M20 e PDF

Maintenance A0
Maintenance
M 20 / M 20 C
en / 26.01.2011 AA047781 1/1

Total Index A0.01
Maintenance A0
Total Index A0.01
Introduction A0.02
Emergency Stop Safety System A0.04
Maintenance A5
Table of Contents A5.01
Introduction A5.02
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Introduction A0.02
M20/M25/M32/M43
The present operating instructions include notes and guidelines for proper handling of the engine plant. It is
matched with the equipment condition and the type of fuel sold.
Since the type of fuel used considerably influences the service life of the components, the Caterpillar after-
sales service has to be consulted when it is required to change from destillate fuel operation to heavy fuel
oil operation, in order to ensure an expert retrofit of the engine plant and to exchange the necessary docu-
mentation. When changing over from heavy fuel oil operation to destillate operation, the Caterpillar after-
sales service should also be consulted for a longer period of time so that a documentation with extended
maintenance intervals can be made available.
With regard to operation and maintenance of the engine including the necessary work to be carried out, the
operating instructions are subdivided into the following chapters:
Operating Instructions
Maintenance
Technical Engine Data
Operating Media
Control/Regulation
Tool Catalogue
With the respective information contained in the individual chapters, the technical personnel is able to
maintain the engine in such a manner that regarding its output, reliability, economy and service life opti-
mum operating results can be achieved.
If you need further information or if you have any other questions, we kindly ask you to contact our respon-
sible service organization.
The operating instructions do not release the personnel in charge of this engine plant from their duty to take
care. The recognized rules of technology are to be observed, taking into account overriding regulations,
observance of the general safety measures and locally applicable accident prevention regulations. Data or
explanations assumed to be the basic knowledge of trained technical and engine room personnel, are not
contained.
Caterpillar Motoren GmbH Co. KG is not responsible for damage caused by improper operation and
maintenance.
These operating instructions are only intended for our customers. All rights reserved for this docu-
ment. All technical data contained in these operating instructions must neither be reproduced, dis-
tributed nor utilized for competitive purposes or disclosed to third parties without our express
approval.
Postal address: Caterpillar Motoren GmbH & Co. KG, P.O. Box 9009, D-24157 Kiel
Telephone: +49(0)431- 3995-01(chief operator)
Telefax: +49(0)431-3995-2010(after-sales service only)
http://www.marine.cat.com
en / 26/1/11 AA047587 1/1

Emergency Stop A0.04
Safety System
M20/M25/M32/M43
WARNING
Do not perform further starting attempts for a while after the safety/emergency stop
device has triggered!
Note and observe the following points and actions.
If these actions are not observed, severe personal injuries as well as damage to the
engine can occur, which may void the warranty.
NOTE*
With some engine assemblies, in particular in marine applications, an alarm or a po-
wer reduction may be triggered before a safety/emergency stop is performed. If there
are no safety concerns, the engine must also be shut down, if an alarm occurs or en-
gine power is reduced and the causes have to be eliminated.
Actions that must be performed after a safety/emergency stop* occurred:
- Identify the reason for emergency stop based on the points listed below.
- Work through list of corresponding sub-points.
- Contact your Caterpillar Service.
Type of emergency stop:
1. Overspeed condition
2. Lubrication oil (pressure and temperature)
3. Engine room monitoring
4. Cooling water - fresh water - HT (pressure and temperature)
5. Exhaust gas
6. Check pneumatic emergency stop system on engine after every emergency stop
7. Fault messages and measuring points
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Safety System
M20/M25/M32/M43
NOTE
The following checks may be of assistance during troubleshooting and permit identi-
fication of root causes of an emergency stop. However, they cannot cover the entire
spectrum of possible causes.
1. Overspeed condition
Emergency stop due to excessive rpm.
1.1 How high was the maximum rpm before emergency stop was triggered?
1.2 Why did engine go into an overspeed condition?
Check:
• Check if emergency stop safety device is operational.
• Check free operation of adjustment shaft and joint
• Check every single regulator rack of fuel pumps in both directions for proper operation by
pulling and pressing.
• Checking governor drive.
• Verification of possible out of calibration of actuator (if fitted).
1.3 Contact your Caterpillar Service.
2. Lube oil (lube oil pressure, lube oil temperature)
2.1 Emergency stop due to lack of lube oil
Checks:
• Visual inspection of engine.
• Lube oil pump drive:

- Check gears for damage or loss.
• Check lube oil pressure switch.
• Check lube oil filter for metal chips.
• Check oil sump and piping for leaks and cracks.
2.2 Contact the Caterpillar Service.
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Safety System
M20/M25/M32/M43
2.3 Emergency stop due to high lube oil temperature
Checks:
• Check temperature sensor.
• Check oil cooler.
• Check cooling water circuit.
• Pressurize each cylinder through opened indexing valves with shop air.
If there is a rapid pressure drop or if no pressure builds up the cause must be investigated.
2.4 Contact the Caterpillar/ MaK Service.
3. Engine room monitoring
Emergency Stop due to excessive oil mist concentrationsee engine documentation, chap-
ter "Operating Instructions".
Checks:
• Check engine room monitoring device (operational test),

see "engine documentation, chapter "External Documentation" C5.05.11.02.03. nn.
• Visual inspection of engine and gear train,
• of cam shaft trough,
• of combustion chamber,
• of turbo charger.
4. Cooling water (fresh water - HT, pressure and temperature)
Emergency stop due to excessively high cooling water temperature
Checks:
• Visual inspection of engine
• Check temperature sensors
• Check fresh water cooler
• Operational test of LT - Cooling water circuit with cooling water pump.
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Safety System
M20/M25/M32/M43
5. Exhaust gas
Emergency stop due to excessively high exhaust temperature
Checks:
• Check exhaust gas temperature sensors.
• Aftercooler (differential pressure) (refer to A5.05.06.04.02.nn).
• Fuel pumps and fill level scale on each fuel pump.
• Injection valves (refer to A5.05.07.08.01.nn).
• Turbocharger
6. Check pneumatic emergency stop system on engine after every emergency

stop
NOTE
In order for emergency stop safety device to operate properly, 7,5 bar pneumatic
supply has to be available continuously.
Checks:
• Check emergency stop pneumatic system on the engine for leaks.
• Stop valve to main start line upstream from start valve must constantly be open during
operation, see engine documentation, chapter "Operating Instructions".
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Safety System
M20/M25/M32/M43
7. Fault messages and measuring points
CAUTION
The fault messages listed below do not directly lead to an emergency stop, but they
considerably affect reliable engine operation.
If such a fault message appears on the monitoring display of the alarm system, the
engine plant may only be operated for a short time and under permanent observati-
on.
At any rate, the cause of the fault message must be remedied immediately.
7.1 General fault messages:
Fault message: Description:

(Measuring point number)
6105 * Low shutdown air pressure

9631 * Oil mist detector failure
9601 * Terminal set X1 voltage failure
9717 * Terminal set X3 voltage failure
* see also List of Measuring Points, see "engine documentation, chapter "Control/Regulati-
on". C5.05.02.01.nn.nn.
7.2 Plant-specific fault messages:
- Safety system failure

- RPM switch unit failure (overspeed)
7.3 Please contact the Caterpillar Customer Service.
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Maintenance A5
Maintenance
en / 26.01.2011 AA000026 1/1

Maintenance A5
Introduction A5.02
Periodical schedule
Distillate fuel A5.04.01
Periodical schedule
Heavy fuel A5.04.02
Engine, cylinder head A5.05.01

Valve Clearance A5.05.01.01.01.00
Valve clearance A5.05.01.01.01.02
Valve Rocker Brackets A5.05.01.02.01.00
Valve Rocker A5.05.01.02.02.00
Valve Rotator A5.05.01.03.01.00
Valve Guide / Oil Scraper Ring A5.05.01.05.01.01
Media line A5.05.01.05.50.00
Cylinder Head A5.05.01.06.01.00
Nozzle Sleeve A5.05.01.06.50.00
Inlet and Exhaust Valve Cones A5.05.01.07.01.01
Valve Cones A5.05.01.08.01.00
Inlet Valve Cones A5.05.01.08.01.01
Exhaust Valve Cones A5.05.01.08.01.03
Inlet Valve Cones A5.05.01.08.01.04
Valve Seat Ring A5.05.01.08.02.00
Valve Seat Ring A5.05.01.08.02.01
Engine, gear A5.05.02

Running Gear/Engine Timing A5.05.02.01.01.00
Crank Web Deflection A5.05.02.02.01.00
Bearing Shells A5.05.02.03.07.01
Al-Grooved Bearings A5.05.02.03.09.01
Big-End Bearings A5.05.02.04.01.01
Big-End Bearings A5.05.02.04.02.00
Main Bearings A5.05.02.05.01.01
Main Bearings A5.05.02.05.02.00
Piston A5.05.02.06.01.01
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Piston A5.05.02.06.01.02
Piston Rings and Grooves A5.05.02.07.01.01
Piston Rings and Grooves A5.05.02.07.01.03
Piston A5.05.02.10.01.01
Engine, housing A5.05.03

Crankcase Explosion Relief Valves A5.05.03.01.01.00
Explosion Relief Valve A5.05.03.01.01.02
Explosion relief valve A5.05.03.01.01.03
Zylinderbuchse A5.05.03.03.01.02
Cylinder Liner A5.05.03.04.01.00
Cylinder Liner A5.05.03.04.02.00
Engine Bolting and Unions A5.05.03.07.01.00
Engine, control A5.05.04

Camshaft Bearing A5.05.04.01.01.00
Camshaft A5.05.04.04.01.00
Camshaft A5.05.04.04.01.01
Camshaft A5.05.04.04.01.02
Timing Gear Train A5.05.04.08.01.00
Governor Drive A5.05.04.08.03.00
Vibration damper on camshaft A5.05.04.09.01.00
Vibration damper on camshaft A5.05.04.09.01.01
Vibration Damper on Camshaft A5.05.04.09.01.02
Engine, regulation A5.05.05

Control shaft bedding A5.05.05.01.02.00
Fuel Limiter A5.05.05.04.01.00
Fuel Limiter A5.05.05.04.01.01
Servo-Actuator A5.05.05.04.02.00
Servo-Actuator A5.05.05.04.02.01
Starting Fuel Limiter A5.05.05.05.01.00
Control Valves A5.05.05.09.05.00
Compressed-Air Filter A5.05.05.09.06.00
Compressed-Air Filter A5.05.05.09.06.01
Regleröl A5.05.05.25.00.01
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Engine, exhaust gas system/supercharging A5.05.06

Exhaust Manifold A5.05.06.01.01.00
Exhaust Manifold A5.05.06.01.01.01
Charge Air Cooler A5.05.06.04.02.00
Exhaust gas turbocharger A5.05.06.05.00.01
Exhaust gas turbocharger
Turbine cleaning A5.05.06.05.02.03
Exhaust gas turbocharger
Turbine cleaning A5.05.06.05.02.04
Turbocharger A5.05.06.13.01.00
Abgasturbolader A5.05.06.13.01.07
Exhaust gas turbocharger - HPR 5000 -
(KBB) A5.05.06.13.02.11
Exhaust gas turbocharger - HPR 4000 -
(KBB) A5.05.06.13.02.12
Engine, fuel system A5.05.07

Injection Pump A5.05.07.02.01.00
Fuel Injector A5.05.07.07.01.00
en / 26.01.2011 AA020041 3/4


Duplex Fuel Filter A5.05.07.12.01.00
Duplex Fuel Preliminary Filter A5.05.07.12.02.02
Duplex Fuel Preliminary Filter A5.05.07.12.02.04
Fuel Feed Pump A5.05.07.13.01.00
Fuel Distributor Line/Manifold Line A5.05.07.15.01.00
Fuel / Fuel collector rail A5.05.07.15.01.01
Engine, lubricating oil system A5.05.08

Lubricating Oil System A5.05.08.02.01.00
Lube Oil Pump A5.05.08.03.01.00
Lube Oil Pump A5.05.08.03.02.00
Lubricating Oil Duplex Filter A5.05.08.04.01.00
Oil pressure control valve A5.05.08.05.01.00
Oil pressure control valve A5.05.08.05.01.01
Prelubricating pump/Prelubrication A5.05.08.10.00.00
Engine, cooling water system A5.05.09

Centrifugal Cooling Water Pump A5.05.09.07.01.00
Engine control equipment A5.05.11

Pressure Switches A5.05.11.01.02.01
Pressure Switches A5.05.11.01.03.00
RPM Switch A5.05.11.05.01.02
Lubricating Oil/Cooling Water Thermostat A5.05.11.06.01.00
Lubricating Oil/Cooling Water Thermostat A5.05.11.06.01.01
Pressure Switch A5.05.11.06.05.02
Pressure Switch A5.05.11.06.06.02
Crankcase Monitoring Device A5.05.11.09.01.03
Engine auxiliary units A5.05.12

Vibration Damper A5.05.12.04.01.03
en / 26.01.2011 AA020041 4/4

Introduction A5.02
M20/M25/M32/M43
1. General
It is assumed that the engine room personnel has the necessary knowledge and experi-
ence required for the proper maintenance and servicing of diesel engines. For this rea-
son and in the interest of clearness we did not go too much into details in the
maintenance documents.
No claims can be raised owing to missing instructions in the maintenance documents, if

damage is caused by improper handling.
All information refers to the date of printing.
2. Explanation of the maintenance system
2.1 Scheduled maintenance
Without “Scheduled maintenance” the economic operation of supercharged engine is in

the long run not possible at today's state of art.
The explanations are used to make the user of this engine plant familiar with the existing
maintenance system of Caterpillar Motoren GmbH & Co. KG and to interest and deepen
the understanding of the user for the problems and importance of the “Scheduled
maintenance”.
It is the purpose of the maintenance to replace parts subject to wear and tear or to repair
these parts before they are damaged.
The “Scheduled maintenance” is thereby supported by inspections according to fixed

deadlines. These inspections are decision criteria for the need and extend of mainte-
nance and servicing.
The following is used as parameter:
• data on wear and tear

• evaluation criterion and
• performance checks
Most of the work to be carried out does not have a fixed deadline since the service life of
individual components is highly influenced by environmental and operating conditions,
fuel qualities and their care.
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Introduction A5.02
M20/M25/M32/M43
Therefore the present interval schedule shall not be considered stringent in the long run,
but it is left to the user to modify the maintenance schedule in accordance with own
experiences.
But in any case a sufficient safety margin - even if the mean wearing levels are well-
known - is to be calculated in order to cover the always occurring variations.
It is recommended to consult Caterpillar Motoren GmbH & Co. KG with regard to exten-
ded intervals in order to maintain the guarantee.
The information given by us gives no rise to legal claims.
2.2 Maintenance system
The maintenance system consists of:
• work interval schedule
• job cards
• maintenance schedule (large-scale plan) *
While the work interval schedule indicates the date when inspection, maintenance or
repair shall be carried out, the job cards indicate the manner in which the work is to be
carried out.
* will be handed during commissioning of the engine
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Introduction A5.02
M20/M25/M32/M43
2.2.1 Work interval schedule
The work interval schedule shall provide for a quick summary of all intended inspection,
maintenance and repair work occurring up to 90,000 operating hours.
The interval schedule is subdivided into the following four areas:
• Daily inspection and control work
• Initial inspection and maintenance work
Work which has to be carried out after first commissioning or commissioning after
major repair work.
• Periodic maintenance work
A list of all recurrent inspection, maintenance and repair work to be carried out at the
scheduled date.
The indicated intervals are statistical mean values. Other values may be obtained,
depending on equipment condition, operating and maintenance conditions.
• Maintenance work to be carried out independent of deadlines
List of work which may be required in the scope of scheduled work which cannot be
allocated to a deadline.
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Introduction A5.02
M20/M25/M32/M43
2.2.2 Job cards
The job cards are instructions for inspection, maintenance, repair and safety check.
¬
Title of the job card
Maintenance work Activity
Discharge valve A5.05.01.04.01.03

Inspection / Dismounting and mounting
Operating hours/maintenance deadline
M20/M25/M32/M43
6,000 / 12,000
Engine type 01
Register
Main maintenance group
See also: 01.01.01.nn, 01.02.01.nn, 01.08.01.nn

