MaK M20 [PDF]

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Engineer’s Handbook M 20



Engineer’s Handbook



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Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cylinder arrangement according to DIN: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9



Engine Data / Engine operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10



Firing Sequences / Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11



Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Oil filling quantities for deep oil pans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Oil filling quantities for flat oil pans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Oil filling quantities for diesel generator sets installed on a standard base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Alarm values for oil filling quantities: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14



Engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Tightening torques for screw plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Crankcase covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15



Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Tightening torques for screw plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Plug installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Rocker arm bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Rocker arm (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Valve clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Adjustment of valve bridges with respect to valve stems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Valve rotator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Guide bolts for the valve bridges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 en / 24/8/10



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Sleeve for the fuel injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Tightening instruction for fuel injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Removal of fuel injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Installation sequence for fuel injection valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Exhaust manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Valve stems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Radial valve stem runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installation of valve seat rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Refinishing of the valve seat rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27



Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Mahle 1.10.7-26.70.00-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Mahle 1.10.7-26.70.00-02 / 03 / 04 / 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 MHW 1.10.7-26.70.00-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Kolbenschmidt 1.10.7-26.70.00-07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Wear limits and limit clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Piston rings for gas oil operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Piston rings for heavy fuel operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Installation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Removal: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33



Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Big-end bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Installation of small-end bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Limit clearance between piston pin and small-end bush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Measurement of the gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Reference dimensions of the big-end bearings after proper tightening . . . . . . . . . . . . . . . . . . 35



Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Nominal dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Wear limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Anti-polishing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Removal of anti-polishing ring (without groove) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Removal of anti-polishing ring (with groove) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Cylinder liner installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 en / 24/8/10



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Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Crankshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Disassembly of crankshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Marking of the crankshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Measurement of the gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Locating and normal bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Crank web deflection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Counterweight installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6 M 20: 12 counterweights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Vibration damper installation with and without power take-off . . . . . . . . . . . . . . . . . . . . . . . . . 45



Timing gear train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Crankshaft gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Installation of crankshaft gear wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Thrust rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Lube oil nozzles for timing gear train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49



Governor drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Governor drive, old design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Bushes in the engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Governor drive, new design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52



Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Vibration damper for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Tightening torques for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Max. radial runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Camshaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54



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Lower valve drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Installation (M 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Installation (M 20 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Plug installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Adjusting instruction (M 20 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57



Injection pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Injection pump 0.00.6-43.12.00-72 type: DSFP 1M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Injection pump 0.00.6-43.12.00-79 type: DSFP 1MW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Injection pump 0.00.6-43.12.00-92 type: DSFP 1MWA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Fuel distributing and collecting pipe (compensator tubes / old design). . . . . . . . . . . . . . . . . . . 61 Fuel distributing pipe (plug-in tubes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Dismounting - mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Check of commencement of fuel delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Determination of spacer plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Adjustment of commencement of fuel delivery with injection pump mounted . . . . . . . . . . . . . . 63



IMO engine adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 M 20 C 170 kW/cyl. 900 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 IMO Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 M 20 C 190 kW/cyl. 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 M 20 170 kW/cyl. 900 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 M 20 190 kW/cyl. 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 8 M 20 170 kW/cyl. 1000 rpm engine adjustment, RheinSchUO II . . . . . . . . . . . . . . . . . . . . . 68 6 M 20 190 kW/cyl. 1000 rpm engine adjustment, RheinSchUO II . . . . . . . . . . . . . . . . . . . . . 69 IMO adjustment: Check (M 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 IMO adjustment: Marking of the flywheel (M 20). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 IMO adjustment: Check (M 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 IMO adjustment: Marking of the flywheel (M 20 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71



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Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Fuel rack position transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Cooling water distributing pipe / cooling water pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Governor arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Level probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Expander in the distributor casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75



Pump support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Pump mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Cooling water pump TN 40-200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Fuel feed pump (gear pump, M 20). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Fuel feed pump (M 20, M 20 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78



Flywheel installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Installation - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Gear ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Used flywheel variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82



Flexible flange connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 VULKAN RATO-R G192 TR, series 2200 (6 M 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 VULKAN RATO-DG A2710G, series 2200 (8 M 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 VULKAN RATO-DG A2710, series 2200 (8 M 20 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 VULKAN RATO-DG A2911G, series 2200 (9 M 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Installation description for the above flange connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 VULKAN RATO-DS 2511 (6 M 20), 2515 (8 M 20) series 2100 . . . . . . . . . . . . . . . . . . . . . . . . 86 VULKAN RATO-DS 2911, series 2100 (9 M 20 / 8 M 20 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Installation description for the above flange connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86



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Table of Contents



M 20



c2



Charge air cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Plug installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88



Turbocharger installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 ST 5 (8 M 20 C) HPR 4000 (6 M 20 C) HPR 5000 (8 M 20 C, 9 M 20 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89



Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Expansion joint installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90



Exhaust pipe cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Assembly gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Diesel generator set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Engine and generator fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Sealing surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Alignment instruction for diesel generator sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Axial alignment:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Radial alignment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Angular alignment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95



Resilient mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Conical elements 8 M 20 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Conical elements 8 M 20 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Conical elements 6 M 20 C, 8 M 20 C, 9 M 20 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102



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Engineer’s Handbook General Notes



M 20



General Notes Due to design features implemented on the injection system and a simple and permanent adjustment of ignition timing and fuel rack position - already during assembly of the engine - no adjustment of firing pressures during the testbed trials will be necessary.



Therefore, no firing and compression pressures are indicated on the acceptance test records. On the occasion of checks and measuring trips later on indicating shall not be carried out. Only in exceptional cases and only after consulting technical Customer Service Support (VT5) the setting of the injection pumps may be changed. The following parameters can be used for identifying possible malfunctions: 1.



Engine speed



2.



Fuel rack position



3.



Lubricating oil



t engine inlet



t oil cooler inlet



4.



Freshwater



t engine inlet



t engine outlet



t ch. air cooler inlet t ch. air cooler outlet t turbocharger outlet 5.



Charge air temperature



t before cooler



t before engine



6.



Exhaust temperature



t after cylinder



t after turbocharger



7.



Lubricating oil pressure



8.



Freshwater pressure



9.



Charge air pressure after charge air cooler



10. Charge air cooler differential pressure



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M 20



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Cylinder arrangement according to DIN:



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Engineer’s Handbook Engine Data / Engine Operating Data



Engine Data / Engine operating



M 20



Engine data



Engine Operating Data



Stroke:



300 mm



Temperatures



Bore:



200 mm



Lube oil, inlet:



60 - 65



°C



Engine speed:



900 - 1000



Temperature rise:



10 - 14



°C



rpm



Crankshaft bearing



Freshwater circulation cooling



Inside Ø:



180



mm



Outlet:



60 - 70



°C



Outside Ø:



190



mm



Temperature rise:



6 - 12



°C



Charge air, inlet:



46 - 60



°C



Big end bearing



Pressures



Inside Ø:



152



mm



Lube oil, at last



Outside Ø:



161



mm



main bearing:



Valves (inlet and exhaust)



4.0 - 5.0 bar



Freshwater circulation cooling



Length:



336



mm



Stem Ø:



14.05



mm



Valve head Ø:



66



mm



Valve guide



at min. 4 mWC:



2.5 - 5.0 bar



Fuel pressure before injection pumps



Length:



175



mm



Gas oil operation:



3.0 - 5.0 bar



Inside Ø:



14.15



mm



HFO operation:



4.0 - 5.0 bar



Data for rated engine power and rated engine speed



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Engineer’s Handbook Firing Sequences / Valve Timing



Firing Sequences / Valve Timing



M 20



c2



Firing sequences 6 M 20



8 M 20



9 M 20



clockwise



1-3-5-6-4-2



counter-clockwise



1-2-4-6-5-3



clockwise



1-2-4-6-8-7-5-3



counter-clockwise



1-3-5-7-8-6-4-2



clockwise



1-2-4-6-8-9-7-5-3



counter-clockwise



1-3-5-7-9-8-6-4-2



Valve timing Old output 170 kW / cyl. Exhaust opens



60° crank angle bef. BDC



Exhaust closes



55° crank angle after TDC



Inlet opens



55° crank angle before TDC



Inlet closes



40° crank angle after BDC



New output 190 kW / cyl.



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Exhaust opens



40° crank angle bef. BDC



Exhaust closes



45° crank angle after TDC



Inlet opens



45° crank angle before TDC



Inlet closes



5° crank angle after BDC



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Engineer’s Handbook Dimensions and Weights



M 20



Dimensions and weights Designation



Length mm



Width mm



Height mm



Weight kg



Engine block without studs 6 M 20



3190



8 M 20



4040



9 M 20



4530



Crankshaft 6 M 20



2428



Ø 374



730



8 M 20



3088



Ø 374



1000



9 M 20



3415



Ø 374



1100 22



Balance weight 83



Ø 273



16



597



Ø 277



60



594.4



Ø 277



60



Gear wheel on crankshaft Cylinder liner Variants 01 + 02 Cylinder liner Variants 04 to 08 Piston with connecting rod



60.5



Cylinder head, complete



121



Cylinder head, naked



85.5



Main bearing



72



Ø 190



1.5



Big-end bearing



69



Ø 161



1.1



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Engineer’s Handbook Dimensions and Weights



M 20



Designation



Length mm



Width mm



Height mm



Weight kg



Cooling collar



602



328



170



43.5



Injection pump



123



133



342



18



Camshaft section



330



Ø 142



19



Camshaft bearing



40



Ø 160



1.3



Camshaft gear wheel



65



Ø 533



105 23



Intermediate gear



210



Casing for charge air cooler 877



Charge air cooler



540



440



170



Oil cooler



82



Pump mounting plate



78



Starter



34



Flywheel, generator



217



Ø 1005



320



Flywheel, propeller



204



Ø 1005



307



38



Ø 1015



44



151



Ø 620



263



Gear ring on flywheel Vibration damper Lubricating oil pump



404



230



245



34



Cooling water pump



354



270



335



42



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Engineer’s Handbook Dimensions and Weights



M 20



Oil filling quantities for deep oil pans Free end



Engine



Min. oil level



Max. oil level



6 M 25



550 l*



600 l*



8 M 25



700 l*



800 l*



9 M 25



800 l*



900 l*



* Oil filling quantity when using a measurement sensor on the face end (free end), see drawing. Oil filling quantities for flat oil pans Oil filling quantities for flat oil pans can only be measured in the sump tank or the base frame (see below or plant-specific drawings). Oil filling quantities for diesel generator sets installed on a standard base frame



Connection for sensor



Dipstick: Engine



Min. oil level



Max. oil level



6 M 25



715 l



980 l



8 M 25



915 l



1245 l



9 M 25



1015 l



1385 l



Alarm values for oil filling quantities: Engine



Min. oil level



Max. oil level



6 M 25



470 l



1050 l



8 M 25



600 l



1345 l



9 M 25



670 l



1490 l



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Engineer’s Handbook Engine Block



M 20



Engine block Tightening torques for screw plugs Tighten screw plugs M14x1.5 with



⇒ M = 100



Nm



Tighten screw plugs M22x1.5 with



⇒ M = 180



Nm



Tighten screw plugs M26x1.5 with



⇒ M = 200



Nm



Tighten screw plugs M33x2 with



⇒ M = 200



Nm



For M 20 C tighten screw plugs M33x2 with



⇒ M = 100



Nm



Tighten screw plugs M42x2 with



⇒ M = 300



Nm



Tighten screw plugs M52x2 with



⇒ M = 400



Nm



Crankcase covers Slightly grease the flat gaskets before inserting them. Use liquid sealing compound such as Dirko No. 610.020 (Dirko, grey) for covers without any gasket.



