATO_S_R_englisch1.pdf.................................................................... 0 Criteria for the inspection of.................................................................................. 0 VULKAN-RATO-S/R couplings................................................................................... 0 Beurteilungskriterien für RATO_S_R_englisch2.pdf.................................................................... 0 Criteria for the inspection of..................................................................................2310 VULKAN-RATO-S/R couplings...................................................................................2310
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.V