Spare parts list: B1.05.01.7.2104, B1.05.01.7.2220
Time requirement: 1 Pers. / 3 h
Personnel qualification: skilled engine hand
Operating medium: Heavy fuel and destillate fuel
Breakdown
Chapter maintenance Subchapter
Operating Instructions Job cards
Job cards
Document number
A5.05. 01.04.01.03
Main maintenance group
Maintenance group
Subgroup
Variant
en / 30.01.10 IB000003 1/1
Date of issue
Registration number Page/number of pages
Language
The job card number consists of the index breakdown (A5.05) and the maintenance
number (bold) subdivided into four pairs of digits.
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Introduction A5.02
M20/M25/M32/M43
• The first pair of digits indicates the engine main maintenance group:
01. Cylinder head 08. Lube oil system
02. Driving mechanism 09. Cooling water system
03. Engine housing 10. Starting air system
04. Engine control 11. Monitors
05. Regulation 12. Auxiliary generator sets and tools
06. Exhaust gas system/ 13. Additional installation

supercharging
07. Fuel system
In order to facilitate the finding of the engine main group, the pair of digits on the right
margin has been set as register 01 .
• The second and third pair of digits indicates the subgroups of the main group and
the titles of the job card where maintenance work is required.
• The fourth pair of digits indicates the type of variant.
• See job card: Reference is made to other job cards required for maintenance work.
At this point the types of variants (fourth pair of digit) are marked “nn”.
• Spare parts sheets: For easy finding of necessary comsumables and spare parts for
the maintenance group in the Spare parts catalogue, indicating other design details
in the illustrations, if necessary.
The third pair of digits in the index breakdown in the spare parts number indicates the
main group/register.
• Fuel: Documenting the sold type of fuel of the engine plant.
• In the maintenance sheets the checks, maintenance, cleaning and repair works of the
maintenance sheets are briefly designated
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Introduction A5.02
M20/M25/M32/M43
• Under the designation "tools (W)" only special and additional tools are listed with the
tool No. Not all of these tools are included in the normal scope of supply.
• Together with the engine type it will be indicated for what engine the job card is valid.
• The indicated personnel and time requirement does not define the working time of
the individual person.
• The indicated time is based on estimated mean values which may deviate according
to the equipment of the plant and its maintenance conditions. Wherever the required
working time depends on the number of cylinders the indicated time of the mainte-
nance sheets refers to one cylinder unit only.
2.2.3 Maintenance schedule (Periodic maintenance work)
A large-scale plan showing all maintenance work up to the largest maintenance interval
clearly indicating all occurrences and the future work expenditure for the individual
components.
It would be useful to mount the plan on a wall; when this is not possible for space rea-
sons, it has to be folded and filed in the map “maintenance forms” *.
We cannot and will not give instructions for handling this plan but we will only give you
some guidelines how to use this plan as an aid for the maintenance system.
The work already carried out will be countersigned in fields intended for this purpose.
Different colours can be used to differentiate between the results, e.g.: green = no
defects/o.k.; yellow = readjustment/correction (e.g. clearances); red = damage/replace-
ment of parts.
Typical consumption parts which are replaced routinely or any time mounting is carried
out (O-ring seals, O-rings etc.) are not considered defective parts.
* The map will be handed during commissioning of the engine
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Introduction A5.02
M20/M25/M32/M43
3. Safety instructions
3.1 Safety symbols
In the present operating instructions the following warning notices are used:
DANGER
A warning notice of this risk level signals the threat of a dangerous situation.
If the dangerous situation is not prevented, it will lead to death or serious injury.
Follow the instructions in this warning notice to prevent the risk of death or serious injury to
persons.
WARNING
A warning notice of this risk level signals a potentially dangerous situation.

If the dangerous situation is not prevented, this could lead to death or serious injury to persons.
Follow the instructions in this warning notice to prevent the possible risk of death or serious injury
to persons.
CAUTION
A warning notice of this risk level signals a potentially dangerous situation.

If the dangerous situation is not prevented, this could lead to minor or moderate injury.
Follow the instructions in this warning notice to prevent injury to persons.
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Introduction A5.02
M20/M25/M32/M43
CAUTION
A warning notice of this risk level signals possible damage to property.

If the situation is not prevented, this could lead to damage to property.
Follow the instructions in this warning notice to prevent damage to property.
NOTE
A note identifies additional information that facilitates the handling of the engine.
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Introduction A5.02
M20/M25/M32/M43
3.2 General safety instructions
Our engine is equipped with a monitoring system and an emergency stop system to prevent da-
mage caused to the operators' health as well as damages to the engine.
Within the scope of commissioning all mechanical, electric and pneumatic equipment and sy-
stems allowing the engine to be stopped for safety reasons will be demonstrated and explained
by our commissioning personnel.
Participants in this acceptance procedure are the authorized personnel of Caterpillar Motoren
GmbH & Co. KG, the managing and operating personnel of the operator and also representatives
of the insurance companies.
This important system is subject to recurrent inspections and tests in order to ensure proper
function of its individual components.
In the section "Scheduled Maintenance" you will find the respective test frequencies and related
job instructions that should be followed to protect the personnel from injuries and prevent material
damages.
NOTE
The provisions of the relevant accident prevention regulations of the appro-

priate employer's liability insurance association are to be observed any time
operation and repair work is carried out.
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Introduction A5.02
M20/M25/M32/M43
WARNING
Keep all handles, steps, handrails, platforms, ladders free from dirt, e.g. oil,
grease, fuel!
Use only suitable and technically perfect lifting gear and suspension systems
with adequate lifting capacity!
Never work or stand under suspended loads!
During replacement work, individual parts and large assemblies are to be ca-
refully fastened and secured on hoists to avoid risks of accidents!
Re-install removed guards and protecting devices on completion of work.
When carrying out overhead assembly work, the specially designed or safe-
ty-oriented climbing aids are to be used only!
Do not use engine/plant parts for climbing on!
Use personal protective equipment as far as necessary or as required by the

regulations!
Pressurized plant components (lube oil, hydraulic oil, fuel, cooling water, star-
ting and control air) must be depressurized. Shut-off valves are to be secured
by a plate “Do not open”!
When work is being carried out on engines and systems, the switch-on de-
vices have to be switched off and protected. In order to prevent reconnection,
the engines and systems have to be marked with a plate “Do not switch” or
an appropriate pictogram plate!
Mounting openings are to be protected!
Replaced seals should be disposed of immediately, and above all, it should

be taken care that this material is not overheated even by accident e.g. du-
ring combustion and welding operations. If this should however has happen-
ed, the gases emitted must not be inhaled. Skin contact with decomposed
VITONR is to be avoided at all times. After a fire with VITONR, it is essential
that neoprene gloves are worn during the clearing up operations.
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Introduction A5.02
M20/M25/M32/M43
CAUTION
Seals made of VITONR have been used at various locations in the engine.
With normal engine operation this material is completely harmless, however it
should not be exposed to temperatures above 300 °C, since above 325 °C a
thermal decomposition and the formation of hydrofluoric acid can occur.
CAUTION
Maintenance and repair work must only be carried out by skilled and autho-
rized personnel!
NOTE
Any residues have to be neutralized before their disposal, i.e. saturated with
calcium hydroxide.
Clean the engine parts, especially connections and threaded unions of any
traces of oil, fuel or preservatives before carrying out maintenance/repair (di-
sassembly, assembly)!
Never use aggresive detergents and preservatives!
Use non-fuzzy cleaning rags!
Observe all indicating labels attached to the engine!
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Introduction A5.02
M20/M25/M32/M43
3.3 Working on electrical equipment
CAUTION
Work on the electrical equipment of the engine/plant must be carried out only
by a skilled electrician or by instructed persons under the supervision and
guidance of a skilled electrician in accordance with the electrical engineering
rules and regulations!
Use only original fuses with the specified current raiting! Switch off the engi-
ne/plant immediately if trouble occurs in the electrical system!
The electrical equipment is to be inspected/checked at regular intervals.

Defects such as loose connections or scorched cables must be rectified imme-
diately!
DANGER
Engine or plant parts on which inspection and maintenance work is being car-
ried out have to be - if prescribed - shut off at the power supply and provided
with the notice “Do not switch on” or the corresponding warning sign!
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Introduction A5.02
M20/M25/M32/M43
3.4 Working with hydraulic devices
WARNING
Do not place parts of your body above/below pressurized hydraulic tools!
Replace hydraulic hose lines at regular intervals, even if no safety relevant

defects are detectable!
Operating instructions, tightening torques and setting dimensions specified in

the appropriate job card are to be carefully observed!
The minimum bending radius of the high-pressure hoses are to be strictly ob-
served!
The hose lines are to be protected against damage caused by external

mechanical, thermal or chemical influences!
3.5 Checking and adjustment of injection valve
CAUTION
During testing make sure that no parts of your body are positioned in the area of the
fuel jet!
Do not inhale the fuel mist - respiratory mask!
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Introduction A5.02
M20/M25/M32/M43
3.6 Handling of liquid nitrogen or carbon dioxide snow
WARNING
When handling liquid nitrogen or carbon dioxide snow, safety shoes, safety
gloves and safety glasses are to be worn in order to avoid injuries. Observe
protection against cold!
CAUTION
Parts of the skin which have come into contact with liquid nitrogen or carbon
dioxide snow must not be rubbed but covered with sterile surgical bandage
3.7 Cleansing agents/chemicals
NOTE
Use only cleansing agents with a flash point above 65 °C!
Observe instructions for use in accordance with DIN safety data sheet of the regulati-
ons for dangerous substances!
Observe the specialist disposal of all cleansing agents and chemicals in accordance
with the regulations for dangerous substances!
In case of accident, observe the accident leaflets including first-aid actions for
dangerous substances in accordance with the regulations for dangerous substances!
en / 14.12.2010 AA047605 14/15

Introduction A5.02
M20/M25/M32/M43
3.8 Proposition 65 Warning
NOTE
California / USA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the state of
California to cause cancer, birth defects, and other reproductive harm.
en / 14.12.2010 AA047605 15/15

Periodical schedule A5.04.01
Distillate fuel
M20
Intervall Designation / Doc-Nr.

Work to be carried out
Remarks
Daily inspection and monitoring procedures

(if it is not automated)
--------------------------------------------------------------------------------------------------------------------------------
General Engine operating data Chapter 3
Compare with acceptance test records: Technical engine data
Speed, rating Acceptance test record
Temperature Lubricating oil Chapter 3

Engine inlet; Temperature rise at rated output Technical engine data
see also acceptance test record Temp. of operating medias
Temperature Cooling water Chapter 3

Engine outlet; Temperature rise at rated output Technical engine data
Temperature Nozzle cooling oil Chapter 3 Chapter 3

Upstream nozzles Technical engine data
Temp. of operating medias
Temperature Cooling water A1.10

Upstream charge air cooler; downstream charge air cooler
Upstream charge air cooler; Technical engine data
downstream charge air cooler Acceptance test record
Temperature Exhaust gas Chapter 3

After cylinder; downstream turbocharger Technical engine data
Acceptance test record
Pressure Lubricating oil Chapter 3

At the main bearing or at the camshaft bearing Technical engine data
see also acceptance test record Press. of operating medias
Pressure Cooling water Chapter 3

Upstream engine Technical engine data
Pressure Fuel Chapter 3

Upstream pumps Technical engine data
Press. of operating medias
Pressure Control air Chapter 3

Technical engine data
Pressure Starting air Chapter 3

Pressure Charge air Chapter 3

en / 26.01.2011 AA020780 1/9

Distillate fuel
M20

Remarks
Lube oil Lube oil circulation tank Chapter 1

system Check of the lube oil level Operating instructions
Lube oil Lubricating oil duplex filter A5.05.08.04.01.00

system Maintenance/Cleaning
at 50 % differential pressure
Cooling Expansion tank Chapter 1

water system Check of the cooling water level Operating instructions
Fuel Day tank Chapter 1

system Check of the fuel level Operating instructions
Fuel Fuel duplex filter A5.05.07.12.01.00

Pressure air Air bottles Chapter1

Drain Operating instructions
en / 26.01.2011 AA020780 2/9

Distillate fuel
M20

Remarks
First inspection and maintenance procedures

Work to be carried out after the first commissioning or after major repairs.
--------------------------------------------------------------------------------------------------------------------------------
24 h Duplex fuel filter A5.05.07.12.01.00
Maintenance/Cleaning
at 50 % differential pressure clean strainer
24 h Lubricating oil system A5.05.08.02.01.00

Maintenance/Oil change
24 h Lubricating oil duplex filter A5.05.08.04.01.00

at 50 % differential pressure clean cartridges
150 h Valve clearance A5.05.01.01.01.nn

Inspection/Adjust
150 h Engine bolting and unions A5.05.03.07.01.00

Inspection/Checking
Tight fit and leaks
150 h Compressed air strainer A5.05.05.09.06.nn

en / 26.01.2011 AA020780 3/9

Distillate fuel
M20

Remarks
Periodical maintenance procedures

--------------------------------------------------------------------------------------------------------------------------------
24 h Turbocharger A5.05.06.05.00.01
see book C
150 h Valve rotor A5.05.01.03.01.00

Inspection/Evaluate
150 h Cylinder head A5.05.01.10.00.00

Inspection/Checking
of all cylinder units
150 h Vorschmierpumpe/Vorschmierung A5.05.08.10.00.00

Wartung/Prüfen
300 h Turbocharger A5.05.06.05.00.01

see book C
300 h Turbocharger A5.05.06.13.01.nn

see book C
750 h Cooling water system A4.05.09.01

Inspection/Anti-corrosion oil
750 h Duplex Fuel Filter A5.05.07.12.01.00

1.500 h Valve clearance A5.05.01.01.01.nn

Inspection/Adjust
1.500 h Running gear/Engine timing A5.05.02.01.01.00

Inspection/Checking
1.500 h Crankcase explosion safety valve A5.05.03.01.01.nn

Inspection/Checking
1.500 h Control shaft bedding A5.05.05.01.02.00

Maintenance/Checking
1.500 h Governor
Governor behaviour/Governor control rod
see book C

Inspection/Checking
3.750 h Timing gear train A5.05.04.08.01.00

Inspection/Checking
en / 26.01.2011 AA020780 4/9

Distillate fuel
M20

Remarks
3.750 h Actuator A5.05.05.04.01.nn

Inspection/Adjust
3.750 h Starting fuel limiter A5.05.05.05.01.00

Inspection/Disassembly and reassembly
3.750 h Pressure switch A5.05.11.01.02.01

Inspection/Adjust

Inspection/Adjust
3.750 h Governor
Oil change
see book C
7.500 h Anti-corrosion oil emulsion A4.05.09.02

Changing
7.500 h Inlet and exhaust valves A5.05.01.07.01.01

of one cylinder unit
7.500 h Piston rings and grooves A5.05.02.07.01.nn

Inspection/Checking
7.500 h Compressed air filter A5.05.05.09.06.nn

7.500 h Exhaust manifold A5.05.06.01.01.nn

Maintenance/Disassembly and reassembly
7.500 h Turbo Charger Sound Absorber A5.05.06.05.01.nn

Inspection/Cleaning
7,500 h Injection pump A5.05.07.03.01.nn

of one pump
7.500 h Fuel injector A5.05.07.09.01.nn

Repair/Disassembly and reassembly
7.500 h RPM-switch A5.05.11.05.01.02

Inspection/Adjust
7.500 h Lubricating Oil/Cooling Water Thermostat A5.05.11.06.01.nn

7.500 h Oil mist detector A5.05.11.09.01.03

Inspection/Checking
15.000 h Nozzle sleeve A5.05.01.06.50.00

Maintenance/Disassesmbly and reassembly
en / 26.01.2011 AA020780 5/9

Distillate fuel
M20

Remarks

of all inlet and exhaust valves
15.000 h Big-end bearings A5.05.02.04.01.01

Inspection/Disassembly
of one big-endbearing
15.000 h Main bearings A5.05.02.05.01.01

of two main bearings
15.000 h Governor drive A5.05.04.08.03.00

15.000 h Vibration damper on camshaft A5.05.04.09.01.nn

15.000 h Exhaust gas turbocharger A5.05.06.05.00.01

Maintenance/Cleaning resp. revision of turbocharger
see book C
of all pumps
15.000 h Fuel feed pump A5.05.07.13.01.00

15.000 h Lub oil pump A5.05.08.03.01.00

Inspection/Checking
15,000 h Oil pressure regulating valve A5.05.08.05.01.nn

Maintenance/Adjust
15.000 h Centrifugal cooling water pump A5.05.09.07.01.nn

30.000 h Valve rocker A5.05.01.02.02.00

30.000 h Valve guide/Oil scraper ring A5.05.01.05.01.01

Inspection/Replace
at all valves
30.000 h Cylinder head A5.05.01.10.01.01


exchange all big-end bearings
30.000 h Main bearings A5.05.02.05.01.01

exchange of all bearings
en / 26.01.2011 AA020780 6/9

Distillate fuel
M20

Remarks

Inspection/Checking
all cylinder units
30.000 h Cylinder liner A5.05.03.04.01.00

Maintenance/Disassembly
at all cylinder units
30.000 h Control valves A5.05.05.09.05.00