Insert all O-rings untwisted using liquid suet or green soft soap. For crankcase covers with relief valve Tighten screws (1) with Tighten screws (5) with Molykote



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⇒ M = 15



Nm



⇒ M = 15



Nm



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Engineer’s Handbook Cylinder Head



M 20



Cylinder head Assembly 1.



Insert studs with Molykote



2.



Pretighten round nuts with a pin so as to be finger tight.



3.



Simultaneously stretch studs with ⇒ P = 600 and firmly tighten round nuts with a pin ensuring ease of movement. Molykote (device 1.10.7-92.03.00-01; effective area 54.8 cm2)



⇒ M = 300



Nm



bar



The pressure must remain constant when the pump is not operated, otherwise they are not properly tightened.



Check Reduce pressure by 50 bar. Loosening of the round nuts by means of a pin must not be possible any more. Disassembly If the cylinder head nuts cannot be loosened at the prescribed pressure, increase the pressure by max. 50 bar. If the pressure is increased further, there is a risk of the thread getting stretched and the nuts getting jammed. At control bore (1) leaks between cylinder head, anti-polishing ring and cooling collar can be identified.



Tightening torques for screw plugs Tighten screw plugs M10x1 with Hylomar Tighten screw plugs M30x2 with Hylomar Tighten screw plugs M20x1.5 with Rivolta G.W.F. Tighten screw plugs G 1/2 A with Rivolta G.W.F.



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⇒ M = 30



Nm



⇒ M = 200



Nm



⇒ M = 60



Nm



⇒ M = 60



Nm



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Engineer’s Handbook Cylinder Head



M 20



Plug installation Clean and degrease the sealing faces of the plugs and the corresponding holes. Lubricate the sealing faces of the plugs with Loctite 270. Use the provided drive-in mandrel for installing the plugs. The plug edges must be located 1.5 + 0.5 mm deep in the cylinder head. Rocker arm bracket Insert studs (1) with Oil



⇒ M = 80



Nm



Tighten nuts (2) with Molykote



⇒ M = 120



Nm



Insert studs (3) with Oil



⇒ M = 40



Nm



Tighten nuts (4) with Molykote



⇒ M = 60



Nm



Original clearance (bush and support)



⇒ 0.12 - 0.14



mm



Limit clearance (bush and support)



⇒ 0.20



mm



Reference dimension of the bush after pressing-in, Ø



⇒ 49.99 + 0.109



mm



Rocker arm (inlet and exhaust)



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Engineer’s Handbook Cylinder Head



M 20



After pressing-in the bush shall recede by See detail Z.



⇒ 0.20



mm



Before pressing-in slightly lubricate the bush with oil. Do not use Molykote. When freeze fitting new ball pins (cool down to -195 °C with liquid nitrogen) pay attention to correct position of (1) to ensure proper oil supply.



Valve clearance On a warm engine about 15 minutes after stop: Inlet



⇒ 0.60



mm



Exhaust



⇒ 0.80



mm



Inlet



⇒ 0.60



mm



Exhaust



⇒ 0.65



mm



After maintenance work when the engine is cold:



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Engineer’s Handbook Cylinder Head



M 20



c2



Adjustment of valve bridges with respect to valve stems 1. Open indicator valves. Turn the piston of the cylinder to be adjusted to firing TDC. Inlet and exhaust valves are closed, rocker arms relieved. 2. Relieve the valve bridge from the load of the rocker arm. Increase clearance S between rocker arm and valve bridge and/or fold back rocker arm. 3. Loosen locknut (3) of the valve bridge and unscrew adjusting screw (2) so as to obtain contact free of clearance at X. 4. At this position of the valve bridge screw in adjusting screw (2) so as to obtain contact free of clearance at Y. Do not tilt the valve bridge. 5. Hold adjusting screw (2) and tighten locknut (3). 6. Check for absence of clearance at X and Y with a 0.02 mm feeler gauge. After that, adjust valve clearance S according to the relevant instructions.



After adjusting the valve clearance tighten locknut (4) with ⇒ 90 Nm and check clearance S once more.



The valve bridges have been modified. On newer engines a visual inspection will allow to determine whether the valve bridge rests on the valve stem.



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Engineer’s Handbook Cylinder Head



M 20



Valve guide Measure the diameter of the valve stem in the guided area. Measure the guide in engine transverse direction. Cool the valve guides down to -195 °C with liquid nitrogen and insert them into the cylinder head.



Normal clearance:



(inlet + exhaust)



⇒ 0.10 - 0.17



mm



Limit clearance:



(inlet + exhaust)



⇒ 0.40



mm



Normal dimension: Outside Ø (inlet + exhaust)



⇒ 26.033 - 0.01



mm



Oversize:



⇒ 27.033 - 0.01



mm



Insert guide bolts (thread M30x2) with Loctite 243



⇒ M = 150



Nm



Insert guide bolts (thread M36x2) with Loctite 243



⇒ M = 200



Nm



Outside Ø (inlet + exhaust)



Valve rotator MDO operation:



On inlet valves only



HFO operation:



On inlet and exhaust valves



Guide bolts for the valve bridges



From cylinder head variant 1.10.3-21.51.00-06 cool guide bolts with liquid nitrogen down to -195 °C and insert them. Oversize for repair purposes: Insert guide bolts with Loctite 243 and apply Molykote to the contact faces.



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Engineer’s Handbook Cylinder Head



M 20



Sleeve for the fuel injection valve Tighten sleeve with



⇒ M = 100



Nm



Insert O-rings in correct position using liquid suet or green soft soap. Before fitting the bush make sure there are no burrs where the bush is inserted into the cylinder head.



O-ring Viton, green O-ring, Perbunan



Tightening instruction for fuel injection valve Insert studs with Oil



⇒ M = 40



Nm



Pretighten nuts with and loosen them again.



⇒ M = 55



Nm



Then tighten them with Molykote



⇒ M = 30



Nm



Tighten nozzle nut with Oil



⇒ M = 250 - 20



Nm



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Engineer’s Handbook Cylinder Head



M 20



c2



Removal of fuel injection valve Loosen thrust screws (1) and (2). Loosen transverse thrust piece (3) with cap (4), then pull radial thrust piece (5) out of its end position - about 20 mm. (This is important, otherwise damage is unavoidable) Screw the nuts off the injection valve. Remove flange (6) and put on again turned by 180 . Screw removal device (7) onto adjusting screw (8) and loosen nozzle holder by turning it against flange (6). Pull injection valve out of the cylinder head.



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Engineer’s Handbook Cylinder Head



M 20



Installation sequence for fuel injection valve 1. Lubricate joint ring (10) and nozzle cap with Rivolta G.W.F.. 2. Insert injection valve, tighten according to the instructions and loosen again. 3. Install radial thrust piece (5) and transverse thrust piece (3). 4. First tighten thrust screw (2) and then thrust screw (1) finger tight, then tighten thrust screw (2) and after that thrust screw (1) according to the instructions. 5. Tighten injection valve according to the instructions. 6. Tighten thrust screws (1) and (2) with



⇒ M = 85



Nm



7. Tighten screws for connection housing (9) with Molykote Screws M10x 55 ISO 4762



⇒ M = 35



Nm



⇒ M = 60



Nm



⇒ M = 110



Nm



Exhaust manifold Tighten screws to the cylinder head alternately 1. step up to and 2. step up to Rivolta G.W.F.



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Engineer’s Handbook Cylinder Head



M 20



Valve stems For grinding-in of inlet and exhaust valves apply small dots of the diamond paste Dp 30/10-15 my evenly to the seat face of a new or remachined valve cone. After that, spray the seat ring surface with a thinner (F25) belonging to the diamond paste, for dilution and in order to increase the grip. Insert the lubricated valve stem into the guide bush. Fasten the device on the valve head and grind valve cone and seat by hand for a short time applying a moderate pressure and turning the device back and forth. The percentage contact area “a“ made visible through this procedure shall, over the entire circumference and starting from the outside diameter, not exceed 30 %- 50 % of the seat width. If a bearing pattern as described above is not reached, remachine both sealing faces. After machining check both seats with a luminous magnifier. Do not refinish the fillet. After machining round off the outside edge with a stone. Observe the dimensions and angles indicated in the sketches of the following page. The valves are identified by variant identifications (e.g. 10-07, 10-22 ...) on the circumference of the shaft end.



Variant



Diameter x



Y (new condition)



Y (wear limit)



10-03



62.5 - 0.1 mm



6.93 - 0.3 + 0.1 mm



mm



10-07



62.5 - 0.1 mm



6.55 - 0.4 mm



mm



10-19



62.5 - 0.1 mm



7 - 0.4 mm



mm



10-22



62.5 - 0.1 mm



6.55 - 0.4 mm



mm



10-02



62.5 - 0.1 mm



5.73 - 0.4 mm



mm



10-05



62.5 - 0.1 mm



5.73 - 0.4 mm



mm



10-20



62.5 - 0.1 mm



5.73 - 0.4 mm



mm



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Engineer’s Handbook Cylinder Head



M 20



Inlet valve 10-07



Reference diameter



Inlet valve 10-19 Reference diameter



Inlet valve 10-22



Reference diameter



Reference diameter



Inlet valve 10-03



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Reference diameter



Exhaust valve 10-05 (MDO)



Reference diameter



Exhaust valve 10-02 (HFO)



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M 20



c2



Reference diameter



Exhaust valve 10-20 (MDO)



Radial valve stem runout Radial runout on the valve stem may not exceed 0.04 mm on a measuring distance S of 200 mm. Radial runout on the valve cone must not exceed 0.02 mm. For both measurements the valve stem must rest on points A and B of the measuring device.



Valve stems must not be reused if: 1. There is severe pitting on the bottom side of the valve head (formation of so-called "paving stones), 2. There are corrosion pits and mechanical damage in the area of the valve stem, stem transition and valve head. 3. The limit for refinishing is exceeded, 4. There is corrosive material erosion of 2 % of the head diameter. There is high-temperature corrosion "S" on the bottom of the valve head exceeding 1.50 mm.



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Engineer’s Handbook Cylinder Head



M 20



c2



Installation of valve seat rings 1 Cool the valve seat ring down to -195 °C with liquid nitrogen. 2. Insert the inlet and exhaust valve set rings. 3. When the valve seat rings are tight, press them on with the hydraulic device (50 kN). 4. Check contact face Y2. No air gap is admissible between inlet valve seat ring and cylinder head. 5. Check air gap Y1 between exhaust valve seat ring and cylinder head: Admissible air gap 0.2 + 0.3 mm. Pressure test: 10 bar for cooling water chambers, maintain pressure for 8 min. Refinishing of the valve seat rings Max. admissible dimension for refinishing the exhaust valve seat rings: Step Y must remain palpable. Inlet valve seat rings: Min. dimension for Z = 1 mm must be maintained after refinishing. Refinishing with MaK valve seat refacing machine or MaK valve reseating tool. After grinding there shall be a contact area of 30 - 50 %, starting from the outside diameter.