Inspection/Checking

30.000 h Vibration damper A5.05.12.04.01.03

en / 26.01.2011 AA020780 7/9

Distillate fuel
M20

Remarks
Non-interval dependent maintenance procedures

--------------------------------------------------------------------------------------------------------------------------------
Valve rocker brackets A5.05.01.02.01.00
Media guiding system A5.05.01.05.50.00

Cylinder head A5.05.01.06.01.00

Inlet and exhaust valve cones A5.05.01.08.01.nn

Repair/Checking
Valve seat ring A5.05.01.08.02.nn

Repair/Checking

Repair/Reassembly
Crank web deflection A5.05.02.02.01.00

Inspection/Measuring
Bearing shells A5.05.02.03.07.01

Inspection/Evaluate
Al-grooved bearings A5.05.02.03.09.01

Inspection/Evaluate
Big-end bearings A5.05.02.04.02.00

Inspection/Reassembly
Main bearings A5.05.02.05.02.00

Maintenance/Reassembly
Piston A5.05.02.06.01.nn
Piston A5.05.02.10.01.01
Cylinder liner A5.05.03.04.02.00

Engine bolting and unions A5.05.03.07.01.00

Inspection/Checking
Camshaft A5.05.04.04.01.nn
Charge air cooler A5.05.06.04.02.nn

en / 26.01.2011 AA020780 8/9

Distillate fuel
M20

Remarks
see book C
Injection pump A5.05.07.02.01.nn


Fuel injector A5.05.07.07.01.nn

Fuel injector A5.05.07.08.01.nn

Maintenance/Adjust
Duplex fuel filter A5.05.07.12.01.00

Fuel Distributor Line/Manifold Line A5.05.07.15.01.nn

Lubricating oil system A5.05.08.02.01.00

Maintenance/oil change
Lub oil pump A5.05.08.03.02.00

Lubricating oil duplex filter A5.05.08.04.01.00

en / 26.01.2011 AA020780 9/9

Heavy fuel
M20

Remarks
Daily inspection and monitoring procedures

(if it is not automated)
--------------------------------------------------------------------------------------------------------------------------------
General Engine operating data Chapter 3
Compare with acceptance test records: Technical engine data
Speed, rating Acceptance test record
Temperature Lubricating oil Chapter 3

Engine inlet; Temperature rise at rated output Technical engine data

Engine outlet; Temperature rise at rated output Technical engine data
Temperature Fuel Chapter 3


Temperature Charge air Chapter 3

Temperature Exhaust gas Chapter 3

After cylinder; downstream turbocharger Technical engine data
Acceptance test record
Pressure Lubricating oil Chapter 3

At the main bearing or at the camshaft bearing Technical engine data
Pressure Cooling water Chapter 3

Upstream engine Technical engine data
Pressure Fuel Chapter 3

Pressure Control air Chapter 3

Pressure Starting air Chapter 3

Pressure Charge air Chapter 3

en / 26.01.2011 AA021679 1/9

Heavy fuel
M20

Remarks
Lube oil Lube oil circulation tank Chapter 1

system Check of the lube oil level Operating instructions
Lube oil Lubricating oil duplex filter A5.05.08.04.01.00

Cooling Expansion tank Chapter 1

water system Check of the cooling water level Operating instructions
Fuel Day tank Chapter 1

system Check of the fuel level Operating instructions
Fuel Fuel duplex filter A5.05.07.12.01.00

Pressure air Air bottles Chapter1

Drain Operating instructions
en / 26.01.2011 AA021679 2/9

Heavy fuel
M20

Remarks
First inspection and maintenance procedures

Work to be carried out after the first commissioning or after major repairs
--------------------------------------------------------------------------------------------------------------------------------
24 h Duplex fuel filter A5.05.07.12.01.00
at 50 % differential pressure clean strainer
24 h Lubricating oil system A5.05.08.02.01.00

Maintenance/Oil change
24 h Lubricating oil duplex filter A5.05.08.04.01.00
at 50 % differential pressure clean cartridges
150 h Valve clearance A5.05.01.01.01.nn

Inspection/Adjust
150 h Engine bolting and unions A5.05.03.07.01.00

Inspection/Checking
Tight fit and leaks
en / 26.01.2011 AA021679 3/9

Heavy fuel
M20

Remarks
Periodical maintenance procedures

--------------------------------------------------------------------------------------------------------------------------------
24 h Turbocharger A5.05.06.05.00.01
see book C
150 h Valve rotor A5.05.01.03.01.00
Inspection/Evaluate
150 h Cylinder head A5.05.01.10.00.00

Inspection/Checking
of all cylinder units
150 h Prelubricating pump/Prelubrication A5.05.08.10.00.00

300 h Turbocharger A5.05.06.05.00.01
see book C
300 h Turbocharger A5.05.06.13.01.nn

750 h Cooling water system A4.05.09.01

Inspection/Anti-corrosion oil
750 h Duplex fuel prefilter A5.05.07.12.02.nn

750 h Oil mist detector A5.05.11.09.01.03

Inspection/Checking
1.500 h Valve clearance A5.05.01.01.01.nn

Inspection/Adjust
Inspection/Checking
1.500 h Crankcase explosion safety valve A5.05.03.01.01.nn

Inspection/Checking
1.500 h Control shaft bedding A5.05.05.01.02.00

1.500 h Kurbelraumüberwachungsgerät A5.05.11.09.01.03

Kontrolle/Prüfen
1.500 h Governor
Governor behaviour/Governor control rod
see book C
3.750h Running gear/Engine timing A5.05.02.01.01.00
Inspection/Checking
en / 26.01.2011 AA021679 4/9

Heavy fuel
M20

Remarks
3.750 h Timing gear train A5.05.04.08.01.00

Inspection/Checking
3.750 h Actuator A5.05.05.04.01.nn

Inspection/Adjust
3.750 h Starting fuel limiter A5.05.05.05.01.00

Inspection/Adjust

Inspection/Adjust
3.750 h Governor
Oil change
see book C
7.500 h Anti-corrosion oil emulsion A4.05.09.02
Changing


Inspection/Checking
7.500 h Compressed air strainer A5.05.05.09.06.nn


of one pump
7.500 h Injection valve A5.05.07.09.01.nn
7.500 h RPM-switch A5.05.11.05.01.02

Inspection/Adjust
7.500 h Lubricating Oil/Cooling Water Thermostat A5.05.11.06.01.nn

7.500 h Oil mist detector A5.05.11.09.01.03

Inspection/Checking
15.000 h Valve guide/Oil scraper ring A5.05.01.05.01.01
Inspection/Replace
at all valves
en / 26.01.2011 AA021679 5/9

Heavy fuel
M20

Remarks
15,000 h Nozzle sleeve A5.05.01.06.50.00

Maintenance/Disassesmbly and reassembly

of all inlet and exhaust valves
15.000 h Cylinder head A5.05.01.10.01.01

of one big-end bearing
15.000 h Main bearings A5.05.02.05.01.01

of two main bearings
15.000 h Governor drive A5.05.04.08.03.00

15.000 h Vibration damper on camshaft A5.05.04.09.01.nn

of all pumps
15.000 h Fuel feed pump A5.05.07.13.01.00

Maintenance disassembly and reassembly
15.000 h Lub oil pump A5.05.08.03.01.00
Inspection/Checking
15.000 h Centrifugal cooling water pump A5.05.09.07.01.nn

30.000 h Valve rocker A5.05.01.02.02.00

exchange of all big-endbearings
30.000 h Main bearings A5.05.02.05.01.01

exchange of all bearings

Inspection/Checking
all cylinder units
30.000 h Cylinder liner A5.05.03.04.01.00

at all cylinder units
en / 26.01.2011 AA021679 6/9

Heavy fuel
M20

Remarks
30.000 h Control valves A5.05.05.09.05.00

Inspection/Checking

30.000 h Vibration damper A5.05.12.04.01.03

en / 26.01.2011 AA021679 7/9

Heavy fuel
M20

Remarks
Non-interval dependent maintenance procedures

--------------------------------------------------------------------------------------------------------------------------------
Valve rocker brackets A5.05.01.02.01.00
Media guiding system A5.05.01.05.50.00


Inlet and exhaust valve cones A5.05.01.08.01.nn
Repair/Checking
Valve seat ring A5.05.01.08.02.nn

Repair/Checking

Repair/Reassembly
Crank web deflection A5.05.02.02.01.00
Inspection/Measuring
Bearing shells A5.05.02.03.07.01

Inspection/Evaluate
Al-grooved bearings A5.05.02.03.09.01

Inspection/Evaluate
Big-end bearings A5.05.02.04.02.00

Inspection/Reassembly
Main bearings A5.05.02.05.02.00

Piston A5.05.02.06.01.nn
Piston A5.05.02.10.01.01
Wartung/Montage
Cylinder liner A5.05.03.04.02.00

Engine bolting and unions A5.05.03.07.01.00

Inspection/Checking
Camshaft A5.05.04.04.01.nn
Actuator A5.05.05.04.01.nn
Charge air cooler A5.05.06.04.02.nn

Maintenance/disassembly and reassembly
en / 26.01.2011 AA021679 8/9

Heavy fuel
M20

Remarks



Injection valve A5.05.07.07.01.nn

Injection valve A5.05.07.08.01.nn
Maintenance/Adjust
Duplex fuel filter A5.05.07.12.01.00

Fuel Distributor Line/Manifold Line A5.05.07.15.01.nn

Lubricating oil system A5.05.08.02.01.00

Maintenance/oil change
Lub oil pump A5.05.08.03.02.00

Lubricating oil duplex filter A5.05.08.04.01.00

en / 26.01.2011 AA021679 9/9

Valve Clearance A5.05. 01.01.01.00
Inspection / Adjust
M20
1500
See also: 02.01.01.nn 01

Spare parts list: B1.05.01.2.2107
Time requirement: 1 Pers./ 0,50 h
Operating medium: Heavy fuel and distillate fuel

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
150 operating hours after first commissioning or after basic overhaul, the valve clearance is to
be checked and readjusted, followed by a check after 1,500 operating hours.
Tools:
Turning rod W1 * 2.9100-380

Feeler gauge W2 * 1.9075-3
* not available as figure
NOTE
The valve clearance shall only be measured with warm engine, i.e. 15 min after the
engine is shut down.
Valve clearance (Fig. 1/S):
Inlet0.6 mm
Exhaust:0.8 mm
Readjust the valve bridge position to the valve spindles before each valve clearance adjustment, du-
ring inspections at intervals or due to works at the valve drive components
Sequence of operations:
1. Adjust valve bridge.
1.1 Open decompression valves.
1.2 Remove the hoods without damaging the packing.
1.3 Turn the crank shaft in such a manner that the piston of the cylinder to be adjusted is moved to
the ignition dead center position.
en / 30.09.2010 IB021028 1/2

Valve Clearance A5.05. 01.01.01.00
Inspection / Adjust
M20
1500
1.4 Adjust a sufficiently large clearance “s” 01

between the valve rocker (Fig. 1/1) and/or
valve bridge by folding back the valve
rocker (1) and/or by adjusting the valve
adjusting screw (2).
1.5 Loosen counternut (Fig. 2/3) and unscrew

the adjusting screw (4) until there is
sufficient clearance when the valve bridge
is tipped in the direction of rotation “a”.
1.6 Tilt the valve bridge in the direction of

rotation “b” and screw the adjusting screw
(Fig. 3/4) into the valve bridge until the
valve bridge has contact at both valves.
Tighten counternut (3).
NOTE
During tightening of the coun-
ternut, the adjusting screw (4)
turns back so far that an equal
gap between valve bridge and
both valves is obtained.
2. Adjust the valve clearance.
2.1 Measure the clearance (Fig. 1/S) by

means of a feeler gauge. Thereby, press
the pushrod down.
2.2 Correct clearance “s”.
2.2.1 Loosen counternut.
2.2.2 Turn the square of the valve adjusting

screw (2) until the prescribed clearance is
obtained.
2.2.3 Retighten the counternut to fix the position

of the adjusting screw.
2.2.4 Recheck the clearance after the

counternut is tightened.
en / 30.09.2010 IB021028 2/2

Valve clearance A5.05. 01.01.01.02
Inspection / Adjust
M20
1500
See also: 02.01.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Check valve clearance,

adjust if necessary every 1.500 h
Tools:
Feeler gauge W1 * 1.9075-003

* not illustrated
NOTE
The valve clearance should only be measured when the engine is warm, i.e. 15 min.
after the engine is shut down.
The position of the valve bridge must be readjusted before adjusting the valve
clearance during scheduled inspections or due to work being carried out on the valve
drive components.
1. Adjust valve bridge.
NOTE
The adjustment is necessary so that the clearance “s“ of the valve bridge (Fig.1/1) is
distributed evenly onto the corresponding valve cones (2,3).
There must be a sufficient clearance ”s” between the valve adjusting screw (4) and
the valve bridge (1) when adjusting the valve bridge.
1.1 Open the decompression valve.
1.2 Remove the cylinder head covers.
1.3 Move the cylinder to be adjusted to firing TDC. Inlet and exhaust valves are closed, rocker arm
relieved.
1.4 Release valve bridge (1) of rocker arm (5).

Enlarge clearance „s“ and/or flap back rocker arm (5).
en / 30.09.2010 IB025384 1/2

Valve clearance A5.05. 01.01.01.02
Inspection / Adjust
M20
1500
1.5 Release locknut (6) and unsrew setting 01

bolt (7) until a contact in „X”
without clearance is reached.
1.6 At this position of the valve bridge screw in

setting bolt (7) until contact at „Y” without
any clearance is reached.
Valve bridge must not be tited.
1.7 Hold tight setting bolt (7) and tighten lock-

nut (6) with
M = 30 Nm.
1.8 Check absence of clearance at „X“ and

„Y“ with feeler gauge of 0.02 mm (W1).
Afterwards adjust valve clearance „s“ as
per instruction.
2. Adjust valve clearance
2.1 Press the rocker arm (5) onto the push rod
and measure the clearance „s“ with the
feeler gauge.
2.2 Correct the clearance “s”:
2.2.1 Loosen counter nut (8).
2.2.2 Turn the valve adjusting screws (4) until the specified clearance ”s” has been attained.
Valve clearance „s“:
Inlet: 0.6 mm
Outlet: 0.8 mm
2.2.3 Tighten counter nut (8) with
M = 90 Nm
2.2.4 Check the clearance ”s” again.
2.3 Check the gaskets for the cylinder cover hoods and mount the cylinder cover hood.
2.4 Remove turning rod
2.5 Close decompression valves.
en / 30.09.2010 IB025384 2/2

Valve Rocker Brackets A5.05. 01.02.01.00
Maintenance / Disassembly and reassembly
M20
See also: 01.01.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Torque wrench 40 - 180 Nm 1/2" W1 * 1.9454-40

Auxiliary material:
Molykote paste “G-Rapid Plus” **
** or a product of equal standard
1. Disassembly
1.1 Remove the cylinder head cover.
1.2 Move the piston to firing TDC. Inlet valves and exhaust valves are closed, valve rocker is
relieved.
1.3 Unscrew the nuts (Fig. 1/1 and 2).
1.4 Remove the valve rocker bracket with inlet rocker and exhaust rocker.
2. Reassembly
2.1 Clean the surface for the valve rocker bracket on the cylinder head.
2.2 Blow through the oil transition hole with compressed air.
2.3 Fit the valve rocker bracket via studs on the cylinder head and adjust in such a way that the
adjusting screws rest on the center of the valve bridges.
en / 30.09.2010 IB001341 1/2

Valve Rocker Brackets A5.05. 01.02.01.00
M20
2.4 Grease the thread and nut contact face with Molykote paste “G-Rapid Plus” and tighten the nuts 01
gradually (1) with a
Torque of 120 Nm
and nuts (2) with a
Torque of 60 Nm.
2.5 Set the valve clearance (01.01.01 nn).
2.6 Perform the oil flow control.
2.7 Fit the cylinder head cover (inspect the gasket).
en / 30.09.2010 IB001341 2/2

Valve Rocker A5.05. 01.02.02.00
M20
30000
See also: 01.02.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Disassemble inlet and exhaust valve rocker

and inspect the bearing clearances 30,000 h
NOTE
The bushes must be lubricated with oil only.
Molykote paste must not be used even on assembly.
1. Disassembly
1.1 Disassemble valve rocker bracket

(01.02.01.nn).
1.2 Remove circlip (Fig. 1/1) and supporting

disc (2) from inlet valve rocker (3) and
exhaust valve rocker (4) and pull valve
rocker from rocker axle (5).
NOTE
Further remedial measures are
identical in the case of inlet and
exhaust valve rocker.
2. Clean all parts and check for damage.

Blow through oil holes with compressed air
and check for free passage.
en / 30.09.2010 IB021075 1/3

Valve Rocker A5.05. 01.02.02.00
M20
30000
3. Check the surfaces of the ball pin (Fig. 2/10) and adjusting screw (12) for wear and damage. Re- 01
new parts if as necessary. Undercool and shrink in ball pin with fluid nitrogen to -195 °C. Observe
the marking (x) of the ball pin.
DANGER
Observe safety regulations when handling fluid nitrogen.
4. Measure valve rocker bush (Fig. 2/13) and axle (Fig. 1/5) and renew bushes on attaining the limit
clearance.
New clearance Limit clearance
0,015 - 0.14 0,2
5. Replace bearing bushes.
5.1 Knock bush (Fig. 2/13) out from valve rocker with suitable brass drift.
5.2 Slightly oil the new bush and press in valve rocker.
CAUTION
Observe the position of the oil holes (14) and parting joint (15) as well as the dimen-
sion s = 0.2 mm (Fig. 2/Z) (projection of the valve lever to the bush) when pressing in
the new bushes. Do not damage plastic-laminated surface.
en / 30.09.2010 IB021075 2/3

Valve Rocker A5.05. 01.02.02.00
M20
30000
6. Reassembly 01
NOTE
Valve rocker axle must be un-
damaged and free of burrs.
6.1 Oil surfaces of the bushes of the inlet val-

ve rocker (Fig. 1/3) and exhaust valve rok-
ker (4) and rocker axle and carefully move
the valve rocker onto the axle. Do not tilt
valve rocker.
6.2 Fix the valve rocker with supporting disc

(2) and circlip (1) axially.
6.3 Mount the valve rocker bracket on the cy-

linder head (01.02.01.nn) and carry out
lube oil flow control.
en / 30.09.2010 IB021075 3/3

Valve Rotator A5.05. 01.03.01.00
Inspection / Evaluate
M20
150
See also: 01.07.01.nn, 01.10.00.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of the valve rotator every 150 h
CAUTION
Heavy fuel operation:=4 valve rotatorsinlet and exhaust valves
Distillate fuel operation:=2 valve rotatorsinlet valves only
NOTE
Check the rotational speed of the valves versus engine speed immediately after star-
ting a new engine or when a plant has been overhauled. Use this rotational speed for
reference later.
1. Check valve rotation.
2. The valve rotator works properly if a uniform and engine speed dependent rotation can be detec-
ted.
3. Lubricate the valve rotator with some drops of lubricating oil/gas oil mixture (mixture ratio 1:1) if a
considerable deceleration of rotation, is detected in comparison to the new condition.
3.1 If, at nominal engine speed, the rotational speed goes down to approx 1 rpm, the valve rotator
has to be changed.
NOTE
Deceleration of the valve rotation can also be caused by hard motion of the valve stem
in the valve guide. Remedy: Inject the gas oil/lubricating oil mixture drop by drop onto
the valve stem.
CAUTION
Do not apply too much lubricating oil/gas oil mixture. There is danger of lubricating oil
dilution!
en / 24.09.2010 IB000333 1/1

Valve Guide / Oil Scraper Ring A5.05. 01.05.01.01
Inspection / Replacement
M20
15000
See also: 01.01.01.nn, 01.02.01.nn, 01.06.01.nn, 01.07.01.nn 01

Operating medium: Heavy fuel

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of valve guide clearance of inlet and exhaust valves after 15,000 h
Auxiliary material:
1. Replacement of the oil scraper rings
(O-rings)
1.1 Dismount valve face, thoroughly clean

stem.
1.2 Remove the O-ring (Fig. 1/1) from the

groove of the guide bush by means of a
sharp angle-shaped wire.
CAUTION
The O-ring is used to adjust the
lubricant quantity and must only
be replaced by a new original
MaK spare part.
1.3 Clean the groove.
1.4 Slightly oil the new O-ring and carefully

insert the O-ring in the groove. The ring
must not be twisted in mounting position.
en / 31.05.2010 IB021186 1/2

Valve Guide / Oil Scraper Ring A5.05. 01.05.01.01
M20
15000
01
2. Measurement of the valve guide clearance.
2.1 Measure the outside diameter of the valve stem in the zone of the guide bush.
2.2 Measure the inside diameter of the guide bush in traverse direction of the engine.
2.3
Normal clearance (mm) Limit clearance (mm)
Exhaust
Inlet 0.10 - 0.17 0.4
3. Replacement of the valve guide
NOTE
If possible replace the valve guide in the workshop of a MaK dealer during the over-
haul of cylinder head. There is a risk that the cylinder cover may be damaged when
the old valve guide is knocked out.
en / 31.05.2010 IB021186 2/2

Media line A5.05. 01.05.50.00
M20
See also: 01

--------------------------------------------------------------------------------------------------------------------------------
CAUTION
Depressurize system before commencing work.
Auxiliary material:
soft green soap*
* or product of equal standard
1. Disassembly
1.1 Disassemble lubricating oil line for the injection pump (fig. 1/1) at the flange (3b) of the media li-
ne.
1.2 Remove cheese head screws (2).
2 4 2
A A
Z B B
7
6
5
3a 1 3b
1
en / 31.05.2010 IB003153 1/3

Media line A5.05. 01.05.50.00
M20
1.3 Remove flange (3a and 3b) together with sleeves (4). 01
1.4 Remove sleeves (4) from flanges (3a and 3b).
1.5 Check O-rings (fig. 2/12) and, if necessary, insert new O-rings untwisted in the grooves using
soft soap.
A-A
4
11
11
3a 3b
12
1.6 Remove seals (11) and clean sealing surfaces.
2. Assembly
2.1 Mount sleeves (fig. 2/4) with flanges (3a and 3b).
2.2 Replace seals (fig. 3/11) (centering by dowel pins 21).
B-B
11 11
X
21
X
3
2.3 Mount flanges, seals and sleeves with cheese head screws.
en / 31.05.2010 IB003153 2/3

Media line A5.05. 01.05.50.00
M20
3. Cleaning of fuel leakage monitor 01

3.1 Secure pipe (Z/5)!
3.2 Disassemble pipe (5) with screwed socket

(6) and sealing ring (7). Y
3.3 Check that bore (Fig. 4/Y) is free and

clean if necessary. 7
3.4 Assemble pipe (Z/5) with screwed socket
(6) and new sealing ring (7).
6
4
3.5 Check operation of alarm probe (41) for

leakage fuel (41).
Z 41
6
7
en / 31.05.2010 IB003153 3/3

Cylinder Head A5.05. 01.06.01.00
Maintenance / Disassembly
M20
See also: 01
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Hydr. equipment set consisting of

High-pressure pump W1 0.9204-D
High-pressure hose (1 m) W2 0.9205-B
High-pressure hose W3 0.9205-C
Hydr. tensioning element W4 0.9213-A
Distributor W5 0.9203-8
Bearing ring W6 0.9203-108
Spacer W7 0.9203-107
Pin W8 0.9203-110
Cylinder head lifting device W9 * 2.9221-A
Turning rod W10 * 2.9100-380
Cylinder liner hold-down W11 * 2.9217-A
NOTE
When lifting the cylinder head or when turning afterwards, the liner is always to be
secured with the hold-down in order to prevent the liner from becoming loose.
CAUTION
Do not fall below minimum bending radius r = 120 mm of the high-pressure hoses.
Only use hydraulic oil as an operating material (see Section A4.05.08, “Operating
materials”). Store equipment protected against corrosion.
DANGER
No parts of the body should be over the equipment which is under pressure. Secure
engine against unintentional starting.
1. Mount liner holding device (W11) (02.10.01.nn). Turn the piston to firing TDC. Remove cylinder
head cover and pump room lining.
2. Drain cooling water completely into a draining tank (connecting line: distributor line inlet/outlet
open).
Inspection:
Unscrew plug in pressure line behind cooling water pump after return valve.
en / 30.09.2010 IB001347 1/4

M20
3. Disassemble lube oil line for the injection pump at the respective block piece of the medium guide 01
and at the injection pump.
CAUTION
Screw off pressure gage line from end flange (lube oil jet cooling) during disassembly
of the last cylinder head at counter-coupling side.
4. Loosen and remove block pieces and/or end flange (Cyl. 1) of the medium guide of the cylinder
head to be disassembled.
5. Loosen pressure screws (Fig. 1/1 and 2) and lever off transverse pressure piece (3) with cover
(X) and pull to the left out of the injection pump and the cylinder head.
6. Slide sleeve (Y) to the left in the cylinder head frame.
7. Disassemble covering plate between exhaust pipe and cylinder head,

unscrew hexagonal screws on exhaust pipe.
en / 30.09.2010 IB001347 2/4

M20
8. Loosen the four cylinder head screws 01

together with the hydraulic tightening
device.
CAUTION
Max. lift of 5 mm must not be
exceeded.
8.1 Screw spacer (Fig. 2/W7) on cylinder

head screw (11).
8.2 Place bearing ring (W6) over round nut

(12), thereby, make surethe slots (13) are
easily accessible.
8.3 Screw hydraulic tensioning element (W4)

on spacer (W7) and connect with high-
pressure pump (W1) via high-pressure
hoses (Fig. 3/W2 and W3) distributor
(W5).
en / 30.09.2010 IB001347 3/4

M20
8.4 Press hydraulic tensioning element (Fig. 3/W4) with pin (W8), by turningdown against the bearing 01
ring (W6) onto block length (Valve [Z] at the high-pressure pump [W1] is open) and establish gap
of
2.5 mm
(approx. 1 rotation) (Fig. 2/S).
8.5 Close valve (Fig. 3/Z) at high-pressure pump (W1) and at the same time extend all 4 cylinder
head screws continuously with a hydraulic pressure of
p = 600 bar.
8.6 Disconnect round nuts (Fig. 2/12) with pin (W8).
NOTE
If the round nuts cannot be loosened, the cylinder head screw can be further
prestressed with approx.
50 bar.
If the pressure is increased further, there is a risk of the round nut sticking due to
stretching of the bolt thread.
8.7 Release tensioning elements, romove hydr. equipment and screw off round nuts.
9. Mount the cylinder head lifting gear (W11) on the cylinder head by means of the attached
hexagon nut M12x35.
Lift the cylinder head by means of a crane.
Thereby, observe push-rod fitting!
CAUTION
Risk of damaging cooling water transition nozzles, cylinder head screws, push rods
and charge air intake nozzles.
10. Place cylinder head down on a wooden support.
en / 30.09.2010 IB001347 4/4

Nozzle Sleeve A5.05. 01.06.50.00
M20
15000
See also: 01.06.01.nn, 07.07.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Change the O-rings every 15.000 h
Tools:
Pin spanner W1 2.9122 B
Ring spanner A/F 27 W2* 1.9456 B
Torque wrench W3* 1.9454-6
* no illustration
Auxiliary material
Vaseline**
High-temperature thread paste “Dag S-5080“**
**or product of equal standard
1. Dismount the nozzle sleeve (1).

W1
1.1 Attach the pin spanner (W1) to the nozzle
sleeve (1) so that nozzle sleeve and pin
spanner are engaged.
1.2 Attach the ring spanner (W2) to the pin

spanner and unscrew the nozzle sleeve
until nozzle sleeve and cylinder head (2)
are fully unscrewed and loose.
3
CAUTION
Nozzle sleeve and cylinder 4
head must be fully unscrewed
and loose. 1
1.3 Use a brass mandrel and gently drive out

the nozzle sleeve. 2
en / 30.09.2010 IB021941 1/2

Nozzle Sleeve A5.05. 01.06.50.00
M20
15000
1.4 Remove the O-rings (3 and 4). 01

2. Mount the nozzle sleeve
2.1 Apply a film of green soft soap to the new black O-ring and insert it in the groove (4). Make sure
the O-ring is not twisted.
2.2 Apply a film of green soft soap to the new green O-ring and insert it in the groove (3). Make sure
the O-ring is not twisted.
CAUTION
Do not change the position of the O-rings. Observe the mounting instructions.
2.3 Grease the threads of the nozzle sleeve with high-temperature thread paste.
2.4 Insert the nozzle sleeve and tighten the sleeve with the pin spanner (hand-tight).
2.5 Tighten the nozzle sleeve at a torque of
M =100 Nm.
en / 30.09.2010 IB021941 2/2

Inlet and Exhaust Valve Cones A5.05. 01.07.01.01
Inspection / Disassembly and reassembly
M20
15000, 7500


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of inlet and exhaust valves of one cylinder after 7,500 h

Check contact reflections of the valves and coating.
Maintenance:
of all inlet and exhaust valves after 15,000 h
Tools:
Valve spring compressor W1 2.9222-A
NOTE
The overhaul intervals of the valves depend on the fuel grade used, the operating
conditions of the plant and the quality of the reconditioned valves and seats. They
are therefore different for each plant.
For this reason, the operator must fix the maintenance intervals according to the con-
dition of valves inspected. With any removal of valves, check seat geometry and re-
cut if necessary (01.08.01.nn, 01.08.02.nn.).
Sequence of operations: (Fig. 1)

1. Disassembly
1.1 Remove cylinder head (01.06.01.nn).
1.2 Remove the valve rocker (01.02.01.nn)

and lift off valve bridge.
1.3 Place the valve spring compressor (W1)

onto the spring plate (2).
1.4 Compress the valve springs (3) and

remove the clamping cone halves (4).
Expand valve springs (3) carefully.
WARNING
Spring tension
en / 31.05.2010 IB021215 1/2

Inlet and Exhaust Valve Cones A5.05. 01.07.01.01
M20
15000, 7500
1.5 Remove valve spring compressor (Fig. 1/W1), spring plate (2), internal and external valve springs 01
(3) as well as valve turning device from the cylinder cover.
1.6 Extract valves from the cylinder head
NOTE
Renew any valves which are heavily worn in the clamping area and any clamping
cone halves which have large burrs. Remove projecting burrs before disassembling
such valves. Maintenance of valve cone/valve seat (01.08.01.nn/01.08.02.nn).
2. Reassembly
2.1 Check valve guide clearance, renew the O-ring (01.05.01.nn).
2.2 Lubricate the valve stem well before fitting and fit the valve cone by screwing it in.
2.3 Assembly is carried out in reverse order to removal.
2.4 After inserting the clamping cone halves, slowly expand the valve springs and make sure that the
clamping cone halves are in the correct position.
en / 31.05.2010 IB021215 2/2

Valve Cones A5.05. 01.08.01.00
Repair / Checking
M20
See also: 01.07.01.nn, 01.08.02.nn 01

Personnel qualification: Chief engineer / skilled engine hand

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Valve refacer W1 2.9224-A
Auxiliary material:
Diamond paste Dp 30/10 - 15 µm *

Thinner F25 *
* or a product of equal standard
NOTE
Grind new or refinished and/or used undamaged inlet and exhaust valve cones befo-
re the installation in accordance with sequence of operations 4.
Refinishing of the valve cones (in accordance with sequence of operations 3) may be
necessary in the following cases:
•after extended operating periods,
•in the case of negative result, e.g. damaged sealing faces, deep scars, uneven
contact reflections of the valve cone/seat
1. Check of valve condition
1.1 Valves may be reused without refinishing when
• the circumference of the valve cone face is metallic bright

• the valve cone face does not indicate carbon pockets with blowholes,
• by inspecting cracks, using magnifying glass with light (8 fold magnification) or powder spraying
procedure (Met L'Check) and/or in the flux procedure, no crack formation is discovered at the
valve cone face.
en / 31.05.2010 IB001351 1/5

Valve Cones A5.05. 01.08.01.00
Repair / Checking
M20
• when the deviation from the straightness is not greater than the following values (Fig. 1). 01
Measuring range “s” = 200 mm
= support points for test device
• when the radial run-outs of the valve cones do not exceed the following values:
1.2 Valves cannot be reused when
• the valve cone face is damaged