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Engineer’s Handbook Piston



M 20



Piston



Mahle 1.10.7-26.70.00-01 Insert studs with into the piston crown.



⇒ M = 10



Nm



Pretighten nuts with Loosen nuts again.



⇒ M = 35



Nm



Check the screw-in torque of the studs with



⇒ M = 10



Nm



Pretighten nuts with



⇒ M = 15



Nm



and finally tighten with



⇒ Dw = 50°



Check: At a torque of the nuts must not turn any further.



⇒ M = 35



Nm



⇒ M = 10



Nm



M = 15



Nm



Mahle 1.10.7-26.70.00-02 / 03 / 04 / 05 Insert studs with into the piston crown. Apply Molykote Paste G-n to threads and contact faces of the nuts and pretighten nuts with



⇒



then finally tighten with Loosen nuts again and check the screw-in torque of the studs with



⇒ Dw = 80°



Pretighten nuts with



⇒



and finally tighten with



⇒ Dw = 50°



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⇒ M = 10



Nm



M = 15



Nm



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Engineer’s Handbook Piston



M 20



Shoulder clearance (gap dimension) between piston crown and skirt (studs not tightened) Check: At a torque of the nuts must not turn any further.



⇒ 0.04 - 0.09



mm



⇒ M = 35



Nm



Attention! Replace the studs upon reassembly if the projecting length from crown contact surface exceeds 71.3 mm (see illustration below). (illustration on the right depicts a piston of type Mahle 1.10.7-26.70.00-02 / 03 / 04 / 05, see previous page)



MHW 1.10.7-26.70.00-22 Insert fixing pin (heavy type dowel pin) into the piston crown. Lubricate the thread in the piston crown with engine oil. Apply graphite paste to the threads of the studs. Insert studs into the piston crown and tighten them with without jolts.



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⇒ M = 30



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Nm



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Engineer’s Handbook Piston



M 20



Spray piston crown and skirt with anticorrosion oil. Grease joint ring and insert into the piston skirt untwisted. Put piston skirt onto the crown. Grease spherical washers and thread of the nut with graphite past and tighten the nut until the first resistance is felt. Check gap dimension between piston crown and skirt at 4 points (displaced at 45 from the studs in direction of circumference):



each



Desired value



⇒ 0.06 ± 0.02



mm



Tighten nuts alternately in steps of



⇒ M = 10



Nm



up to and loosen them again.



⇒ M = 50



Nm



Check the tightening torque of the studs in the crown with ⇒ M = 30



Nm



Tighten the nuts until the first resistance is felt and then tighten them alternately in steps of



⇒ M = 10



Nm



up to



⇒ M = 40 + 5



Nm



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Engineer’s Handbook Piston



M 20



Kolbenschmidt 1.10.7-26.70.00-07 Lubricate thread and contact face with Molykote Paste G-n-plus. Tighten nuts crosswise with Loosen the studs again. Pretighten studs with and then finally tighten them with



⇒ M = 24



Nm



⇒ M = 10



Nm



⇒ Dw = 60°



Check: At a torque of the studs must not turn any further. Shoulder clearance (gap dimension) between piston crown and skirt (studs not tightened)



⇒ M = 19



Nm



⇒ 0.06 - 0.10



mm



Wear limits and limit clearances Piston with 4 rings: Grooves Groove height 1 5 +0.12 - 0.14



Ring height 4.95 -0.010 - 0.025



Wear limit 5.60



Limit clearance 0.65



2



5 +0.10 - 0.12



4.95 -0.010 - 0.025



5.60



0.65



3



5 +0.06 - 0.08



4.95 -0.010 - 0.025



5.60



0.65



4



6 +0.06 - 0.08



6.00 -0.010 - 0.025



6.50



0.50



Ring height 4.95 -0.010 - 0.025



Wear limit 5.60



Piston with 3 rings: Grooves Groove height 1 5 +0.12 - 0.14



Limit clearance 0.65



2



5 +0.10 - 0.12



4.95 -0.010 - 0.025



5.60



0.65



3



6 +0.06 - 0.08



6.00 -0.010 - 0.025



6.50



0.50



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Engineer’s Handbook Piston



M 20



c2



Piston rings for gas oil operation Piston 1.10.7-26.70.00-01 / -02 / -03 / -04 Ring groove 1 Rectangular ring 2+3 Taper-faced ring 4 Bevelled-edge oil control ring



Ring 1.10.7-26.17.01-05.1 alternatively -04.1 1.10.7-26.17.01-06.1 1.10.7-26.17.01-03.1



Piston 1.10.7-26.70.00-05 / -22 Ring groove 1 Rectangular ring 2 Taper-faced ring 3 Bevelled-edge oil control ring



Ring 1.10.7-26.17.01-05.1 alternatively -04.1 1.10.7-26.17.01-06.1 1.10.7-26.17.01-03.1



Piston 1.10.7-26.70.00-07 Ring groove 1 Rectangular ring 2 Taper-faced ring 3 Bevelled-edge oil control ring



Ring 1.10.7-26.17.01-05.1 alternatively -04.1 1.10.7-26.17.01-06.1 1.10.7-26.17.01-03.1



Piston rings for heavy fuel operation Piston 1.10.7-26.70.00-01 / -02 / -03 / -04 Ring groove 1 Rectangular ring 2+3 Taper-faced ring 4 Bevelled-edge oil control ring



Ring 1.10.7-26.17.01-04.1 repl. -07.1 1.10.7-26.17.01-06.1 1.10.7-26.17.01-03.1



Piston 1.10.7-26.70.00-05 / -22 Ring groove 1 Rectangular ring 2 Taper-faced ring 3 Bevelled-edge oil control ring



Ring 1.10.7-26.17.01-04.1 repl. -07.1 1.10.7-26.17.01-06.1 1.10.7-26.17.01-03.1



Piston 1.10.7-26.70.00-07 Ring groove 1 Rectangular ring 2+3 Taper-faced ring 4 Bevelled-edge oil control ring



Ring 1.10.7-26.17.01-07.1 1.10.7-26.17.01-06.1 1.10.7-26.17.01-03.1



Piston 1.10.7-26.70.00-03 up to 170 kW/cyl. Piston 1.10.7-26.70.00-04/-05 190 kW/cyl. Piston ring: 1.10.7-26.17.01-07.1 chrome-plated on three sides; 1.10.7-26.17.01.04.1 chrome-ceramic ring



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Engineer’s Handbook Piston



M 20



c2



Installation: Arrange the ring joints in engine longitudinal direction so that they are alternately point in opposite direction. Install the piston rings with the marking pointing upwards.



Removal: In order to avoid loosening of the cylinder liner when removing the cylinder head or turning the crankshaft, always secure the liner in the crankcase by means of a hold-down. Before extracting the piston remove the anti-polishing ring.



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Engineer’s Handbook Connecting rod



M 20



Connecting rod Big-end bearing 1. Tighten bolts (3) and (4) (long + bottom) with Molykote 2. Tighten bolts (1) and (2) (short + top) with Molykote 3. Tighten bolts (1) and (2) once more with



⇒ M = 160



Nm



⇒ M = 160



Nm



⇒ M = 160



Nm



4. Tighten bolts (3) and (4) with



⇒ M = 350



Nm



⇒ M = 350



Nm



⇒ M = 350



Nm



Tighten bolts (1) and (2) mit 5. Tighten bolts (3) and (4) once more with in order to prevent a loss in prestress (settlement phenomenon).



The final tightening torque corresponds to a torque angle of: Bolts (1) and (2) min. 13° - 16° Bolts (3) and (4) min. 17° - 19° starting from a pretightening torque of 160 Nm. The set of tools includes 2 tightening angle gauges to check the above indicated torque angle: One for connecting rod bolts (1) and (2) and one for connecting rod bolts (3) and (4). If after proper tightening of all the connecting rod bearings the minimum torque angle degrees are not reached, repeat the entire tightening procedure.



Bolt 2 Bolt 1



Bolt 3 Bolt 4



Installation of small-end bush Cool small-end bush down to < -160 °C and push into the small end. In doing so, make sure the oil holes are correctly positioned. Lateral projection must be the same on both sides. After reaching normal temperature, measure the small end bush. The reference dimension after freeze fitting is



⇒ Ø 90.09 + 0.06



mm



Limit clearance between piston pin and small-end bush The limit clearance between piston pin and small-end bush is



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⇒ 0.170



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mm



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Engineer’s Handbook Connecting rod



M 20



Measurement of the gap 1. Pretighten bolts (3) and (4) with



⇒ M = 160



Nm



2. Measure dimension X1 with a sliding rule. 3. Tighten bolts (1) and (2) twice one after the other in the sequence 1 - 2 - 1 - 2 with



⇒ M = 160



Nm



4. Tighten bolts (3) and (4) as well as (1) and (2) with



⇒ M = 350



Nm



Gap = X1 - X2



⇒ 0.45 - 0.65



mm



Limit value



⇒ 0.35



mm



5. Measure dimension X2 .



Reference dimension A



Reference dimension B



Reference dimensions of the big-end bearings after proper tightening Reference dimension A



⇒ 152.140 + 0.05



mm



Reference dimension B



⇒ A + 0.04 + 0.01



mm



Dowel pins For inserting dowel pins (5) grease the thread and insert the dowel pins with Loctite 242. After that secure the dowel pins by centre punch.



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Engineer’s Handbook Cylinder Liner



M 20



Cylinder liner Nominal dimension Original size



⇒ Ø 200 + 0.046



mm



Wear limit



⇒ 0.80



mm



Max. ovality



⇒ 0.25



mm



Wear limits



Wedge-shaped indentation (across the entire circumference, beginning at TDC of 1st piston ring) Height



⇒ 6.00



mm



Depth *



⇒ 0.03



mm



Canyons (Individual deep blow-by grooves in the area of TDC of 1st piston ring) Max. number



⇒ 3



Length



⇒ 6.00



mm



Total width



⇒ 3.00



mm



Score marks (Severe vertical, linear friction marks) Number



⇒ 3



Length



⇒ 140.00



mm



Depth



⇒ 0.03



mm



Pockets (Areal, irregular indentations)



*



Number



⇒ 3



Length



⇒ 45.00



mm



Width * *



⇒ 15.00



mm



Depth *



⇒



0.02



mm



Radius r > 3 mm



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Engineer’s Handbook Cylinder Liner



M 20



Pocket Wedge



Score mark TDC 1st ring



Canyon



Anti-polishing ring With a few exceptions, all engines are equipped with anti-polishing rings in the cylinder liners. Currently, a wider joint ring is used between cylinder liner and cylinder head. Old joint ring - 11.8 mm wide New joint ring - 15.0 mm wide Both joint rings are 5 mm thick, the oversize rings are 6 mm thick.