(cracks,blowholes)
• the wear caused by corrosive material is

>2%
of the valve head diameter (comparison
with new valve)
• concave burns “s” caused by high-

temperature corrosion at the lower side
of the valve head
> 1.5 mm (Fig. 2)
• the lower part of the valve head

indicates severe pitting (formation of so-
called “paving stones”)
• corrosion pits and mechanical damage

in the area of the valve stem, stem
transition and valve head
• refinishing limit dimension is exceeded.
en / 31.05.2010 IB001351 2/5

Valve Cones A5.05. 01.08.01.00
Repair / Checking
M20
01
2. Cleaning
Clean the valve cone, e.g. blasting with

glass beads. Cleaning with sharp-edged
tools as well as pickling with inorganic
acids (hydrochloric acid, sulphuric acid,
hydrofluoric acid etc.) is not allowed.
3. Repair (refinishing of the valve cone

face)
NOTE
Refinishing should always be
carried out professionally on
precision spindle grinding ma-
chines. If no such machine is
min. 1 mm
available, the valves should be
given to a MaK workshop for
regrinding.
3.1 Regrind valve cone faces in accordance

with prescribed angle (Fig. 3). Do not
refinish existing concave fillet.
3.2 The appropriate information of the grinding

machine manufacturers is to be observed
during grinding.
3.3 Determine the dimension between visible

edge of the base metal plating “X” and the
outer edge of the seat after completing the
grinding process. Replace the valve cone
if the actual dimension falls below the
minimum dimension.
3.4 Outer edge rounded with stone.
CAUTION
When the valve cone is refinished, the valve seat ring must also be refinished
(01.08.02.nn).
en / 31.05.2010 IB001351 3/5

Valve Cones A5.05. 01.08.01.00
Repair / Checking
M20
01
4. Maintenance (check of contact
reflection/grinding)
4.1 Apply small dots of the diamond paste Dp

30/10 - 15 µm with a syringe to the valve
seat of the new or refinished valve cone
and distribute the paste uniformly (Fig. 4).
Therafter the seat ring surface is to be
sprayed with a thinner (F25) belonging to
the diamond paste, for dilution and in
order to increase of the grip.
4.2 Insert the oiled valve stem into the guide

bush. Fasten the device (Fig. 5/W1) to the
valve head and grind the valve cone face
and seat by hand applying a moderate
pressure, rotating the device. The contact
reflection “a” (Fig. 6/a), visible by the
rough grinding process, should be
30 - 50 % of the circumferential seat

width “b”
starting from the outside diameter.
en / 31.05.2010 IB001351 4/5

Valve Cones A5.05. 01.08.01.00
Repair / Checking
M20
01
4.3 When the contact reflection is poor, the
valve must not be reground anymore,
however, both sealing faces are to be
refinished on a machine.
4.4 Ensure, that the components (valve cone

and seat ring) refaced to one another
remain together.
5. Final inspection
5.1 Ensure that the the refinishing limit

dimensions are maintained.
5.2 Thoroughly clean valve cone/seat and

check sealing faces for cracks with an
illuminated magnifying glass
(magnification 8 times) in the steel plating
and in the adjacent area.
en / 31.05.2010 IB001351 5/5

Inlet Valve Cones A5.05. 01.08.01.01
Repair / Checking
M20
See also: 01.07.01.nn, 01.08.02.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Auxiliary material:

Thinner F25 *
NOTE
Grind new or refinished and/or used undamaged inlet valve cones before the installa-
tion in accordance with sequence of operations 4.

•in the case of negative result, e.g. damaged sealing faces, deep scars, uneven con-
tact reflections of the valve cone/seat.

valve cone face.
en / 31.05.2010 IB022652 1/5

Repair / Checking
M20

(cracks,blowholes)

>2%
with new valve)

of the valve head
> 1.5 mm (Fig. 2)


en / 31.05.2010 IB022652 2/5

Repair / Checking
M20
01
2. Cleaning


face)
NOTE
min. 1 mm
regrinding.


during grinding.

minimum dimension.
CAUTION
(01.08.02.nn).
en / 31.05.2010 IB022652 3/5

Repair / Checking
M20
01



width “b”
en / 31.05.2010 IB022652 4/5

Repair / Checking
M20
01

remain together.
5. Final inspection


en / 31.05.2010 IB022652 5/5

Exhaust Valve Cones A5.05. 01.08.01.03
Repair / Checking
M20
See also: 01.07.01.nn, 01.08.02.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Auxiliary material:

Thinner F25 *
NOTE
Grind new or refinished and/or used undamaged exhaust valve cones before the in-
stallation in accordance with sequence of operations 4.
contact reflections of the valve cone/seat.

valve cone face.
en / 31.05.2010 IB022666 1/5

Repair / Checking
M20

(cracks,blowholes)

>2%
with new valve)

of the valve head
> 1.5 mm (Fig. 2)


en / 31.05.2010 IB022666 2/5

Repair / Checking
M20
01
2. Cleaning


face)
NOTE
min. 1 mm
regrinding.


during grinding.

minimum dimension.
CAUTION
(01.08.02.nn).
en / 31.05.2010 IB022666 3/5

Repair / Checking
M20
01



width “b”
en / 31.05.2010 IB022666 4/5

Repair / Checking
M20
01

remain together.
5. Final inspection


en / 31.05.2010 IB022666 5/5

Repair / Checking
M20
See also: 01.07.01.nn, 01.08.02.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Auxiliary material:

Thinner F25 *
NOTE
Grind new or refinished and/or used undamaged inlet valve cones before the installa-
tion in accordance with sequence of operations 4.
contact reflections of the valve cone/seat.

valve cone face.
en / 05.10.2010 IB023324 1/5

Repair / Checking
M20

(cracks,blowholes)

>2%
with new valve)

of the valve head
> 1.5 mm (Fig. 2)



2. Cleaning
en / 05.10.2010 IB023324 2/5

Repair / Checking
M20
glass beads. Cleaning with sharp-edged 01


face)
NOTE
Refinishing should always be carried out professionally on precision spindle grinding
machines. If no such machine is available, the valves should be given to a MaK
workshop for regrinding.


during grinding.
min. 1 mm
minimum dimension.
CAUTION
(01.08.02.nn).
en / 05.10.2010 IB023324 3/5

Repair / Checking
M20
01



width “b”
en / 05.10.2010 IB023324 4/5

Repair / Checking
M20
01

remain together.
5. Final inspection


en / 05.10.2010 IB023324 5/5

Valve Seat Ring A5.05. 01.08.02.00
Repair / Checking
M20
See also: 01.07.01.nn, 01.08.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Valve refacer W1 * 2.9222-A

Valve seat milling machine W2 2.9224 B
Auxiliary material:
Magnifying glass with light (8-fold magnification)

Diamond paste Dp 30/10 - 15 µm **
Thinner DIAPLASTOL **
NOTE
In case irregular contact reflections or pittings are indicated on the sealing faces of
the valve seat/valve face, both sealing faces are to be refinished in any case.
New or refinished valve seats are to be ground in accordance with operating se-
quence 4.
Refinishing of the seats may be necessary in the following cases:
•after extended operating times
•in the case of negative result, e.g. damaged valve faces, deep scars, uneven contact
reflections of the valve seat/face (Fig. 1 and 2)
en / 31.05.2010 IB001438 1/5

Repair / Checking
M20
01
The hardness of the valve seats is designed in such a manner that a certain adaptability is pre-
sent with regard to the valve face. Carbon deposits are therefore a normal indication and not ha-
zardous if good cooling is present (Fig. 3, 4 and 5).
en / 31.05.2010 IB001438 2/5

Repair / Checking
M20
1.1 The valve seat rings are reusable without refinishing when 01
• the circumference of valve face is metallic bright
• no carbon deposits with blow holes or visible wear are present
• by inspecting cracks using an illuminated magnifying glass (8-fold magnification) or powder
spraying procedure (Met L'Check) and/or in the flux procedure no crack formation is established
at the valve face.
1.2 The valve seat rings are not reusable when
• cracks are present in the seat face

• burn holes are present
• the refinishing limits have been exceeded.
2. Cleaning
Remove the residues from the seat faces.
3. Maintenance (refinishing the valve seat rings)
NOTE
Refinishing is to be carried out with the MaK precision seat grinding machine (W1)
in a workmanlike manner. Refer to special operating instructions.
Alternatively the seats may be refinished by means of the MaK valve seat milling
device (Fig. 6/W2). Unnecessary stock removal is to be avoided, only carbon
pockets are to be repaired if they are present in the contact area.
3.1 Remilling of the valve seat
3.1.1 Clean the valve seat ring thoroughly in the contact area (3) of the centering washer (4) in order to
ensure an absolutely centrical fixing of the guide mandrel (5). Remove O-ring from guide bush.
3.1.2 Insert centering washer (4) with guide mandrel (5) and tighten with tension nut (6).
CAUTION
Handle the cutter head (2) with care, cutters are sensitive to impact, hard touch-down
can also damage the valve seat face.
en / 31.05.2010 IB001438 3/5

Repair / Checking
M20
3.1.3 Place cutter head (Fig. 6/2) on greased 01

mandrel, screw in knurled thumb screw
(1), until resistance becomes noticeable.
3.1.4 Rotate valve seat (clockwise) uniformly

and slowly and remill the seat in one
operation pass. The cutting of the cutters
must be noticeable. Set the contact
pressure by touch.
CAUTION
The machine will rattle when
the contact pressure is too low
and/or the cutting speed is too
high.
3.1.5 Prior to finishing the cutting process,

slowly unscrew the knurled thumb screw
(1) and simultaneously rotate the cutter
head.
3.1.6 Max. permissible dimension for reworking:
Exhaust valve (Fig. 7):
The shoulder "y" must still remain di-

stinct.
Inlet valve (Fig. 7a):
The dimension for "z" must not drop be-

low the minimum dimension of 1 mm
due to the reworking.
3.1.7 If the milling cutters are blunt, the cutter head is to be sent to MaK for refinishing.
en / 31.05.2010 IB001438 4/5

Repair / Checking
M20
3.1.8 Dismount the milling device. Grind sharp edges with the fine emery cloth. 01
4. Check of contact reflection/grinding
4.1 Apply small dots of the diamond paste Dp 30/10 - 15 µm with a syringe to the valve seat of the
new or refinished vlave spindle and distribute the paste uniformly. Thereafter spray the complete
seat ring surface with thinner DIAPLASTOL (01.08.01.nn).
4.2 Insert the lubricated valve stem into the guide bush. Fasten the device (W1) (01.08.01.nn) to the
valve head and grind the valve face and seat by hand applying a moderate pressure, rotating the
device. The contact reflection “a” which is visible by the rough grinding process shall be
30 - 50 % of the circumferential seat width “b”
starting from the outside diameter (01.08.01.nn).
4.3 If the contact reflection is poor, the valve must not be reground anymore, however, both sealing
faces are to be refinished.
4.4 Ensure that the components (valve face and seat ring) refaced to one another will be held
together.
5. Final check of valve condition
5.1 Check whether the refinishing limit dimensions have been observed.
5.2 Clean valve face/seat thoroughly and check the sealing faces with an illuminated magnifying
glass (8-fold magnification) for cracks in the armouring and in the adjacent zone.
en / 31.05.2010 IB001438 5/5

Repair / Checking
M20
See also: 01.07.01.nn, 01.08.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Valve refacer W1 * 2.9224 A

Valve seat milling machine W2 2.9224 C
Auxiliary material:
Magnifying glass with light (8-fold magnification)

Diamond paste Dp 30/10 - 15 µm **
Thinner DIAPLASTOL **
NOTE
In case irregular contact reflections or pittings are indicated on the sealing faces of
the valve seat/valve face, both sealing faces are to be refinished in any case.
New or refinished valve seats are to be ground in accordance with operating se-
quence 4.
Refinishing of the seats may be necessary in the following cases:
•after extended operating times
•in the case of negative result, e.g. damaged valve faces, deep scars, uneven contact
reflections of the valve seat/face (Fig. 1 and 2)
en / 30.09.2010 IB023062 1/5

Repair / Checking
M20
01
The hardness of the valve seats is designed in such a manner that a certain adaptability is pre-
sent with regard to the valve face. Carbon deposits are therefore a normal indication and not ha-
zardous if good cooling is present (Fig. 3, 4 and 5).
en / 30.09.2010 IB023062 2/5

Repair / Checking
M20
01
1.1 The valve seat rings are reusable without refinishing when
• the circumference of valve face is metallic bright

• no carbon deposits with blow holes or visible wear are present
• by inspecting cracks using an illuminated magnifying glass (8-fold magnification) or powder
spraying procedure (Met L'Check) and/or in the flux procedure no crack formation is established
at the valve face.
1.2 The valve seat rings are not reusable when
• cracks are present in the seat face

• burn holes are present
• the refinishing limits have been exceeded.
2. Cleaning
Remove the residues from the seat faces.
3. Maintenance (refinishing the valve seat rings)
NOTE
Refinishing is to be carried out with the MaK precision seat grinding machine (W1)
in a workmanlike manner. Refer to special operating instructions.
Alternatively the seats may be refinished by means of the MaK valve seat milling
device (Fig. 6/W2). Unnecessary stock removal is to be avoided, only carbon pockets
are to be repaired if they are present in the contact area.
3.1 Remilling of the valve seat
3.1.1 Clean the valve seat ring thoroughly in the contact area (3) of the centering washer (4) in order to
ensure an absolutely centrical fixing of the guide mandrel (5). Remove O-ring from guide bush.
3.1.2 Insert centering washer (4) with guide mandrel (5) and tighten with tension nut (6).
CAUTION
Handle the cutter head (2) with care, cutters are sensitive to impact, hard touch-down
can also damage the valve seat face.
en / 30.09.2010 IB023062 3/5

Repair / Checking
M20
3.1.3 Place cutter head (Fig. 6/2) on greased 01

mandrel, screw in knurled thumb screw
(1), until resistance becomes noticeable.
3.1.4 Rotate valve seat (clockwise) uniformly

and slowly and remill the seat in one
operation pass. The cutting of the cutters
must be noticeable. Set the contact
pressure by touch.
CAUTION
The machine will rattle when
the contact pressure is too low
and/or the cutting speed is too
high.
3.1.5 Prior to finishing the cutting process,

slowly unscrew the knurled thumb screw
(1) and simultaneously rotate the cutter
head.
3.1.6 Max. permissible dimension for reworking:
Exhaust valve (Fig. 7):
The shoulder "y" must still remain di-

stinct.
Inlet valve (Fig. 7a):
The dimension for "z" must not drop be-

low the minimum dimension of 1 mm
due to the reworking.
en / 30.09.2010 IB023062 4/5

Repair / Checking
M20
3.1.7 If the milling cutters are blunt, the cutter head is to be sent to MaK for refinishing. 01
3.1.8 Dismount the milling device. Grind sharp edges with the fine emery cloth.
4. Check of contact reflection/grinding
4.1 Apply small dots of the diamond paste Dp 30/10 - 15 µm with a syringe to the valve seat of the
new or refinished vlave spindle and distribute the paste uniformly. Thereafter spray the complete
seat ring surface with thinner DIAPLASTOL (01.08.01.nn).
4.2 Insert the lubricated valve stem into the guide bush. Fasten the device (W1) (01.08.01.nn) to the
valve head and grind the valve face and seat by hand applying a moderate pressure, rotating the
device. The contact reflection “a” which is visible by the rough grinding process shall be
30 - 50 % of the circumferential seat width “b”
starting from the outside diameter (01.08.01.nn).
4.3 If the contact reflection is poor, the valve must not be reground anymore, however, both sealing
faces are to be refinished.
4.4 Ensure that the components (valve face and seat ring) refaced to one another will be held
together.
5. Final check of valve condition
5.1 Check whether the refinishing limit dimensions have been observed.
5.2 Clean valve face/seat thoroughly and check the sealing faces with an illuminated magnifying
glass (8-fold magnification) for cracks in the armouring and in the adjacent zone.
en / 30.09.2010 IB023062 5/5