Removal of anti-polishing ring (without groove) 1. Bar the engine so that piston top edge is below the anti-polishing ring. 2. Place the removal device on the piston so that the recess is inside the anti-polishing ring. 3. Slightly tighten the removal device by turning spindle nut (1). 4. Press out the anti-polishing ring by barring the piston upwards.



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Engineer’s Handbook Cylinder Liner



M 20



Removal of anti-polishing ring (with groove) (old, very rare device) 1. Clean the groove in the anti-polishing ring. 2. Bar the engine to move the piston downwards until pressure ring (1) of the removal device with spring ring (2) can be inserted. The spring ring must rest safely in the groove of the anti-polishing ring. 3. Put liner supports (3) onto an unusable joint ring and tighten with the cylinder head nuts so as to be finger tight. The unusable joint ring serves as a protection of the sealing surface in the liner. The liner must not be lifted when barring the engine to remove the anti-polishing ring. 4. Carefully bar the engine to move the piston upwards. In doing so, permanently watch the anti-polishing ring in the cylinder liner.



Unusable joint ring for protection of the sealing surface



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Engineer’s Handbook Cylinder Liner



M 20



c2



Cylinder liner installation The cylinder liner must slide into the engine block by its own weight. Make sure the liner is installed in correct orientation, i.e. marking (1) must point to the free end in longitudinal direction. On the cooling collar there is a cast lug (2), which serves as an alignment aid. Install the anti-polishing in such a way that its marking has the same orientation as the marking of the cylinder liner.



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Engineer’s Handbook Crankshaft



M 20



Crankshaft Crankshaft bearing 1. Insert studs (1) with Molykote



M = 400 Nm



⇒



2. Tighten round nuts for crankshaft bearing (2) evenly by hand. 3. Tighten hexagon screws (lateral screws) (3) starting at camshaft (operator) side alternately in three steps. Molykote 3.1



⇒



M = 100 Nm



3.2



⇒



M = 300 Nm



3.3



⇒



M = 480 Nm



3.1



⇒



M = 100 Nm



3.2



⇒



M = 280 Nm



3.3



⇒



Dw = 30°



Alternative tightening (alternately in three steps):



Exhaust side



Camshaft side



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Engineer’s Handbook Crankshaft



M 20



4. Mount device as per drawing 1.10.7-92.03.00-01 (sheet 2) and stretch crankshaft bearing bolts with (effective area: 54.8 cm2) and tighten nuts with a pin. Molykote



⇒



P = 750 bar



This corresponds to a torque angle of ⇒ Dw = 135° or 3 holes (additional check) Always tighten the crankshaft bearing nuts of one bearing block in one operation. 5. Check: Decrease pressure to ⇒ P = 700 bar Loosening of the nuts must not be possible any more. The pressure must remain constant when the pump is not operated, otherwise they are not properly tightened.



Disassembly of crankshaft bearings If the crankshaft bearings cannot be loosened at P = 750 bar, the pressure can be increased by 50 bar to 800 bar. If the pressure is increased further, there is a risk of the thread getting stretched and the nuts getting jammed.



Marking of the crankshaft bearings Bearing caps and bearing shells are marked on camshaft side with the respective cylinder numbers, counted from the driving end. The parts must not be mixed up. The bearings subjected to highest load are: 6 M 20: Bearing 4 8 M 20: Bearing 5 9 M 20: Bearing 6



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Engineer’s Handbook Crankshaft



M 20



Measurement of the gap 1. Remove lateral screws of the crankshaft bearing and loosen those of the adjacent crankshaft bearings by a few turns. 2. Loosen both crankshaft bearing nuts of one bearing block in one operation. Use hydraulic device as per drawing 1.10.7-92.03.00-01 (sheet 2). 3. Tighten crankshaft bearing nuts alternately and evenly by hand until the joint faces of the bearing shells just touch each other. 4. Check the projecting length of the bearing shell by measuring the gap between engine block and bearing cap on camshaft and exhaust gas sides. Gap K = KA+KS (values see below) 5. Then tighten all screws again as described above under "Crankshaft bearing".



Locating and normal bearings Locating and normal bearings are identical. The bottom shells of the normal bearings have a guide groove on camshaft side. The locating bearing cap (bearing 2) has a fixing pin on exhaust gas side. For axial fixation at bearing 2 (locating bearing) install thrust washers (1) with spring dowel pins (2) on bearing cap (3) .



End clearance S = S1 + S2 is



⇒



0.23 + 0.165



mm



Gap K



⇒



0.50 - 0.80



mm



Limit value



⇒



0.40



mm



Locating bearing End clearance



⇒



0.23 + 0.165



mm



Limit clearance



⇒



0.60



mm



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Engineer’s Handbook Crankshaft



M 20



Crank web deflection Limit for cylinders not subjected to any external load (generally applicable to all cylinders, also to cylinder 1 if flywheel hub and flywheel are not yet mounted)



⇒ 0.04 to - 0.06



mm



Limit for cylinders subjected to additional load (normally cylinder 1, on account of the flywheel, and last cylinder if power is actually taken of at the free end)



⇒ 0.04 to - 0.09



mm



⇒ M = 450



Nm



Counterweight installation Tighten screws with Lubricate thread and contact faces with Molykote. Contact pattern of the counterweight surface in accordance with the following schema:



Contact area absolutely required Contact area permissible only in combination with No material build-up permissible



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Engineer’s Handbook Crankshaft



M 20



c2



6 M 20: 12 counterweights 8 M 20: 12 counterweights Crank pin 1 Crank pin 2 Crank pin 3 Crank pin 4 Crank pin 5 Crank pin 6 Crank pin 7 Crank pin 8



2 pcs. 1 pc. left * 1 pc. right * 2 pcs. 2 pcs. 1 pc. left * 1 pc. right * 2 pcs.



9 M 20: 12 counterweights Crank pin 1 Crank pin 2 Crank pin 3 Crank pin 4 Crank pin 5 Crank pin 6 Crank pin 7 Crank pin 8 Crank pin 9



2 pcs. 1 pc. left * none 2 pcs. 2 pcs. 2 pcs. none 1 pc. right * 2 pcs.



* = seen from camshaft side.



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Engineer’s Handbook Crankshaft



M 20



Vibration damper installation with and without power take-off All tightening torques on this page apply to flange shaft installation with and without power take-off. Attention: In case of power take-off at the free end particular attention should be paid to crank web deflection of the last cylinder. The vibration damper is connected to the lubricating oil system of the engine. Each spring pack has its own feed hole. When inspecting the vibration damper check the oil holes for free passage.



Degrease flange surfaces at (2). Pretighten fixing screws (1) with



⇒ M = 100



and finally tighten with Coat thread and screw head contact surface with Molykote paste



⇒ Dw = 90°



Nm



Mount fixing screws (1); at the same time fasten the pump gear support and the gear wheel for the lubricating oil pump drive.



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Engineer’s Handbook Timing gear train



M 20



Timing gear train



Crankshaft gear wheel Put the gear wheel on the crankshaft cone by hand. By means of the hydraulic device build up a pressure of and press gear wheel into its final position.



⇒



P = 500



bar



The slide-on distance is: for 1.10.7-25.30.00-01



⇒



7.2 - 2.7



mm



for 1.10.7-25.30.00-02



⇒



9.1 - 2.95 mm



Dimension from front edge of gear wheel to end of crankshaft ⇒



186 + 0.1 mm



Do not start the engine earlier than 2 hours after releasing the pressure!



Hydraulic connection



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Engineer’s Handbook Timing gear train



M 20



c2



Installation of crankshaft gear wheel 1. Bar the engine so that cylinder 1 is at TDC position (both pressure connections in the crankshaft are vertically aligned). 2. Slide on the crankshaft gear wheel so that the blind hole (without thread) is positioned at about 30° to the left (vertically above the pressure connections there is now a threaded hole). 3. Measure the distance from end of crankshaft to gear wheel. Put on the adapter ring making sure that the locating pin engages in the blind hole. 4. Screw the threaded rod into the crankshaft.The two screw plugs are in the holes. Remove screw plug of hole Z. 5. Screw in and fasten the pressure connection line. Slide on the thrust ring with the smooth side pointing towards the gear wheel. The pressure line is in the recess. 6. Screw the nut onto the threaded rod and tighten it finger tight. Connect the pressure pump and build up a pressure of about 500 bar. Slide the gear wheel onto the cone up to limit stop using a ratchet and the nut. The slide-on distance is for older engines (variant -01) 4.5 mm - 7.2 mm for new engines (variant -02) 6.1 mm - 9.1 mm. 7. Decrease the pressure down to 0 bar. Do not dismount the hydraulic pump. After a minimum dwell time of 20 minutes the device can be removed. 8. Fit the splash plate to the gear wheel. Install the end cover. If there are no spring dowel pins (older engines) center this cover using a dial gauge. Disassembly is to be carried out in reverse order. In doing so, make sure that a distance of about 1 mm is adjusted between pressure nut and thrust ring. Connection S for the flywheel, connection Z for the gear wheel.



Blind hole



With thread for fastening the support ring



M30 for the threaded rod



Connection S



Connection Z



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Engineer’s Handbook Timing gear train



M 20



Intermediate gear Tab washer (2) must firmly rest in the root of the groove of intermediate gear shaft (3). Tighten screws (1) for the tab washer with Molykote



⇒ M = 60



Nm



End clearance on the intermediate gearis



⇒ 0.20 - 0.80



Nm



New design



Old design Extension sleeve



Extension sleeve



Thrust rings Gap min. 0.30 max. 1.40



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Engineer’s Handbook Timing gear train



M 20



Thrust rings Thrust washers of new design are glued in. The adherends must be free of grease. The lubrication grooves of the thrust rings must point towards the gear wheel. Lubrication grooves



Attention! When replacing the O-ring on the intermediate gear shaft make sure that the intermediate gear remains engaged with camshaft and crankshaft gear. Otherwise, there is a risk of valve timing getting misadjusted.



Lube oil nozzles for timing gear train Tighten banjo bolts with



⇒ M = 40



Nm



Backlash values Crankshaft gear wheel - intermediate gear



⇒ 0.20 - 0.40



Nm



Intermediate gear - camshaft gear wheel



⇒ 0.20 - 0.40



Nm



Camshaft gear wheel Cool hub (3) down to -195 °C with liquid nitrogen, insert into ring (4) and secure with circlips (5). After installing the gear wheel on camshaft do not start the engine earlier than 2 hours after releasing the pressure. Tighten screws (1) with Molykote



⇒ M = 85



Nm



Tighten screws (2) with Molykote



⇒ M = 100



Nm



Tighten screws (6) with Molykote



⇒ M = 200



Nm



Tighten screws (7) with Molykote



⇒ M = 60



Nm



Tighten screws (8) with Molykote



⇒ M = 110



Nm



End clearance S is



⇒ S = 0.3 to 0.7 mm



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Engineer’s Handbook Timing gear train



M 20



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Engineer’s Handbook Governor drive



M 20



Governor drive Governor drive, old design Tighten fixing screws (1) for the governor drive pinion with Molykote Tighten castle nut for fastening of helical gear wheel (2) with and then continue to tighten up to the next split pin hole. Molykote paste G



⇒



M = 60



Nm



⇒



M = 30



Nm



Backlash Between helical gear wheel (2) and big governor drive pinion



⇒



0.15 - 0.28 mm



End clearance at (3) between governor bracket and coupling bushing



⇒



0.10 - 0.30 mm



⇒



0.30 - 0.75 mm



at (4) between big governor drive pinion and cover Note: Insert cover with liquid seal. Bushes in the engine block



When replacing bushes (5) and (6) in the engine block, keep the dimensions indicated in the sketch. Before pressing-in lightly oil the bushes, do not use Molykote.



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Engineer’s Handbook Governor drive



M 20



Governor drive, new design Use expander (5) according to the instructions of the manufacturer and with the tools and tests specified by the manufacturer. For assembly, cool helical gear wheel (6), bushes (7) and governor drive shaft (8) down to ⇒ Tighten screws (1) with Loctite 243 Backlash between governor drive pinion (2) and camshaft gear wheel Screw on governor drive casing with sealing compound. If the backlash is too small, insert gasket 1.10.7-41.11.08-03. End clearance at (3) and (4)



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T = - 195



°C.



⇒



M = 40



Nm



⇒



0.2 - 0.38



mm



⇒



0.2 + 0.3



mm



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Engineer’s Handbook Camshaft



M 20



Camshaft Camshaft bearings Tighten fixing screws for the camshaft bearings with Notch (if provided) points upwards. Fixing hole located at the front.



⇒ M = 30



Nm



1.10.7-31.40.00-01 - replaced by 1.10.7-31.40.00-05 (6 M 20) Tighten screws with Molykote 4 screws M12 x 1.5 x 55 ISO 4762 8.8-A3C



⇒ M = 60



Nm



1.10.7-31.40.00-02 - replaced by 1.10.7-31.40.00-06 (8 M 20 / 2 vibration dampers) Tighten screws with Molykote 4 screws M12 x 1.5 X 90 ISO 4762 8.8-A3C



⇒ M = 60



Nm



Vibration damper for camshaft



1.10.7-31.40.00-03 - replaced by 1.10.7-31.40.00-07 (9 M 20 / 3 vibration dampers) Tighten screws (1) and (2) with ⇒ M = 60 Molykote (1) = 4 cheese head screws M12x1.5x130 ISO 4762 8.8-A3C (2) = 2 cheese head screws M12x1.5x45 ISO 4762 8.8-A3C



Nm



Make sure the hole is correctly positioned!



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Engineer’s Handbook Camshaft



M 20



Tightening torques for camshaft Tighten hexagon socket screws (1) with Molykote Tighten screws (2) for flange (3) with Molykote Cheese head screws (4) see



⇒ M = 100



Nm



⇒ M = 100



Nm



⇒ timing gear train



Max. radial runout at (5) (at all bearing supports) of the preassembled camshaft, measured in preassembly device:



⇒ 0.04



mm



Camshaft assembly Before assembly of the camshaft provide camshaft flanges (1) with one parallel pin (2) each. Always press in the parallel pin up to limit stop next to flange index (3) according to the following tables:



6 M 20 Section 1 2 3 4 5 6



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Flange index 4 2 3 4 5 6



©



8 M 20 Section 1 2 3 4 5 6 7 8



Flange index 5 2 3 4 5 6 7 8



9 M 20 Section 1 2 3 4 5 6 7 8 9



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Engineer’s Handbook Lower valve drive



M 20



Lower valve drive Installation (M 20) No air gap is admissible at the joints of the cam follower shafts. Push the cam follower shafts with loosened bearing caps together from both sides so as to be flush. End clearance between two adjacent bearing brackets is



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⇒ 0.10 - 0.20



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Engineer’s Handbook Lower valve drive



M 20



Installation (M 20 C) When replacing shims (1) of any cylinder bar the engine until all rollers of the respective cylinder unit are on the base circle of the camshaft. After that, adjust according to the adjusting instructions on the next page. Pay attention to the position of the shims (1). Document the thickness of the shims for the respective cylinder. Tighten screws (2) with Molykote



⇒ 130



Nm



The end clearance at S is min.



⇒ 0.10



mm



Plug installation Clean and degrease the sealing faces of the plugs and the corresponding holes. Lubricate the sealing faces with Loctite 270 and use the provided drive-in mandrel for installation. After installation the plug edges must be located 1.5 ± 0.5 mm deep in the ends of the cam follower shaft.



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Engineer’s Handbook Lower valve drive



M 20



c2



Adjusting instruction (M 20 C) For IMO version with shim, ccw and cw rotation Note: ± 0.2 mm graduation corresponds to a change in crank angle of about ± 0.3 1. Adjust assembly reference dimension on all cylinders by means of spacer sheets (see chapter “Injection pump“). The lower valve drive is installed with a 2.0 mm basic shim. 2. Turn camshaft in direction of rotation of the engine until the injection pump of cylinder 1 is at commencement of fuel delivery. 3. Loosen the camshaft gear wheel and turn the engine until the graduated disc indicates the corresponding engine adjustment (see chapter "IMO Adjustment", section "Engine adjustments") for cyl. 1. Fix the camshaft gearwheel. 4. Turn the other cylinders to the same position and check the commencement of fuel delivery. Correct the commencement of fuel delivery on the lower valve drive in the following way only if necessary: 4.1 4.2 4.3 4.4



Unscrew upper screws (1) Unscrew lower screws (2) max. 3 mm Replace shim (basic adjustment 2.0 mm) If a subsequent check (replacement of the shims) shows that the adjustment with respect to cylinder 1 is not okay, repeat the adjustment starting from step 2. As from Assembly step: 3 turn the camshaft again counter-clockwise/ clockwise until all cylinders are within the tolerance range with respect to cylinder 1. 4.5 Mount the lower valve drive (see previous page).



5. Check the adjustment of firing on the engine test bed by measuring the injection points (needle bounces) with the injection point tester (as mean value over all cylinders) according to the engine adjustment (see chapter "IMO Adjustment", section "Engine adjustments").



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Engineer’s Handbook Injection pumps



M 20



Injection pumps Insert studs with Molykote Tighten fastening nuts with Molykote



⇒ M = 40



Nm



⇒ M = 50



Nm



Injection pump 0.00.6-43.12.00-72 type: DSFP 1M Tightening torques also apply for 0.00.6-43.12.00-97 and 0.00.6-43.12.00-67 Tighten screws (1) with



⇒ M = 45



Nm



Tighten screws (2) with



⇒ M = 50



Nm



Tighten screws (3) with



⇒ M = 45



Nm



Tighten screws (4) with



⇒ M = 25



Nm



Mixed oil return Stop Lube oil inlet Control travel 36 mm



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Engineer’s Handbook Injection pumps



M 20



Injection pump 0.00.6-43.12.00-79 type: DSFP 1MW Tightening torques also apply for 0.00.6-43.12.00-98 Tighten screws (1) and (2) with



⇒ M = 45



Nm



Tighten screws (3) with



⇒ M = 25



Nm



Tighten spill plugs (4) with



⇒ M = 50



Nm



Tighten countersunk screws (5) with Loctite 243



⇒ M=5



Nm



Mixed oil return Stop Lube oil inlet Control travel 36 mm



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Engineer’s Handbook Injection pumps



M 20



Injection pump 0.00.6-43.12.00-92 type: DSFP 1MWA This injection pump replaces injection pump 0.00.6-43.12.00-79 Tighten screws (1) and (2) with



⇒ M = 45



Nm



Tighten screws (3) with



⇒



M = 25



Nm



Tighten spill plugs (4) with



⇒ M = 90



Nm



Tighten countersunk screws (5) with Loctite 243



⇒ M=5



Nm



Tighten throttle screws (6) with



⇒ M = 90



Nm



Mixed oil return Stop Lube oil inlet Control travel 36 mm



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Engineer’s Handbook Injection pumps



M 20



Fuel distributing and collecting pipe (compensator tubes / old design) Tighten screws (1) (M12 x 95 DIN 931) to the fuel pump alternately with



⇒ M = 50



Nm



Fuel distributing pipe (plug-in tubes) (for injection pump variants -79 and -92) Remove spring ring (1), then axially displace and remove plug-in tubes (2)



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Engineer’s Handbook Injection pumps



M 20



c2



Dismounting - mounting During dismounting / mounting do not remove the respective spacer plates.The spacer plates are used for adjusting the pre-lift. If for any reason the spacer plates have to be removed, they are to be marked with the respective cylinder number. The thickness of the spacer plates for each cylinder is indicated on the testbed record.



Check of commencement of fuel delivery 1. Remove the injection pump delivery valve. 2. Mount dial gauge with extension. 3. Turn the engine so that the roller rests on the cam base circle and the TDC mark is abt. 45 before the dead centre indicator. 4. Set dial gauge to "0", turn the engine in direction of rotation until the dial gauge indicates 5 mm (for 170 kW/cyl.) or 4 mm (for 190 kW/cyl.). 5. Check the dimension on the flywheel from TDC mark to dead centre indicator.(1 = 8.8 mm. For commencement of fuel delivery please refer to the testbed record. Commencement of fuel deliveryFiring TDC



Adjustment of commencement of fuel delivery



Determination of spacer plate thickness 1. Place the gauge with measuring device onto a level support with the adjusting bush (dimension = 44.2 mm) and set gauge to "0". 2. Insert measuring device into the injection pump hole in the engine block and read the value off the dial gauge (roller on cam base circle). 3. Displayed value = thickness of spacer plates. Available thicknesses: 2.00 mm 2.10 mm 2.20 mm 2.30 mm 2.40 mm 2.50 mm 2.60 mm 2.70 mm 2.80 mm 2.90 mm 3.00 mm



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Engineer’s Handbook Injection pumps



M 20



Adjustment of commencement of fuel delivery with injection pump mounted The roller of the pump drive of cylinder 1 is on the base circle. Remove the connecting piece and the constant pressure valve from the injection pump. Put a dial gauge on the pump plunger. Turn the engine in direction of rotation until the dial gauge indicates 5 mm (non-current engines with 170 kW/cyl.) or 4 mm (new engines with 190 kW/cyl.). Screw the pressure pipe of the hydraulic pump into the respective threaded hole of the camshaft and tighten it. Mount hydraulic pump and apply a pressure of approximately 900 - 1000 bar. Turn the crankshaft to the respective commencement of fuel delivery (see testbed record). Note: If necessary, fix the camshaft (with mounted injection pumps this is normally not necessary ). After mounting crankshaft gear wheel and flywheel check the TDC position of the first cylinder for correct flywheel markings. If necessary, apply new markings.



Adjustment of assembly reference dimension Determine dimension 44.2 mm with device



For adjusting the correct dimension use a spacer plate (1) of corresponding thickness



Top edge of engine block



Dimension 44.2 mm including a clearance of



⇒ S = 0.2



mm



Max. limit clearance



⇒ S = 0.6



mm



Max. deviation between spacer plate and measuring value ⇒ S = 0.05



mm



Tighten nuts (2) with Molykote



Nm



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⇒ M = 50



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Engineer’s Handbook IMO Adjustment



IMO Adjustment



M 20



c2



Note: When the IMO adjustment is changed the engine will loose its certificate.