Inspection / Checking
M20
150


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of the cylinder heads every 150 h
1. Check the sealing between cylinder head,
cylinder liner and cooling water distributor
housing for exhaust gas blow-by and/or
cooling water at the inspection bore (Fig.
1/1).
Loosen cylinder head nuts in the case of

leakages and retighten them according to
prescriptions (01.11.01.nn). If no tightness
is obtained, remove the cylinder head -
clean and check the sealing faces - and 1
refit with a new gasket according to Fig. 1
prescriptions (01.11.01.nn).
2. Check cylinder head externally for leaks.
2.1 If lubricating oil leaks out, check fixing screws of the cylinder head cover for tight fit and/or check
profile seal for damage.
2.2 In the case of leaks at the wedged pieces of the medium guide check fastening screws for tight fit.
Renew gaskets if necessary.
3. Remove cylinder head cover. Inspect cylinder head upper side.
3.1 Check uniform valve motion. Irregularities can be stated best at low engine speed.
3.2 Check proper function of the valve rotators (01.03.01.nn).
3.3 Check valve springs for damage.
3.4 Check lubricating oil supply of the rockers and rocker bearings.
en / 30.09.2010 IB001447 1/1

Maintenance / Cleaning
M20
15000


--------------------------------------------------------------------------------------------------------------------------------
NOTE
Put the cylinder head down with its bottom part only on a wooden support
The following parts are disassembled:
inlet-, exhaust-, injection valve, valve rocker brackets.
1. Wash cylinder head with cold cleaner.
2. Remove carbon deposits from inlet- and exhaust ducts and cylinder head bottom (do not clean
the valve seats!) with a wire brush and scraper. Do not damage sealing recess.
3. Clean cooling water inlet and cooling water outlet.
4. Inspect cylinder head bottom for cracks especially at the valve channels.
5. Clean sealing face for injection valve.
6. Check inlet- and outlet bores of the medium guide for free access.
7. Check alarm probe for leaking fuel for function in distributor plate at connector of the medium
guide (Cyl. 1).
en / 31.05.2010 IB022277 1/1

Repair / Reassembly
M20
See also: 01.01.01.nn, 01.02.01.nn, 01.06.01.nn, 02.06.01.nn, 07.07.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Tools:
See maintenance sheet 01.06.01.nn.
Auxiliary material:
High-temperature thread paste “Dag S-5080” *

Molykote paste “G-Rapid Plus” *
Vaseline *
NOTE
When lifting the cylinder head or when turning afterwards, the cylinder liner is always
to be secured with the hold-down to prevent the liner from coming loose.
CAUTION
Only use hydraulic oil as an operating material.
DANGER
No parts of the body should be over the equipment which is under pressure.
en / 30.09.2010 IB001353 1/5

Repair / Reassembly
M20
Sequence of operations: 01
1. Turn the piston to firing TDC.
2. Clean sealing faces and contact surfaces of cylinder head and liner thoroughly and check for
damage. Insert new sealing ring (Fig. 1/1) into cylinder liner collar.
3. Renew the following O-rings: Top O-ring at the cylinder liner collar (X/2), at cylinder head (3), on
pushrod passage (4), at the cooling water transition (Y/5) and at charge air intake nozzle (6).
1
7
Fig. 1
X
3 4
Y
6
5
en / 30.09.2010 IB001353 2/5

Repair / Reassembly
M20
01
NOTE
Insert all O-rings with vaseline or green grease soap untwisted into grooves.
4. Carefully place cylinder head with cylinder head lifting device (W9) and lifting gear onto cooling
water distributor housing. Avoid jamming of cooling water transition on pushrod passage.Insert
pushrods into cylinder head. Observe fixing pin in the cooling water distributor ring.
5. Insert new seal (Fig. 1/7) for exhaust flange and align cylinder head. Lubricate screws for
exhaust pipe with “Dag S-5080” high-temperature thread paste and screw in loosely with resilient
sleeves.
6. Tighten the four cylinder head screws

together with the hydr. tightening
device.
CAUTION
Max. lift of 5 mm must not be
exceeded. W8
W4
6.1 Tighten round nuts (Fig. 2/12) with pin W6

(W8) hand-tight.
6.2 Screw spacer (W7) onto cylinder head

screw (11).
W7
6.3 Place bearing ring (W6) over round nut 11
(12), thereby, make sure the slots (13) are
easily accessible. 13
W8
12
Fig. 2
en / 30.09.2010 IB001353 3/5

Repair / Reassembly
M20
6.4 Screw hydr. tensioning element (Fig. 2/W4) onto spacer (W7) and link with high-pressure pump 01
(W1) via high-pressure hoses (Fig. 3/W2 and W3) distributor (W5).
W2
W5
W8 W3 Z W1
Fig. 3
6.5 Press hydraulic tensioning element (Fig. 2/W4) by means of pin (W8) by turning down against the
bearing ring (W6) onto block length and tighten hand-tight (valve [Fig. 3/Z] open at the high-pres-
sure pump (W1)).
6.6 Close valve (Fig. 3/Z) at high-pressure pump (W1) and simultaneously extend all 4 cylinder head
screws steadily with a hydraulic pressure of
p = 600 bar.
CAUTION
Pressure must remain constant in case the pump is not activated, otherwise a tighte-
ning error occurs.
6.7 Firmly tighten all round nuts (Fig. 2/12) uniformly with pin (W8), ensure smooth running.
6.8 Check the fixed rest of round nuts.
• Lower pressure by 50 bar.

• Round nuts should no longer be able to be loosened with the pin.
6.9 Release and remove hydraulic tensioning element.
en / 30.09.2010 IB001353 4/5

Repair / Reassembly
M20
01
7. Tighten screws for exhaust pipe on alternate sides in 2 stages with a torque of
M = 60 and 110 Nm.
8. Fit disassembled block pieces and/or flanges of the medium guide with new seals. Ensure correct
fit of the dowel pin.
9. Connect lube oil line and transverse thrust pieces of the respective injection pump in reverse
order to the disassembly instructions (01.06.01.nn). The mounting instructions of 07.07.01.nn,
sequence of operations 2., must be observed by all means. Tighten compression screws with
a torque of
M = 85 Nm.
10. Mount removed pressure gage lines and refill cooling water.
11. Set valve clearance (01.01.01.nn.) and fit pump room lining.
12. After commissioning of the engine, check tightness of all connections.
en / 30.09.2010 IB001353 5/5

Running Gear/Engine Timing A5.05. 02.01.01.00
M20
1500, 3750
See also: 03.01.01.nn, 04.08.01.nn, 01.01.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
NOTE
The temperature check for the bearings must be carried out with the engine at opera-
ting temperature after switching off the circulation system lubrication. The remaining
tasks are to be carried out after allowing a period of ventilation.
1. Open indicator valve and engage turning gear.
2. Open crank case cover approx. 10 min. after shutting down the engine.
3. Check crankshaft bearings and big end bearings for even and normal temperatures.
4. Visually check screws and nuts.
5. Check extent of soiling of the engine room (silt deposits, corrosion, bearing metal particles, de-
tached paint).
6. Check cylinder liner surface on engine side. Carry out lubrication oil flow check and check oil de-
livery at bearing points.
7. Remove camshaft cover. Check screws of camshaft components and the lower valve mechanism
for proper tightness.
8. Turn engine and check bearing surfaces of cams and rollers for scoring, pitting or other damage.
9. Check lubricating oil flow for camshaft bearing and valve mechanism.
10. Check wheel mechanism (04.08.01.nn).
11. Check oil tray and crank case for left-behind tools, cloths etc. Check seals of all crank case and
sealing lids and refit cover.
12. Remove cylinder head cover.

Check mechanical components like valve springs, valve bridges with guides, and rocker arms for
irregularities.
Look out for water or oil leaks.
en / 30.09.2010 IB021322 1/1

Crank Web Deflection A5.05. 02.02.01.00
Inspection / Measuring
M20
See also: 02

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
In the following cases additional measurements have to be made: In the case of suspect or dan-
ger of foundation deformation, e. g.:
• by collision of a ship
• subsidence of the foundation
• bearing or crankshaft damages
• prior and after every docking of a ship.
Tools:
Crank web measuring device W1 1.9425-300
NOTE
Crank web deflection is the change in distance beween a web pair during one rotati-
on of the crankshaft (Fig. 1). Depending on the location of the engine, the rigidness
of the foundation and the ship, different values are given in comparison with loaded
and unloaded condition of the ship as well as warm or cold engine. Measurements
should therefore be carried out when the engine is warm, with normal loading and
even keel; not in dock! Changes that suddenly appear or appear after a longer period
under otherwise uniform conditions point to a deformation or subsiding of the founda-
tion.It is therefore suggested to collect the measurement sheets extra so that the
chronological allocation of the values and changes are visible. In the event of unper-
missible changes, the installation must be realigned and the respective main bea-
rings inspected.
a) Initial position
b) Negative deflection
c) Positive deflection
en / 14.10.2010 IB001439 1/4

M20
1. Bar crank pin from BDC in direction of exhaust side to such an extent that the dial gauge can be
applied between the crank webs at the point farthest away from the crank pin and the
connectiong rod just passes by the dial gauge (Fig. 2/1st measuring point).
Where punch holes are found, do not place the measuring tips on the centring marks, the
purpose of the latter is only to indicate the space in which to use the measuring tips.
2. Adjust the value of scale “20” to the pointer: 1st measuring point (initial point).
3. Bar the crankshaft so that the crank pin turns in direction of the exhaust side and the dial gauge
towards the camshaft side.
4. Continually watch the gauge and read off the values in the measuring points 2 - 5. If before or be-
hind a measuring point a higher value than at the prescribed measuring point itself is read, this
value has to be recorded.
5 1
2
4
Fig. 2
1 = 1st measuring point (initial point)

2 = 2nd measuring point (pin on exhaust side)
3 = 3rd measuring point (pin in TDC)
4 = 4th measuring point (pin on camshaft side)
5 = 5th measuring point (pin in BDC camshaft side)
en / 14.10.2010 IB001439 2/4

M20
02
NOTE
Crank web deflection first of all is a criterion of the alignment of the engine with the
shafting.
Heavy crank web deflection imposes additional loads on crankshaft and main
bearings. This means that the admissible deflection is determined by the engine
load. A high load admits less deflection than a low one.
The values below must be observed, if it is impossible to obtain the admissible limits
for the plant from MaK.
Only the values measured on an engine at operating temperature has to be used for
assessment. Values from a cold engine are of inferior importance.
Values for crank web deflection in mm:
M20
Cylinder 1 or last cylinder

with additional load + 0,04 / - 0,09 mm
(flywheel/coupling)
All cylinders
without external load + 0,04 / - 0,06 mm
Permissible values for realignment

of base frame mounted gensets + 0,03 / - 0,03 mm
in horizontal direction
en / 14.10.2010 IB001439 3/4

M20
02
5 1
4 2
en / 14.10.2010 IB001439 4/4

Bearing Shells A5.05. 02.03.07.01
M20
See also: 02.05.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
NOTE
Contaminated oil, solid foreign matters, water and tool deficiencies are the cause of
85 % of all cases of bearing damage.
Dirt is the worst enemy of all bearings! A thorough oil treatment and a careful filter
maintenance are therefore indispensable for a reliable operation and a long service
life.
The following criteria catalogue shows various wear stages caused by mechanical
abrasion and fatigue the bearing shells.
Refitting
Criteria catalogue:
Fig. 1 - The contact reflection is uniformly formed on the entire bearing width. This bearing shell can
be reused.
Fig. 2 - The contact reflection is uniformly formed on the entire bearing width. From experience the dirt
scratches caused by a foreign matter in the lubricating oil do not influence the further
safety of operation of the slide bearings. This bearing shell can be reused.
Fig. 3 - The contact reflection is uniformly formed on the entire bearing width. The scratches running
radially are caused by fine solid matter particles contained in lubricating oil. If the depth
of these scratches is neither to be measured nor to be sensed, the bearing shell can be
reused.
If the number, depth and a large circumference length affects the production of the
grease film, the bearing is to be exchanged.
en / 30.09.2010 IB001449 1/4

M20
02
Replacement
Fig. 4 - The contact reflection shows the presence of heavy pressure on one bearing edge with
scratches in the sliding surface made from aluminium alloy. This bearing shell is not
reusable. The cause for this damage has to be determined and eliminated.
Fig. 5 - The contact reflection shows a large area of damage with various degrees of scratching. This
bearing shell is not reusable. The cause for this slide bearing damage has to be
determined and eliminated. Further bearing shells are to be inspected.
Fig. 6 - The load bearing area of the bearing shell shows breakages in the breaking metal, provoked
by fatigue of the sliding surface made from aluminum alloy. Several bearing metal
pieces are loose in the fatigue zone. The surface structure in the base of the breakage
indicates a firm composition of steel and aluminum alloy. This bearing shell must be
exchanged. Further shells are to be inspected.
en / 30.09.2010 IB001449 2/4

M20
02
en / 30.09.2010 IB001449 3/4

M20
02
en / 30.09.2010 IB001449 4/4

Al-Grooved Bearings A5.05. 02.03.09.01
M20/M25
See also: 02

--------------------------------------------------------------------------------------------------------------------------------
Criteria for replacement of the grooved

bearings
The running surface of the bearings con-

sists of approx. 75 % electroplated overlay
(Fig. 1/a), approx. 25 % aluminium alloy
ridges (b) and max 5 % nickel dam (c).
First signs of running surface wear appear

of the electroplated running layer (a). The
overlay in the groove (a) is worn down by
a few 0,001 mm.
As wear increases, the difference between
the aluminium alloy ridges (b) and the
overlay (a) remains more or less the sa-
me, approx. 0,005 mm.
NOTE
For precise assessment of the degree of wear of the running surface, a
magnifying glass (minimum magnification 5x) is necessary.
Under the magnifying glass, the overlay appears as a dark area, and the aluminium alloy ridge as
a light area.
The most important criteria for assessing the degree of wear of the grooved bearing are
•the ratio of the aluminium alloy ridge width to the groove width, as well as
•the size of worn surface
The grooved bearing can still function when the overlay in the grooves has partly worn away. In
actual practice it has been proven that the grooved bearing can continue to function without any ill
effects, even with partially empty grooves.
When assessing the conditions of the grooves, the running surface in the area subject to
the lowest load (condition of groove generally as new) should be used as a point of
comparsion.
The condition of the grooved bearings is assessed according to five different categories:
1. Reuse possible
2. Wear
3. Wear and levelling of the ridges (borderline case)
4. Overlay fatigue ruptures
5. Overlay fatigue ruptures and empty grooves (borderline case)
en / 24.01.2011 IB023929 1/7

M20/M25
Should more than one of the conditions described appear together, the respectively 02
lowest limits apply.
1. Reuse possible
Condition:
Geometrie of the groove is as new. The overlay inside the groove is intact.
The dark points are predominantly embedded oil coke particles (Fig. 2).
Assessment:
The ratio between the overlay and the aluminium alloy ridges is 75 % / 25 %.
Reuse possible!
Condition:
The overlay in the grooves has worn through uniformly by about 0,005 mm.
The aluminium alloy ridges show no sign of wear. The dark points are predominantly embedded
oil coke particles (Fig. 3).
Assessment:
As a result of overlay wear, the aluminium alloy ridges appear slightly wider.
Reuse possible!
en / 24.01.2011 IB023929 2/7

M20/M25
1.1 Reuse possible 02
Condition:
Small foreign particles spread over the entire running surface. No significant alteration of the alu-
minium allow ridges (Fig. 4).
Assessment:
Reuse of the bearing shell is possible, since foreign particles are embedded in the grooves.
Condition:
The overlay has been locally “dragged” and “smeared” over the aluminium alloy ridges. The alu-
minium alloy ridges can no longer be seen in some places.
Assessment:
Reuse of the bearing shell is possible.
en / 24.01.2011 IB023929 3/7

M20/M25
2. Wear 02
Overlay-groove
Bearing metal ridge
Condition:
The bearing has in some places been worn down to such an extent that the bearing metal ridges
and the overlay grooves have reached a ration of 1:1. The width of the bearing metal ridges has
increased from 25 % (when new) to 50 %. Some overlay still exists in the grooves (Fig. 6).
Wear limits:
a) max. 30 % of circumference
b) max. 70 % of width = Wear 1:1
c) max. 50 % of circumference
d) max. 35 % of width
Assessment:
Bearing is operative. Should a condition of wear as shown in 3 be expected within the next in-
spection interval, bearing has to be replaced for safety reason.
en / 24.01.2011 IB023929 4/7

M20/M25
3. Wear and levelling of the ridges (borderline case) 02
Condition:
Bearing metal ridges are worn locally.
Wear limits:
a) max. 20 % of width
b) max. 5 % of circumference = Bearing metal ridges worn
c) max. 10 % of width
d) max. 35 % of circumference
e) max. 10 % of width = Wear 1:1
f) lock of chamber
Assessment:
When reaching the conditions of wear as shown above, bearing should be replaced.
en / 24.01.2011 IB023929 5/7