IMO engine adjustments



M 20 C 170 kW/cyl. 900 rpm



1. Commencement of fuel delivery Commencement of fuel delivery as arithmetic mean value over all cylinders. 7.5° (+0.5° -2° ) Nominal value: Measured according to: Overflow method, control travel = 25 mm or: Pre-lift dimension 4.2 mm at the auxiliary device 2. LT cooling water temperature Water inlet temperature: Nominal value:



38 °C (±2 °C)



3. HT cooling water temperature Water outlet temperature: Nominal value:



90 °C (±2 °C)



4. Charge air temperature Nominal value:



50 °C (±5 °C)



5. Piston distance Distance: Nominal value: Measured:



Piston - liner: 12 mm (±1.0 mm) Top edge of piston - top edge of anti-polishing ring



Adjustment of TDC mark, IMO marking and adjustment of commencement of fuel delivery of the injection pumps according to the relevant job cards.



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Engineer’s Handbook IMO Adjustment



M 20



c2



M 20 C 190 kW/cyl. 1000 rpm



1. Commencement of fuel delivery Commencement of fuel delivery as arithmetic mean value over all cylinders. Nominal value: 9.5° (+0.5° -2° ) Measured according to: Overflow method, control travel = 25 mm or: Pre-lift dimension 4.2 mm at the auxiliary device 2. LT cooling water temperature Water inlet temperature: Nominal value:



38 °C (±2 °C)



3. HT cooling water temperature Water outlet temperature: Nominal value:



90 °C (±2 °C)



4. Charge air temperature Nominal value:



50 °C (±5 °C)



5. Piston distance Distance: Nominal value: Measured:



Piston - liner: 12 mm (±1.0 mm) Top edge of piston - top edge of anti-polishing ring



Adjustment of TDC mark, IMO marking and adjustment of commencement of fuel delivery of the injection pumps according to the relevant job cards.



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Engineer’s Handbook IMO Adjustment



M 20



c2



M 20 170 kW/cyl. 900 rpm



1. Commencement of injection Needle bouncing as arithmetic mean value over all cylinders. Nominal value: 1.5° (+0.5° -2° ) before TDC. Measured with: MaK injection point tester. 2. Commencement of fuel delivery Commencement of fuel delivery as arithmetic mean value over all cylinders. Nominal value: 7.5° (+0.5° -2° ) before TDC Measured according to: Overflow method, control travel > 25 mm or: Pre-lift dimension 4.2 mm at the auxiliary device 3. Cooling water temperature Water inlet temperature: Nominal value:



36 °C (±2 °C)



4. Charge air temperature Nominal value:



45 °C (±5 °C)



5. Piston distance Distance: Nominal value: Measured:



Piston - liner: 12 mm (±1.0 mm) Top edge of piston - top edge of anti-polishing ring



Adjustment of TDC mark, IMO marking and adjustment of commencement of fuel delivery of the injection pumps according to the relevant job cards.



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Engineer’s Handbook IMO Adjustment



M 20



c2



M 20 190 kW/cyl. 1000 rpm



1. Commencement of injection Needle bouncing as arithmetic mean value over all cylinders. Nominal value: 3.5° (+0.5° -2° ) before TDC. Measured with: MaK injection point tester. 2. Commencement of fuel delivery Commencement of fuel delivery as arithmetic mean value over all cylinders. Nominal value: 9.5° (+0.5° -2° ) before TDC Measured according to: Overflow method, control travel > 25 mm or: Pre-lift dimension 4.2 mm at the auxiliary device 3. Cooling water temperature Water inlet temperature: Nominal value:



36 °C (±2 °C)



4. Charge air temperature Nominal value:



45 °C (±5 °C)



5. Piston distance Distance: Nominal value: Measured:



Piston - liner: 12 mm (±1.0 mm) Top edge of piston - top edge of anti-polishing ring



Adjustment of TDC mark, IMO marking and adjustment of commencement of fuel delivery of the injection pumps according to the relevant job cards.



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Engineer’s Handbook IMO Adjustment



M 20



c2



8 M 20 170 kW/cyl. 1000 rpm engine adjustment, RheinSchUO II



1. Commencement of fuel delivery Commencement of fuel delivery as arithmetic mean value over all cylinders. Nominal value: 7° (+0.5° -0.5° ) before TDC Measured according to: Overflow method, control travel > 25 mm or: Pre-lift dimension 4 mm at the auxiliary device 11.01-1040 2. LT cooling water temperature LT water inlet temperature: Nominal value: Working range:



28 °C (±2 °C) for PI governors 20 - 30 °C with P governors



3. HT cooling water temperature Engine cooling water outlet temperature: Nominal value: 85 °C (±2 °C) for PI governors Working range: 80 - 9 °C with P governors 4. Charge air temperature Nominal value: 5. Piston distance (check) Nominal value: 6. Max. firing pressure Nominal value:



40 °C (±5 °C) X = 12 mm (±1.0 mm) See figure below 190 bar (±3 bar)



Adjustment of TDC mark, IMO marking and adjustment of commencement of fuel delivery of the injection pumps according to the relevant job cards.



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Engineer’s Handbook IMO Adjustment



M 20



c2



6 M 20 190 kW/cyl. 1000 rpm engine adjustment, RheinSchUO II



1. Commencement of fuel delivery Commencement of fuel delivery as arithmetic mean value over all cylinders. Nominal value: 8.5° (+0.5° -0.5° ) before TDC Measured according to: Overflow method, control travel > 25 mm or: Pre-lift dimension 4 mm at the auxiliary device 11.01-1040 2. LT cooling water temperature LT water inlet temperature: Nominal value:



28 °C (±2 °C)



3. HT cooling water temperature Engine cooling water outlet temperature: Nominal value: 85 °C (±2 °C) 4. Charge air temperature Nominal value: 5. Piston distance (check) Nominal value:



40 °C (±5 °C) X = 12 mm (±1.0 mm) See figure below



Adjustment of TDC mark, IMO marking and adjustment of commencement of fuel delivery of the injection pumps according to the relevant job cards.



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Engineer’s Handbook IMO Adjustment



M 20



c2



IMO adjustment: Check (M 20) 1. Remove screw plug (1). 2. Turn the engine until the Ø 4 mm hole in the helical gear is centrical with regard to the M10x1 hole in the cover. 3. Check at the flywheel whether the IMO marking coincides with the dead centre indicator (2). 4. After checking screw the screw plug (1) into the cover again.



IMO adjustment: Marking of the flywheel (M 20) 1. After the adjustment turn the engine until the Ø 4 mm hole in the helical gear at (1) is centrical with regard to the M10x1 hole in the cover. 2. Stamp the IMO notch at the dead centre indicator (2) of the flywheel.



IMO adjustment: Check (M 20) 1. Unscrew screw plug at (3). 2. Turn the hole in the camshaft gear wheel so that it is congruent with the IMO check bore in the cover. 3. Check the IMO notch at the dead centre indicator (4) of the flywheel.



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Engineer’s Handbook IMO Adjustment



M 20



c2



IMO adjustment: Marking of the flywheel (M 20 C) 1. Unscrew screw plug at (3). 2. Turn the Ø 4 mm hole of the camshaft gear wheel so that it is congruent with the IMO check bore in the cover. (Notches are provided for additional orientation) 3. Stamp the IMO notch at the dead centre indicator (4) of the flywheel.



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Engineer’s Handbook Miscellaneous



M 20



Miscellaneous Control shaft Insert the control shaft with grease. Do not use Molykote. Tighten screw (1) for the bearing bracket with Molykote



⇒



M = 60



Nm



Check the control shaft for ease of movement. Put coupling lever of the control stand onto the control shaft and clamp it (emergency stop lever in the control stand and fuel rack position of the injection pump at stop). Pin the lever and check adjusting force (30 N): For this purpose connect all injection pumps, connect control stand, disconnected the linkage to the governor. Control shaft adjustment 1. Connect the shaft of the control stand with the control shaft by means of the coupling. Do not yet remove assembly pin for shaft fixation. 2. Shift control rod of the injection pump at cylinder 1 so that line mark and indication coincide. 3. In this position tighten articulated lever with ⇒ M = 25 Nm Molykote In doing so, make sure that a distance of 0.5 mm is kept between control rod head and articulated lever. 4. Repeat the instructions of par. 2 and 3 for all remaining cylinders. 5. Remove assembly pin for shaft fixation in the control stand. 6. Check the fuel rack linkage for ease of movement. 7. Seal the articulated lever with lead. 0.20 clearance



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Engineer’s Handbook Miscellaneous



M 20



Tighten screws (1) and (2) with Molykote



⇒



M = 25



Nm



Fuel rack position transmitter Adjust cam (1) so that at stop position the centre of the fuel rack position transmitter is aligned with the punch mark (2). The dimension at (3) is 3 mm. Make sure there is ease of movement in the pivoting area of the cam disc. If necessary, rework the cam disc.



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Engineer’s Handbook Miscellaneous



M 20



Cooling water distributing pipe / cooling water pipe Tighten screws (1) (M16) at the cooling water blocks with ⇒ Molykote



M = 140



Nm



⇒



M = 20



Nm



2. step Molykote



⇒



M = 50



Nm



Tighten screws (3) (M8, if provided) with Molykote



⇒



M = 15



Nm



Tighten screws (2) (M12, if provided) in two steps: 1. step



Governor arrangement Follow the settings specified on the governor data sheet. Change the governor settings only in exceptions and only after consulting the Technical Customer Service VT5. For further information please also refer to chapter "Governor" in the general section of this handbook.



Fuel filter When installing the filter insert the studs with Do not use lubricants. Screw on intermediate piece with sealing compound.



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⇒



M = 30



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Nm



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Engineer’s Handbook Miscellaneous



M 20



Level probes Tighten the level probes of the electrical equipment with max.



⇒ M = 50



Nm



Expander in the distributor casing Insert expander (1) into distributor casing only in accordance with the instructions of the manufacturer and with the tools and tests specified by the manufacturer.



Starter Upon assembly, insert the pin down to the root of the hole. Pinion and gear ring are to be sufficiently greased. The backlash is ⇒



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0.4 mm - 1 mm



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Engineer’s Handbook Pump support



M 20



Pump support Pump mounting plate Coat thread and screw head contact surface with Molykote paste. Tighten screws (M12) with Molykote



⇒ M = 60



Nm



Tighten screws (M8) with Molykote



⇒ M = 25



Nm



Align pump mounting plate (1) via the centering of pump gear support (2), pin it and screw onto the engine block using sealing compound. Apply sealing compound in the hatched area (5) only. For engines with flange shaft first mount the housing for the flange shaft to the pump mounting plate using sealing compound. Then centre the pump mounting plate with respect to the flange shaft, pin it and screw onto the engine engine block using sealing compound. Secure all unions of the lubricating oil pipe for the pump gear wheels with Loctite 270. Keep the tubes free of contamination. Lubrication nozzles to be oriented towards meshing. Insert expander into pump mounting plate according to the instructions of the manufacturer and with the tools and tests specified by the manufacturer.



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Engineer’s Handbook Pump support



M 20



c2



Cooling water pump TN 40-200 Impeller removal: - Loosen nuts (1) and (2). Then remove washer (3). - Remove impeller in cold or warm condition (max. 200 °C) from shaft by means of the extractor. Note: Impeller and extractor may "jump" off the shaft! Impeller installation: - Press impeller in cold or warm condition (max. 200 °C) onto shaft. Observe reference dimension X = 1.8 ± 0.1. - Slip on washer (3). ⇒ M = 90 - Tighten nut (2) with -



Nm



Secure nut (1) with Loctite and lock against nut (2).



Impeller Shaft



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Engineer’s Handbook Pump support



M 20



Fuel feed pump (gear pump, M 20) Tighten screws (1) with



⇒



M = 14



Nm



Fuel feed pump (M 20, M 20 C) 1. For fastening the gear wheel on the fuel pump drive shaft check the contact surface on the related drive shaft cone by means of a gear cone covered with blue paste. Only a contact surface displaced towards the thick end is admissible. 2. M 20 C: Heat gear wheel up to 120 °C to 130 °C above temperature of the drive shaft and mount it firmly on the related drive shaft cone up to limit stop (e.g. at 20 °C shaft temperature ⇒ 140 °C to 150°C gear wheel temperature). The cone surfaces must be free of grease and dry. The slide-on distance is 0.44 mm. M 20: Heat gear wheel up to 70 °C to 80 °C above temperature of the drive shaft and mount it firmly on the related drive shaft cone up to limit stop (e.g. at 20 °C shaft temperature ⇒ 90 °C to 100 °C gear wheel temperature). The cone surfaces must be free of grease and dry. The slide-on distance is 0.180 mm to 0.216 mm.



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Engineer’s Handbook Pump support



M 20



3. Put on washer (1) and tighten screw (2) with Molykote The backlash is



⇒



M = 60



Nm



⇒



0.24 mm - 0.50 mm



Screw pump onto pump mounting plate using sealing compound.



Heat coupling halves (3) up to 100 °C and shrink fit them onto the related shaft journal as per drawing. After mounting, a clearance of 1 mm shall remain between the coupling halves (see data on dimension X). Observe the installation position of the elastic intermediate body of the coupling.



X-1 (~40)



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Engineer’s Handbook Pump support



M 20



Lubricating oil pump (suction and pressure pump) Cooling water pump (HT and LT circuit) Hydraulic feed pump 1. Check the contact surface of the pump gear wheel cone by means of a gear wheel cone covered with blue paste. Only a contact surface displaced towards the thick end is admissible. Contact surface for oil pumps and cooling water pumps at least 80 %. 2. Heat up gear wheels -



of cooling water pumps to of lubricating oil pumps to of seawater pumps to of hydraulic feed pumps to



80 °C 90 °C 100 °C 120 °C



to to to to



90 °C 100 °C 110 °C 130 °C



above temperature of the pump shaft and firmly mount on the related pump cone up to limit stop. (example: At a shaft temperature of 20 °C heat up the gear wheel of a hydraulic feed pump to 140 °C to 150 °C). The cone surfaces must be free of grease and dry. 3. Mount screw (1) with washer (2) and tighten at room temperature. (Tightening torques see below).



Screw cooling water pumps and lubricating oil pumps onto the pump mounting plate using sealing compound. In doing so, tighten the screws for cooling water pumps with ⇒ M = 52 Molykote



Nm



Slide-on distance for lubricating oil pump



⇒ 0.33 - 0.41



mm



Slide-on distance for cooling water pump



⇒ 0.29 - 0.32



mm



Tighten screw for cooling water pump gear wheel with Molykote



⇒ M = 60



Nm



Tighten screw for lubricating oil pump gear wheel with Molykote



⇒ M = 60



Nm



Tighten screw for hydraulic feed pump gear wheel with Molykote



⇒ M = 60



Nm



Backlash - lubricating oil pump



⇒ 0.20 - 0.47



mm



Backlash - cooling water pump



⇒ 0.20 - 0.47



mm



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Engineer’s Handbook Flywheel installation



M 20



Flywheel installation Installation - removal Note: Before removing a flywheel mark flywheel and crankshaft to avoid installation errors. 1. Turn crankshaft to TDC position of cylinder 1 and position the flywheel in the Ø 50 mm transportation opening so that it is suspended vertically. (In this position the projecting screw heads on the gear wheel on crankshaft are aligned with respect to the corresponding receiving pockets in the flywheel). 2. Push the flywheel onto the crankshaft cone until contact is reached. 3. Mount device and oil press fit and press flywheel to final position on the crankshaft cone with a pressure of 1300 bar (with hand pump). Final position means flush with the end of the crankshaft (as shown on the right). The slide-on distance is or



15.5 - 2.8 mm 16.5 - 3.05 mm



(see overview of flywheel variants on the next page) 5. Loosen the device only 24 hours after releasing the oil press fit. Do not start the engine earlier than 96 hours after removing the holding device.



Gear ring When replacing the gear ring it is not required to disconnect the generator from the engine. Cut through the old gear ring at two positions at random. The new gear ring consists of two gear ring halves. Tighten screws for fastening of the gear ring on the flywheel with Molykote



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⇒ M = 115



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Engineer’s Handbook Flywheel installation



M 20



Used flywheel variants The flywheel variant is stamped on the face end of the flywheel, e.g. 1-09. The following table shows the corresponding slide-on distances for each flywheel variant: Flywheel 1.10.7-73.10.01Old var.



Slide-on distance



- 03



New var.



Slide-on distance



15,5 -2,8 mm



- 09



16,5 - 3,05 mm



- 04



15.5 -2.8 mm



- 10



16.5 - 3.05 mm



- 05



15.5 -2.8 mm



- 11



16.5 - 3.05 mm



- 06



15.5 -2.8 mm



- 12



16.5 - 3.05 mm



- 07



15.5 -2.8 mm



- 14



16.5 - 3.05 mm



- 13



16.5 - 3.05 mm



- 15



16.5 - 3.05 mm



- 16



16.5 - 3.05 mm



- 17



16.5 - 3.05 mm



- 18



16.5 - 3.05 mm



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Engineer’s Handbook Flexible flange connection



M 20



Flexible flange connection VULKAN RATO-R G192 TR, series 2200 (6 M 20) Tighten screws (1) (M12x30, 10.9) with Oil Tighten screws (2) (M18x70, 10.9) with Oil Tighten screws (3) (M12x60, 8.8) with Oil Assembly reference dimension X is



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⇒ M = 100



Nm



⇒ M = 350



Nm



⇒ M = 75



Nm



⇒ 367



mm



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Engineer’s Handbook Flexible flange connection



M 20



VULKAN RATO-DG A2710G, series 2200 (8 M 20) Tighten screws (1) as friction-type connection with Oil (assembly of screws (1) takes place at CAT) Tighten screws (2) (M22x70, 10.9) with Oil Tighten screws (2) (M24x70, 10.9) with Oil Assembly reference dimension Z is



⇒ M = 170



Nm



⇒ M = 675



Nm



⇒ M = 660



Nm



⇒ 365



mm



⇒ M = 250 + 30



Nm



⇒ M = 675 + 75



Nm



⇒ M = 660 + 70



Nm



⇒ 365 ± 0.5



mm



⇒ M = 235



Nm



⇒ M = 675



Nm



⇒ M = 960



Nm



⇒ 389



mm



VULKAN RATO-DG A2710, series 2200 (8 M 20 C) Tighten screws (1) (M16x120, 10.9) with Oil Tighten screws (2) (M22x70, 10.9) with Oil Tighten screws (2) (M24x70, 10.9) with Oil Assembly reference dimension Z is



VULKAN RATO-DG A2911G, series 2200 (9 M 20) Tighten screws (1) as friction-type connection with Oil (assembly of screws (1) takes place at CAT) Tighten screws (2) (M22x70, 10.9) with Oil Tighten screws (2) (M27x80, 10.9) with Oil Assembly reference dimension Z is



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Engineer’s Handbook Flexible flange connection



M 20



c2



Installation description for the above flange connections 1. 2. 3. 4.



Remove screws (3) and washers and free them of preservative. Attach RATO element (5) with assembled chamfered ring (6) to a suitable hoist. Fit hub (4) on the generator shaft journal. Mount RATO element (5) with screws (3) and washers on hub (4) and tighten screws (3) with the a.m. torque. 5. Push the generator with mounted hub and RATO element towards the flywheel until the assembly reference dimension is reached. 6. Mount RATO element with screws (1) and washers on the flywheel of the engine with the a.m. torque. In doing so, make sure that the RATO element has metal-to-metal contact at the outer circumference of the centering of the flywheel. 7. Check the tightening torque of screws (2) and, if necessary, retighten with the a.m. torque.



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Engineer’s Handbook Flexible flange connection



M 20



VULKAN RATO-DS 2511 (6 M 20), 2515 (8 M 20) series 2100 Tighten screws (1) (M14x160, 10.9) with Oil Tighten screws (3) (M16x50, 10.9) with Oil Assembly reference dimension Z is



⇒ M = 165 + 20



Nm



⇒ M = 250 + 30



Nm



⇒ 265 ± 0.5



mm



VULKAN RATO-DS 2911, series 2100 (9 M 20 / 8 M 20 C) Tighten screws (1) (M18x180, 10.9) with Oil Tighten screws (3) (M20x55, 10.9) with Oil Assembly reference dimension Z (9 M 20) is Assembly reference dimension Z (8 M 20 C) is



⇒ M = 350 + 40



Nm



⇒ M = 505 + 55



Nm



⇒ 265 ± 0.5 ⇒ 315 ± 0.5



mm mm



Installation description for the above flange connections 1. Remove screws (3) and washers and free them of preservative. 2. Attach RATO element (5) to a suitable hoist. 3. Fit hub (4) on the generator shaft journal. 4. Mount RATO element (5) with screws (3) and washers on hub (4) and tighten screws (3) with the a.m. torque. 5. Push the generator with mounted hub and RATO element towards the flywheel until the assembly reference dimension is reached. 6. Mount RATO element with screws (1) and washers on the flywheel of the engine with the a.m. torque. In doing so, make sure that the RATO element has metal-to-metal contact at the outer circumference of the centering of the flywheel. en / 24/8/10



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Engineer’s Handbook Charge air cooler



M 20



Charge air cooler



Installation Note: For further details please refer to chapter "Turbocharger Installation". The details below apply for driving end and free end. Tighten screws (1) and (2) with Molykote



⇒ M = 60



Nm



Note: Tighten screws (3) and (4) alternately and in small steps. Finally tighten screws (4) first and then screws (3).



Plug installation Clean and degrease the sealing faces of the plugs. Lubricate the sealing face of the plug with Loctite 270. Use the provided drive-in mandrel for installation. The plug edges must be located 1.5 ± 0.5 mm deep in the casing of the charge air cooler.



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Engineer’s Handbook Charge air cooler



M 20



c2



Cleaning The acceptance test record indicates the differential pressure before / after charge air cooler. In case of an increase to 1.5 the indicated value clean the cooler.



Dismounting Remove cooling water inlet and outlet tubes. Loosen screws (1) and (3) and pull charge air cooler out of the casing. Installation is to be carried out in reverse order. In doing so, pay attention to proper fit of the sealing plates.