M20/M25
4. Overlay fatigue ruptures 02
Conditions:
Rupture of electroplated overlay in the grooves as a result of overloading at certain points
Wear limits:
a) max. 25 % of circumference
b) max. 70 % of width = Overlay fatigue ruptures
c) max. 50 % of circumference
d) max. 35 % of width
Assessment:
Bearing is operative. Should a condition of wear as shown in 5) be expected within the next in-
spection interval, bearing has to be replaced for safety reason.
en / 24.01.2011 IB023929 6/7

M20/M25
5. Overlay fatique ruptures and empty grooves 02
Condition:
In certain areas empty grooves are visible after washing out the ruptured overlay.
Wear limits:
a) max. 40 % of width
b) max. 10 % of circumferende = Overlay fatique ruptures
c) max. 30 % of width
d) max. 40 % of circumference
e) max. 15 % of width = Empty grooves
Assessment:
When reaching the condition described = Bearing metal ridges worn
above, bearing must be replaced.
en / 24.01.2011 IB023929 7/7

Big-End Bearings A5.05. 02.04.01.01
Inspection / Disassembly
M20
30000, 15000
See also: 02.03.09.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
a) of a big-end bearing after 15,000 h

b) exchange of all big-end bearings after 30,000 h
Tools:
Piston suspension equipment W1 2.9226-A

Tightening angle gage big-end bolts W3 2.9180-A
Auxiliary material:
NOTE
Coat threads and contact
surfaces of the bolts with Moly-
kote paste “G-Rapid Plus”.
Before removing the big-end
x1
bearing, measure clearance
“K”.
3
4
1. Clearance measurement
Y
1.1 Turn crankpin approx. 20° before TDC to
camshaft side.
1.2 Loosen all big-end bolts.
1.3 Pretighten bolts 3 and 4 with a torque Y
M = 160 Nm
Fig. 1
and measure dimension x1 between the
bore holes on the camshaft side with
caliper gage (Fig. 1).
en / 31.05.2010 IB021371 1/3

M20
30000, 15000
1.4 Tighten bolts 1 and 2 twice in the 02

sequence 1 - 2 - 1 - 2 with a torque W3
M = 160 Nm.
1
1.5 Mark the bolt position or put on a 2
tightening angle gauge
1.6 Clamp the bolts tight in the sequence 3 - 4 x2

- 1 - 2 with a torque
3
M = 350 Nm 4
corresponding to a minimum tightening Z

angle of bolts:
1 and 2 of min. 13°° - 16 W

3 and 4 of min. 17°° - 19°°
CAUTION Z
the minimum tightening angle is

to be kept Fig. 2
1.7 Measure dimension x2 between the bore

holes on the camshaft side and determine
the differential dimension
x1 - x2 = clearance.
Clearance Limit value

mm mm
0.45 - 0.65 0.35
If the limit value is not reached, renew

bearing shells pairwise and mark both
halves in accordance with the numbers of W
impacts cylinder No., connecting rod and
bearing cap (W).
en / 31.05.2010 IB021371 2/3

M20
30000, 15000
2. Removing the big-end bearing cap 02

2.1 Turn crankshaft into a convenient position
for removing (crankpin 20° before of TDC
to the camshaft side).
2.2 Loosen big-end bearing bolts and screw

out off connecting-rod big end.
2.3 Lift bearing cap out of the crankcase.
2.4 Check the toothing in the joint faces of

connecting rod, big-end bearing cap and
thread for damage. W1
3. Removing the bearing shells
3.1 Move piston to TDC position, fit piston

suspension device (Fig. 3/W1) and move
crankshaft carefully to camshaft side until Fig. 3
the piston rests on the suspension device
and the crankpin swings out of the
connecting-rod big end.
3.2 Remove bearing shells from crankpins.
3.3 Bearing shells, rating/replacement criteria:
• AL groove bearing: 02.03.09.nn.
en / 31.05.2010 IB021371 3/3

Inspection / Reassembly
M20
See also: 02.04.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Tools:

Clamp W2 2.9125-A
Tightening angle gage W3 2.9180-A
Auxiliary material:
NOTE
The bearing caps, shells and bolts have been marked according to their cylinder
numbers and must not be interchanged. New parts are to be marked accordingly.
Lubricant for threads and bolt contact surfaces Molykote paste “G-Rapid Plus”.
1. Fitting the bearing shells
1.1 Clean and oil the crankpin.
1.2 Oil the inside and outside of the bearing

shells and put them on the crankpin.
CAUTION
Hole (Fig. 1/X) for the fixation of
the bearing shells at the face of
the bottom and top shell of the
shell half pointing to the clutch
side.
en / 01.10.2010 IB001357 1/4

M20
1.3 Hold the bearing shells in this position and 02

shift the clamp (Fig. 2/W2) over the shells
so that the lower dog of the clamp
engages in the oil hole of the bottom shell.
The dog of the screw (Fig. 2/1) engages in
the hole of the top shell. Slightly tighten 1
the screw of the clamp.
1.4 Let the clamp rest against the top joint

face of the big end and turn the crankshaft
until the big end lightly rests on the bearing
shells.
NOTE 3
Lug (Fig. 2/2) of the clamp W2
engages in the groove of the
joint face for centrical guide of
the bearing shells of big-end 2
bearing (4).
Fig. 2
1.5 Turn the bearing shells with the handle of
the clamp so that the dowel pin (3) in the
big-end bore engages in the hole of the
bearing shells and that the shells have
good contact in the big-end bore. The
bearing shells might get damaged if the
reassembly is incorrect.
1.6 Move the piston to TDC. remove clamp

and piston suspension device.
2. Fitting the bearing cap.
2.1 Bring bearing cap into a convenient

position and hold against the connecting-
rod big end. Lubricate threads and contact
faces of the bolt heads with Molykote
paste “G-Rapid Plus” exclusively.
Screw in the bolts.
en / 01.10.2010 IB001357 2/4

M20
3. Tightening the big-end bolts. 02

3.1 Measuring the gap (02.04.01.nn, W3
sequence of operations 1) is only required
4
if new shells are fitted or the gap was not
measured on disaassembly.
3.2 Tighten the lower bolts 3 and 4 with a

torque
M = 160 Nm.
3.3 Tighten upper bolts 1 and 2 twice in the

sequence 1 - 2 - 1 - 2 with a torque
3
M = 160 Nm.
Fig. 3
3.4 For checking the tightening operation, place the angle gages (Fig. 3/W3) over the bolt head
collars according to the marking and pull the pointer against the stop.
Check the set collars of the gage for freedom. Mark the position of the bolts if you have no
tightening angle gage (tightening angle gages for big-end bolts 3 and 4 shown).
3.5 Tighten the lower bolts 3, 4 with a torque
M = 350 Nm.
3.6 Tighten the upper bolts 1, 2 with a torque
M = 350 Nm.
CAUTION
After tightening big-end bolts 1 and 2 up to a final torque of 350 Nm, tighten bolts 3
and 4
again with the final torque of 350 Nm to avoid a loss of pretension by settling.
en / 01.10.2010 IB001357 3/4

M20
02
3.7 Tightening check
3.7.1 Upper bolts 1 and 2: The maximum pointer must have been pulled beyond the angle marking.
When checking without gage, the bolts must have turned through an angle of
13°° - 16°°.
3.7.2 Lower bolts 3 and 4: The maximum pointer must have passed the angle marking or the bolts must
have turned through 17°° - 19.
NOTE
If these angles are not reached, undo the bolts with the ratchet handle (02.04.01.nn)
and check the parts for damage. For this, grease the threads and the contact faces of
the bolts again with Molykote paste “G-Rapid Plus”.
en / 01.10.2010 IB001357 4/4

Main Bearings A5.05. 02.05.01.01
M20
30000, 15000
See also: 02.03.07.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
a) of one main bearing bearing after 15,000 h
Cylinder Bearing
number No.
6 4
8 5
9 6
b) exchange all crankshaft bearings every 30,000 h
Tools:
Hydraulic equipment set, consisting of:

Bearing ring W1 0.9203-109
Hydr. tensioning element W2 0.9213 A
High-pressure pump W3 0.9204 D
High-pressure hose (1 m) W4 * 0.9205 C
Pin W5 0.9203-110
Lowering device for main bearings W6 2.9214 A
Dog W7 2.9114 A
DANGER
CAUTION
Do not fall below the minimum bending radius r = 120 mm of the high-pressure hoses.
en / 31.05.2010 IB021418 1/5

M20
30000, 15000
02
NOTE
The bearing caps and bearing shells are marked continuously on the camshaft side
starting from the clutch side according to which cylinder they belong and must not be
exchanged. New parts are to be marked correspondingly.
Even within the prescribed interval, the main bearings are to be removed, checked
and measured if:
Substructure deformations and/or crank web deflection changes after crashes

appear and/or if the connecting rod bearings are found in a poor condition.
1. Remove main bearing.
1.1 Open driving room covers on camshaft and exhaust side and turn crankshaft into favorable
position for removing.
1.2 Measure axial play “s” by the locating bearing (Fig. 1).
1.2.1 Place gage with magnetic holder on flywheel set and align at the cylinder block and crankcase.
1.2.2 Offset crankshaft axially, until bearing is on one side. Set gage to “zero”. Shift crankshaft in the
opposite direction and read off axial clearance “s” at gage.
1.2.3 Axial play “s”:

s1 s2
s = s1 + s2
New clearance Limit clearance 1

mm mm
0.23 - 0.4 0.6 2
If the limiting clearance is exceeded,

renew the stop disk segments and bearing
shells in pairs.
3
NOTE
Fig. 1
Lower stop disk halves (Fig. 1/
1) are pinned with clamping
pins (2) at the bearing cap (3).
CAUTION
It is imperative to mark the stop disks before a possible disassembly for checking
purposes, so that they cannot be interchanged. Afterwards re-assemble them imme-
diately!
en / 31.05.2010 IB021418 2/5

M20
30000, 15000
1.3 Loosen bearing bolts with hydraulic tightening equipment. 02

1.3.1 Remove hexagon screws (Fig. 2/11) of the main bearing which is to be removed.
1.3.2 Place bearing ring (W1) over the round nut (12) and turn hydraulic tensioning element (W2) on
bearing bolt (13) and screw against bearing ring. Make sure that the slots (14) are easily accessi-
ble.
1.3.3 Link hydraulic tensioning element (W2) with high-pressure pump (W3) via high-pressure hose
(W4) and press onto block length (Valve [Z] open at the high-pressure pump).
W4
W1
Z W3
11
12
14
W2
13
Fig. 2
1.3.4 Set a gap “s” of 2.5 mm (Fig. 3) between

bearing ring and tensioning element.
1.3.5 Stretch both bearing bolts in one work se-

quence with
W5
p = 750 bar s 12
and loosen round nuts (12) with pin (W5).
NOTE
Prestress bearing bolts by
approx. 50 bar more if required.
If the pressure is increased
further the round nut might stick
due to stretching of the bolt
thread.
Fig. 3
en / 31.05.2010 IB021418 3/5

M20
30000, 15000
1.4 Measure clearance. 02

1.4.1 Remove hexagon screws (Fig. 4/11) of the
respective main bearing on exhaust and
camshaft side.
KA KS
1.4.2 Hydraulically loosen both round nuts (12)
in accordance with sequence of
operations 1.3.
1.4.3 Relieve hydr. removal equipment and

11
remove.
1.4.4 Tighten round nuts in turn by hand and

uniformly, until the parting faces of the
bearing shells just come into contact with
each other. 12
1.4.5 Measure clearance “K” between cylinder

block and crankcase and bearing cap on Fig. 4
exhaust and camshaft side with feeler
gage and add the two measured values.
K = KA + KS
Clearance “K” Operating limit value W6

mm mm
0.50 - 0.80 0.4
1.5 Screw lowering device (Fig. 5/W6) onto

bearing cap (21) on exhaust and camshaft
side.
1.6 Twist down round nuts (12) uniformly from

bearing bolts and lower bearing cap
carefully. Bearing cap is suspended on
lowering device in the cylinder block and 21
crankcase.
12
1.7 Remove lower bearing shell from bearing
cap.
Fig. 5
1.8 Insert dog (Fig. 6/W7) into oil bore of the
crankshaft and twist out top bearing shell
to the exhaust side.
1.9 Check AL-groove bearings in accordance

with rating criteria 02.03.09.nn.
W7
1.10 In the case of 2-material bearings, check
wearing of the wall-thickness in the main
load region at check points (Fig. 7/X) with Fig. 6
micrometer caliper.
en / 31.05.2010 IB021418 4/5

M20
30000, 15000
Wear = new dimension - 02

actual dimension
New dimension: 4.927-0.015 mm
In the case of a wear of > 0.05 mm the

bearing shells are to be changed. Further
rating criteria, 02.03.07.nn.
CAUTION
If a bearing shell has to be
changed during inspection, the
adjacent bearings are also to
be checked.
en / 31.05.2010 IB021418 5/5

Maintenance / Reassembly
M20
See also: 02.05.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Torque wrench W9 1.9454-500

Square-driven W10 1.9459-006
Socket wrench W11 1.9024-036
See job chart 02.05.01.nn.
Auxiliary material:
DANGER
CAUTION
NOTE
Bearing caps and bearing shells are marked continuously on the camshaft side star-
ting from the clutch side according to which cylinder they belong and must not be ex-
changed. New parts are to be marked correspondingly.
The specified torques only apply to the lubrication the thread and the contact faces of
the nuts with Molykote.
Only replace damaged bearing bolts and nuts together.
1. Fitting the bearing shells.
NOTE
Top bearing shell is fitted with oil groove and oil bores.
en / 30.09.2010 IB001361 1/4

M20
1.1 Lubricate working face of the top bearing 02

shell well, wipe bearing back dry and
press bearing shell into the bearing so far
that the dog (Fig. 1/W7) can be inserted
into the oil bore of the crankshaft.
1.2 Twist in top bearing shell. Thereby,

maintain central position of the bearing
shell. The fixing lug must slide into the
guide groove of the bearing seat.
1.3 Lubricate working face of the lower

bearing shell, wipe bearing back dry and
insert into bearing cap.
W7
CAUTION
The bearing guide groove for
the lower shell is on the cams- Fig. 1
haft side. Observe fixing pin on
the exhaust gas side in the case
of locating bearing cap.
2. Tightening of the bearing shells. W6
2.1 Lift the bearing cap with the aid of the

lowering device (Fig. 2/W6) over the
bearing bolts and screw round nuts (1)
uniformly on bearing bolts and tighten
hand-tight with pin (W5). Remove lowering
device (W6).
NOTE
During the installation of new
bearing shells, the clearance
“K” and in the case of locating
bearings, the axial play 1
(02.05.01.nn) is to be measu-
red.
Fig. 2
en / 30.09.2010 IB001361 2/4

M20
2.2 Coat threads and contact surfaces of the hexagon screws (Fig. 3/11) with Molykote paste “G- 02
Rapid Plus” and tighten on alternate sides in 3 stages with torque wrench (W6) with torque
1st stage: M = 100 Nm

2nd stage: M = 300 Nm
3rd stage: M = 480 Nm.
Alternative bolt tightening:
Tighten in 2 steps with the following torques 30°

After that the lateral bolts are to be tightened with an

angle of :
30 = (1/2 hexagon) (X).
11
Z W3
1
W1
12
W2
Fig. 3
Place hydraulic tightening equipment on bearing bolts (12), connect to high-pressure

pump (W3) and press hydraulic tensioning element (W2) onto block length. There should
now be no gap between bearing ring (W1) and tensioning element (W2).
2.3 Close valve (Z) at the high-pressure pump (W3) and extend both bearing bolts uniformly in one
work sequence with a pressure of
p = 750 bar.
en / 30.09.2010 IB001361 3/4

M20
02
CAUTION
The pressure must remain constant if the pump is not activated. Otherwise tightening
errors occur.
2.4 Firmly tighten round nuts (1) uniformly with pin (W5).
3. Inspection:
Lower pressure by 50 bar. Round nuts (1) should no longer be able to be loosened by hand.
4. Lower pressure at valve (Z) and remove hydraulic tightening equipment.
5. Carry out lube oil flow-through inspection.
en / 30.09.2010 IB001361 4/4

Piston A5.05. 02.06.01.01
M20
See also: 01.06.01.nn, 02.04.01.nn, 02.07.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Dismounting device, calibrating ring 2.9216 B

consisting of:
liner support W1.1 2.9216-103
thrust ring W1.2
ring bolt M12 W2 1.9080-12

turning rod W3 * 2.9100-380
*no illustration Z
Auxiliary material:
1
Rust removal spray “Caramba“**
** or product of equal standard 5