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Engineer’s Handbook Turbocharger installation



M 20



Turbocharger installation Note: For further details please refer to chapter "Charge Air Cooler". ST 5 (8 M 20 C) HPR 4000 (6 M 20 C) HPR 5000 (8 M 20 C, 9 M 20 C) Note: The details below apply for driving end and free end. (The illustrations below show a turbocharger of type HPR 5000 installed at the free end.) Before installing the turbocharger mount the bottom plate of the exhaust cladding. If the turbocharger is to be installed at the free end, the pre-assembly part for the turbocharger foot is to be fitted additionally beforehand. Insert bolts and nuts on the expansion joint with Rivolta G.W.F. Do not use any gaskets on expansion joints. When installing charge air cooler covers (1) make sure the contact surfaces are contacting and prevent contact between O ring and liquid seal. Ensure stress-free installation of bracket and turbocharger at (5). Contact surface: Turbocharger cladding. Tighten screws (2) with Molykote



⇒ M = 60



Nm



Tighten screws (3) with Molykote



⇒ M = 130



Nm



Tighten screws (4) with Molykote



⇒ M = 375



Nm



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Engineer’s Handbook Exhaust manifold



M 20



Exhaust manifold



General Insert all screws with Rivolta G.W.F.. Before mounting, spray all connecting links with graphite or molybdenum spray. Insert clamps (1) with Rivolta G.W.F. on the contact surface.



Expansion joint installation Use suitable chocks to adjust the installation length of the expansion joints. After tightening of the exhaust tubes replace the chock by an expansion joint. When mounting the expansion joints pay attention to the flow direction (arrow on the flange). Do not fit any gaskets between expansion joints and exhaust tubes. Insert the screws from expansion joint side. Attention: Displaced drilling pattern in the flanges. Ensure correct screw length. No projection admissible.



Max. 5 mm Recession High nut



Tightening torques Tighten all M12 screws with Rivolta G.W.F.



⇒ M = 60



Nm



Tighten screws (2) with Rivolta G.W.F.



⇒ M = 200



Nm



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Engineer’s Handbook Exhaust manifold



M 20



Tighten screw plugs (3) with Rivolta G.W.F.



⇒ M = 85



Nm



Step 1: Tighten with



⇒ M = 60



Nm



Step 2: Tighten with Rivolta G.W.F.



⇒ M = 110



Nm



Tighten hexagon screws (4) M16 alternately in two steps:



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Engineer’s Handbook Exhaust manifold



M 20



Tighten clamp screws (5) with Rivolta G.W.F.



⇒ M = 25



Nm



Tighten screws (6) with Rivolta G.W.F.



⇒ M = 90



Nm



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Engineer’s Handbook Exhaust pipe cladding



M 20



c2



Exhaust pipe cladding



Tightening torques Tighten the high-temperature screws on the exhaust pipe cladding with the following torques. Insert all screws of the exhaust pipe cladding with Rivolta G.W.F..



Coarse pitch thread



Tightening torque



Pretreatment



M8



11 Nm



Molykote



M10



21 Nm



Molykote



M12



36 Nm



Molykote



M14



58 Nm



Molykote



M16



90 Nm



Molykote



M18



128 Nm



Molykote



M20



179 Nm



Molykote



Assembly gap Pay attention to the assembly gap between the sections of the exhaust pipe cladding.



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Engineer’s Handbook Diesel generator set



M 20



Diesel generator set



Engine and generator fastening Tighten the fastening screws in several steps. Step 1



⇒



20 %



Step 2



⇒



60 %



Step 3



⇒



100 %



Tighten M10 screws of strength class 8.8 with Oil



⇒ M = 40



Nm



Tighten M12 screws of strength class 8.8 with Oil



⇒ M = 70



Nm



Tighten M16 screws of strength class 8.8 with Oil



⇒ M = 170



Nm



Tighten M20 screws of strength class 8.8 with Oil



⇒ M = 400



Nm



Tighten M24 screws of strength class 8.8 with Oil



⇒ M = 500



Nm



Tighten M27 screws of strength class 8.8 with Oil



⇒ M = 800



Nm



Tighten M30 screws of strength class 8.8 with Oil



⇒ M = 1200



Nm



Note: Exceptions to the above tightening torques are the types of generator fastening listed in the following. If you are in doubt, ask VT5 about the tightening torques to be applied in your case. In case of variants 1.13.7-15.30.00-34, 1.19.7-15.30.00-09 tighten the M24 screws on the generator with Oil



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⇒ M = 600



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Engineer’s Handbook Diesel generator set



M 20



In case of variants 1.14.7-15.30.00-06 1.13.7-15.30.00-18 1.14.7-15.30.00-07 1.13.7-15.30.00-28 1.14.7-15.30.00-10 1.13.7-15.30.00-35 1.14.7-15.30.00-19 tighten the M20 screws on the generator with Oil



⇒ M = 420



Nm



Sealing surfaces Apply Hylomar universal sealing compound to the sealing surfaces of engine and base frame. The GORETEX flat gasket to be inserted in between has to be laid towards the engine inside, the cutting points are to overlap by about 200 mm.



Alignment instruction for diesel generator sets Alignment instructions are cost unit specific. The drawing number applicable in your case can be found in PIDS from position 9000 (normally position 9212). The values belonging to the drawing number are included in the table below. In the following alignment instruction replace placeholders A and B by the values from the table that apply for your drawing number. Align the generators in cold condition as follows.



Axial alignment: Push the generators towards the engine until assembly reference dimension of the coupling is A mm (see also chapter "Flexible Flange Connection").



Radial alignment: Raise the generators by means of the jacking screws so that the generator shaft is positioned 0.2 ± 0.1 mm higher than the crankshaft. Angular alignment: Angular ± 0.2 mm measured at coupling outside diameter B mm. In this position place the Vibracon elements onto the top plate. Put through the foundation bolts and fasten finger tight (about 20 Nm). Centre the Vibracon elements with regard to the bolt and raise them by turning until the spherical cap fits closely without any clearance (about 20 Nm). Slacken the jacking screws and tighten the foundation bolts with the prescribed torque.



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Engineer’s Handbook Diesel generator set



M 20



During electrical testing of the generator sets measure crank web deflection at operating temperature (about 10 minutes after shutdown from full load) and record it. Drawing number



A



B



1.10.7-15.33.00-01



265 ± 0.5 mm



730 mm



1.10.7-15.33.00-02



367 ± 0.5 mm



585 mm



1.10.7-15.33.00-03



265 ± 0.5 mm



820 mm



1.10.7-15.33.00-04



265 ± 0.5 mm



730 mm



1.10.7-15.33.00-05



315 ± 0.5 mm



860 mm



1.10.7-15.33.00-06



265 ± 0.5 mm



730 mm



1.10.7-15.33.00-07



365 ± 0.5 mm



800 mm



1.10.7-15.33.00-08



247 ± 0.5 mm



730 mm



For notes regarding tightening torques of the coupling please refer to chapter "Flexible Flange Connection".



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Engineer’s Handbook Resilient mounting



M 20



Resilient mounting



Assembly 1.



When using pourable resin: Clean the unmachined top plates. When using steel chocks: Machine the top plates.



2.



Align the engine with jacking screws. Vertically approx. 3.3 mm above gearbox shaft (gearbox with vertical shaft offset) and horizontally approx. 3.1 mm above gearbox shaft (gearbox with horizontal shaft offset) Transversely Axially



in true alignment with the gearbox. coupling axially relieved.



3.



Drill the top plates for bonded rubber rail fixation (1) and (2) (max. Ø 20 mm).



4.



Install bonded rubber rails (1) and (2) and tighten nuts (3) with Oil



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⇒ M = 160



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Engineer’s Handbook Resilient mounting



M 20



5.1



Pourable resin: Pour the resin around the bonded rubber rails according to the instructions of the resin manufacturer (resin must not contact the rubber). Lower the engine after curing of the resin. (Relieve the jacking screws completely). Static deflection about 2.9 mm.



5.2



Steel chocks: Measure the distance between top plate and bonded rubber rails. Manufacture steel chocks and insert them. Lower the engine according to 5.1.



6.



Fasten bonded rubber rails with screws (4) and washers (5) on the top plate. Tighten screws (4) with Oil



⇒ M = 200



Nm



Adjust 1.5 mm upon assembly



7.



8.



Install stoppers (6) according to their marking (numbers)on the engine mount and tighten nuts (7) with ⇒ M = 160 Oil Weld tube (8) so as to be centered with regard to the stopper.



Nm



Drill top plates for tie rods (9). (The tie rods are yard supply)



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Engineer’s Handbook Resilient mounting



M 20



9.



Install tie rods (9). Adjust a vertical clearance of 1.5 mm between stopper (6) and ⇒ M = 1400 Nm washer (10) and lock nuts (15) with Loctite 242 Lock nuts (11) with ⇒ M = 1400 Nm Oil



10.



Insert rubber lining (12).



11.



Further static deflection (subsidence of the engine after 24 hours) about 0.4 mm. The engine will then be approximately in line with the gearbox shaft. (Gearbox with vertical shaft offset)



12.



At operating temperatures the engine will be about 0.5 mm higher than the gearbox (due to thermal expansion of bonded rubber rail, engine, gearbox and foundation). The flexible coupling is designed for this. Later re-alignment is not necessary.



Tighten nuts (13) with Oil Tighten nuts (14) with Loctite 242



⇒ M = 160



Nm



⇒ M = 160



Nm



After completing the resilient mounting secure the jacking screws against unintentional tightening and loosening by means of spacer tubes between screw head and engine mount. Tighten all M16 hexagon screws used in this procedure with ⇒ M = 200 Oil



Nm



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Engineer’s Handbook Resilient mounting



M 20



Conical elements 8 M 20 C Tighten screws (1) with



⇒ M = 300



Nm



Tighten screws (2) with



⇒ M = 180



Nm



Tighten nuts (3) with



⇒ M = 500



Nm



Tighten nuts (4) with



⇒ M = 260



Nm



Tighten screws (5) with Loctite 243



⇒ M = 180



Nm



Thickness of resin at X:



⇒ 20 mm - 60 mm



Remove all jacking screws after alignment and curing of the resin.



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Engineer’s Handbook Resilient mounting



M 20



Conical elements 8 M 20 C Tighten nuts (1) with



⇒ M = 500



Nm



Tighten screws (2) with



⇒ M = 180



Nm



Tighten nuts (3) with



⇒ M = 500



Nm



Tighten nuts (4) with



⇒ M = 260



Nm



Tighten threaded bolts (5) with Loctite 243



⇒ M = 180



Nm



Thickness of resin at X :



⇒ 35 mm



Remove all jacking screws after alignment and curing of the resin.



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Engineer’s Handbook Resilient mounting



M 20



Conical elements 6 M 20 C, 8 M 20 C, 9 M 20 C Tighten nuts (1) with



⇒ M = 500



Nm



Tighten screws (2) with



⇒ M = 180



Nm



Tighten nuts (3) with



⇒ M = 500



Nm



Tighten nuts (4) with



⇒ M = 260



Nm



Tighten threaded bolts (5) with Loctite 243



⇒ M = 180



Nm



Thickness of resin at X:



⇒ 20 mm - 60 mm



Remove all jacking screws (6) after alignment and curing of the resin.



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