6
NOTE
The cylinder liner is to be secured
2
with the liner supports (W1.1) to
prevent loosening of the cylinder
liner (Fig.1 / 4). W1.1
W1.2
1. Use turning rod (W3) and turn crank pin Z
approx. 20° before TDC in direction of the
control side.
2. Dismount cylinder head (01.06.01.nn)
3. Place a used joint ring (Fig.1 / 1) onto the

cylinder liner (4) to protect the sealing sur-
face.
4. Attach the liner supports (W1.1) to the

used joint ring (1) as shown in the illustrati-
on
3 4
5. Tighten round nuts (2) by hand.
1
en / 31.05.2010 IB004750 1/3

Piston A5.05. 02.06.01.01
M20
02
CAUTION
The sealing surfaces of the cylinder liner have to be protected against damage!
6. Fill the ring gap between piston (3)and cylinder liner (4) with grease.
7. Carefully scrape off and completely remove carbon deposits in the liner (4) ) between TDC of the
first piston ring and the lower edge of the calibrating ring (5).
NOTE
Do not damage the surface of the liner !
8. Clean the groove in the calibrating ring (5).
9. Spray a thin film of rust removal spray „Caramba“ in the ring gap between calibrating ring (5) and
liner (4).
10. Allow the rust removal spray to react.
11. To loosen the calibrating ring (5) slightly beat it with a copper hammer until you can turn the guide
of the calibrating ring by hand.
12. Turn piston (3) with turning rod (W3) approx. 50° to TDC.
13. Insert thrust ring (W1.2) and compressed snap ring (6) until the lower edge rests on the piston.
14. Carefully turn piston (3) and thrust ring (W1.2) upwards until the snap ring (6) is engaged in the
groove of the calibrating ring (5).
15. Turn piston (3) further upwards and press out the calibrating ring (5. ). Watch the position of the
calibrating ring.
CAUTION
In case the calibrating ring is tilted, you have to lower the piston and align the calibra-
ting ring.
The connecting-rod must not strike on the crank pin. Turn crank pin aside, if neces-
sary.
16. Remove calibrating ring (5) and thrust ring (W1.2).
17. Dismount big-end bearing cover (02.04.01.nn).
18. Turn piston (3) in TDC position, re-tap threaded hole (M12, 11 mm deep) in piston head.
en / 31.05.2010 IB004750 2/3

Piston A5.05. 02.06.01.01
M20
19. Screw the ring bolt (Fig. 2 / W2)into the 02

piston .
20. Mount the crane to the ring bolt (W2).
21. Slowly pull out the piston; carefully insert

con-rod foot into the liner and remove big-
end bearing shells.
22. Place piston in a suitable device. W2
en / 31.05.2010 IB004750 3/3

Piston A5.05. 02.06.01.02
M20
See also: 01.06.01.nn, 02.04.01.nn, 02.07.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Sleeve support W1 2.9216-103

Eye screw M12 W2 1.9080-012
Turning rod W3* 2.9100-380
Disassembly unit W4 2.9216 C
*not shown
Aids:
“Caramba“** deruster
**or equivalent product
NOTE
To prevent loosening of the cylinder sleeve (4), it should also be secured with the
sleeve supports (W1).
W1
Y
6
5 W4
Z
Y
Z 1
W2
3 4
en / 05.10.2010 IB004756 1/3

Piston A5.05. 02.06.01.02
M20
Procedure: 02
1. Turn the crank pin with the turning rod (W3) approx. 20°in front of the top section to the control si-
de.
2. Remove the cylinder head (01.06.01.nn)
3. Place a used sealing ring (1) as sealing surface protection on the cylinder sleeve (4).
4. Position sleeve supports (W1) on the used sealing ring (1) as shown in the drawing.
5. Hand-tighten the round nuts (2).
CAUTION
The sealing surfaces of the sleeves must be protected from damage!
6. Fill the annular gap between the piston (3) and the cylinder sleeve (4) with grease.
7. Carefully scrape off the accumulated coke in the cylinder sleeve between the top section of the
1st piston ring and the lower edge of the calibration ring (5) and remove so that the shoulder of
the calibration ring can be clearly felt all round.
NOTE
Take care not to damage the cylinder sleeve surface!
8. Lightly spray the annular gap between the calibration ring and the cylinder sleeve (4) with deru-
ster.
9. Allow the deruster to take effect.
10. Insert the disassembly unit (W4) so that the recess (Z) is inside the calibration ring (5).
11. Lightly tension the disassembly unit (W4) by turning the spindle nut (6).
12. Force out the calibration ring (5) by turning up the piston (3) into the top position.
13. Recut the threaded hole (M12, 11 mm deep) in the top of the piston.
14. Insert the eye screw (W2) in the piston (3).
15. Remove the cover of the connecting rod bearing (02.04.01.nn).
16. Attach the crane to the eye screw (W2) and slowly remove the piston (3).
en / 05.10.2010 IB004756 2/3

Piston A5.05. 02.06.01.02
M20
02
CAUTION
Make sure that the calibration ring is drawn out smoothly when removing the piston.
If the calibration ring becomes tilted, lower the piston and align the calibration ring.
The connecting rod must not strike the crank pin; if necessary turn the crank pin to
the side.
17. Drop the piston in the appropriate direction.
en / 05.10.2010 IB004756 3/3

Piston Rings and Grooves A5.05. 02.07.01.01
M20
30000, 7500
See also: 01.06.01.nn, 02.04.01.nn, 02.06.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of one piston and its rings after 7,500 h
Maintenance:
of all pistons and their rings after 30,000 h
Tools:
Piston ring expander W1 2.9227-A
NOTE
f the running surfaces of all cylinder liners are without scores or high spots or any
other damage and if the parts of the drawn piston are in proper condition, all piston
rings free and no heavy wear can be detected, the inspection of the others pistons
can be postponed to a later date, but not beyond a maximum of 30,000 operating
hours. During the inspection, pay special attention to any sharp edges of the rings,
ring tension or rings sticking due to carbon deposits.
Do not remove graphite coating on the piston skirt.
After fitting new piston rings, the engine must be driven in according to the driving-in
regulation A3.10.01.nn!
Built-up pistons with chrome-plated 1st ring groove may only be reconditioned by the
manufacturer.
1. Piston inspection (7,500 h)
1.1 Open all crankcase doors.
1.2 Check the running surfaces of the cylinder liners from the crank chamber.
1.3 Draw the piston from the liner with worst running pattern (02.06.01.nn).
Draw the other pistons too, if the piston rings are stuck or rotten.
en / 31.05.2010 IB021477 1/3

M20
30000, 7500
1.4 Remove the piston rings only with the 02

correct tool (Fig. 1/W1). Maintain previous
position of the rings referring to the
mounting position of the piston given in the
measuring sheet.
1.5 Clean piston rings.
1.6 Check the the chrome layer for wear,

especially at the cut and at the opposite
side. Renew all rings of this piston even if
only parts of the chrome layer is no longer
visible.
If the chrome layer of one piston ring has

been worn, check the rings of all pistons.
1.7 Clean the piston, ring grooves and oil return holes for the scraper scraper ring.
1.8 Smooth slight friction and seizing marks with an oily fine emery cloth or fine carborundum stone.
Renew the piston in case of heavy damage or deep scores.
1.9 Measure the groove width hN (Fig. 2) in the front area of the groove in longitudinal and transverse
directions of the engine. When exceeding the limits, have the ring grooves reconditioned by MaK.
1.10 Measure the ring thickness hR (Fig. 2) at 4 different points.
hN1 = new
hN2 = worn
en / 31.05.2010 IB021477 2/3

M20
30000, 7500
1.11 Determine the clearance by calculation and check it against the table. 02
Ring thicknes hR Groove width hN Limit of hN - hR
Groove Nominal Wear limit mm
mm mm
1–3 4.95 5.6 0.65
4 6 6.5 0.5
1.12 Fit piston rings with the marking facing

upwards (Fig. 3/X) and with the ring stops
into the ring grooves alternatingly opposite
in engine longitudinal direction.
2. Maintenance (30,000 h)
2.1 Draw all pistons (02.06.01.nn).
2.2 Check the state of lubrication and

appearance of the running surface of the
piston and clean it.
2.3 Remove the piston rings with piston ring

expander (Fig. 1/W1). Maintain previous
measuring sheet.
2.4 Clean all ring grooves.
2.5 Measure the groove width hN in

accordance with sequence of operations
1.9.
2.6 Renew all compression and scraper rings.
2.6.1 Fit piston rings with the marking facing

upwards (Fig. 3/X) and with the ring
stops into the ring grooves
alternatingly opposite in engine
longitudinal direction.
2.7 Fit all pistons (02.06.02.nn).
en / 31.05.2010 IB021477 3/3

M20
30000, 7500
See also: 01.06.01.nn, 02.04.01.nn, 02.06.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of one piston and its rings after 7,500 h
Maintenance:
of all pistons and their rings after 30,000 h
Tools:
Piston ring expander W1 2.9227-A
NOTE
If the running surfaces of all cylinder liners are without scores or high spots or any
other damage and if the parts of the drawn piston are in proper condition, all piston
rings free and no heavy wear can be detected, the inspection of the others pistons
can be postponed to a later date, but not beyond a maximum of 30,000 operating
hours. During the inspection, pay special attention to any sharp edges of the rings,
ring tension or rings sticking due to carbon deposits.
Do not remove graphite coating on the piston skirt.
After fitting new piston rings, the engine must be driven in according to the driving-in
regulation A3.10.01.nn!
Built-up pistons with chrome-plated 1st ring groove may only be reconditioned by the
manufacturer.
1. Piston inspection (7,500 h)
1.1 Open all crankcase doors.
1.2 Check the running surfaces of the cylinder liners from the crank chamber.
1.3 Draw the piston from the liner with worst running pattern (02.06.01.nn).
Draw the other pistons too, if the piston rings are stuck or rotten.
en / 31.05.2010 IB022421 1/3

M20
30000, 7500
1.4 Remove the piston rings only with the 02

correct tool (Fig. 1/W1). Maintain previous
measuring sheet.
1.5 Clean piston rings.
1.6 Check the the chrome layer for wear,

especially at the cut and at the opposite
side. Renew all rings of this piston even if
only parts of the chrome layer is no longer
visible.
If the chrome layer of one piston ring has

been worn, check the rings of all pistons.
1.7 Clean the piston, ring grooves and oil return holes for the scraper scraper ring.
1.8 Smooth slight friction and seizing marks with an oily fine emery cloth or fine carborundum stone.
Renew the piston in case of heavy damage or deep scores.
1.9 Measure the groove width hN (Fig. 2) in the front area of the groove in longitudinal and transverse
directions of the engine. When exceeding the limits, have the ring grooves reconditioned by MaK.
1.10 Measure the ring thickness hR (Fig. 2) at 4 different points.
hN1 = new
hN2 = worn
en / 31.05.2010 IB022421 2/3

M20
30000, 7500
1.11 Determine the clearance by calculation and check it against the table. 02
Ring thicknes hR Groove width hN Limit of hN - hR
Groove Nominal Wear limit mm
mm mm
1–2 4.95 5.6 0.65
3 6 6.5 0.5
1.12 Fit piston rings with the marking facing

upwards (Fig. 3/X) and with the ring stops
into the ring grooves alternatingly opposite
in engine longitudinal direction.
2. Maintenance (30,000 h)
2.1 Draw all pistons (02.06.01.nn).
2.2 Check the state of lubrication and

appearance of the running surface of the
piston and clean it.
2.3 Remove the piston rings with piston ring

expander (Fig. 1/W1). Maintain previous
measuring sheet.
2.4 Clean all ring grooves.
2.5 Measure the groove width hN in

1.9.
2.6 Renew all compression and scraper rings.
2.6.1 Fit piston rings with the marking facing

upwards (Fig. 3/X) and with the ring
stops into the ring grooves
alternatingly opposite in engine
longitudinal direction.
2.7 Fit all pistons (02.06.02.nn).
en / 31.05.2010 IB022421 3/3

Piston A5.05. 02.10.01.01
M20
See also: 02.04.02.nn, 02.07.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Mounting/extraction device for pistons W1 1.9080-012

Cylinder liner holder W2 2.9217 A
Piston assembly ring W3 2.9220 B
Piston insertion device (sheet metal sleeve) W4 259220 A
Auxiliary material:
Molykote paste "G-Rapid Plus“ **
NOTE
The cylinder liner must always be secured by means of the cylinder liner holder (fig.
3/W2) to prevent the cylinder liner from coming loose when turning the engine (wit-
hout dismantled cylinder head)!
Pay attention to the cylinder number mark on the bottom end.
Drive in the engine according to the driving-in regulation (A3.10.01.nn) after fitting a
new piston/new piston rings!
1. Replace the piston rings as required.
2. Fit the new piston rings with the ring joints in a longitudinal direction to the engine alternately
arranged opposite each other! Lubricate the piston rings and pistons well on the outside.
en / 30.09.2010 IB004785 1/3

Piston A5.05. 02.10.01.01
M20
3. Slacken the tightening screw (fig. 1/10) 02

until the piston insertion device (W4) has
been relieved and can be guided freely
over the piston rings.
4. Apply Molykote paste "G-Rapid Plus" to

the thread and contact surface of the
tightening screw (10).
5. Place the piston insertion device (W4)

over the piston ring zone and tighten the
tightening screw (10).
CAUTION
Make sure the piston rings do
not sit on the outer edge of the
ring groove when tightening the
tightening screw. Eliminate any
faulty gripping by tapping the
piston insertion device slightly.
6. Check the floating position of the rings by W3

turning the piston insertion device (W4).
7. Mount the piston assembly ring (fig. 2/

W3).
8. Mount the piston mounting/extraction

device (fig. 3/W1).
CAUTION
2
Turn the crank pin to a favou-
rable installation position. The
bottom end must not knock
against the crank pin when
being lowered.
9. Attach the piston (3) to the crane and raise it.
10. Carefully insert the bottom end in the cylinder liner with the cylinder number mark towards the
control side and lower the piston exactly in the cylinder axis so that the bottom end does
not jam in the cylinder liner.
11. Let the piston insertion device (fig. 1/W4) lie flush on the piston assembly ring (fig. 2/W3) and ca-
refully lower the piston further guiding the bottom end over the crank pin by hand.
en / 30.09.2010 IB004785 2/3

Piston A5.05. 02.10.01.01
M20
12. If it has been removed, mount the cylinder 02

liner holder (fig. 3/W2) on the cylinder liner 1 W1
(2). Only screw the hexagon socket screw
finger (5) tight against the cylinder
crankcase (4).
13. Dismantle the piston insertion device (fig. 3 2

1/W4), piston assembly ring (fig. 2/W3) as
well as the piston mounting/extraction
device (fig. 3/W1).
14. Clean the contact surface on the cylinder

liner collar.
CAUTION
Insert the calibrating ring (1)
only after the piston has been
mounted!
15. Insert a new calibrating ring carefully into

the cylinder liner and lower it down to the 4
recess.
Do not tilt the calibrating ring ! 5
16. Mount the con-rod (02.04.02.nn).
17. Mount the cylinder head (01.11.01.nn). W2

3
18. Dismantle the cylinder liner holder (W2).
19. Mount the power unit cover and close the

indicator valves.
20. Dismantle the turning device.
en / 30.09.2010 IB004785 3/3

Crankcase Explosion Relief Valves A5.05. 03.01.01.00
M20/M282/M332C/M452/M453C/M551/M552C
1500
See also: 02.01.01.nn 03

Spare parts list: B1.05.03.n.1633

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Check the freedom of movement of the relief valves.
Auxiliary material:
Glue “Hymir 1000” and hardener *
Molykote paste “G-Rapid” *
* or a produkt of equal standard
Sequence of Operations:
1. Check the relief valve (2) from the inside of
the crankcase door (1) for freedom of mo-
vement by actuating it by hand.
2. If the valve ist not free on the guide

bolt (3), disassemble the valve.
3. Check the guide bolt and plate (4) and

touch them up if necessary.
4. Check the O-ring (6) on the guide bolt and

renew it if necessary.
5. When fitting a new O-ring, cover the

thread (M 12) portion of the bolt with a
smooth piece of sheet metal, cardboard or
similar.
6. Check the seal (5) of valve plate (4) and

renew it if necessary (fix it with
“Hymir 1000” and hardener). Coat the
shank of the bolt with Molykote paste “G-
Rapid”.
7. Assemble the relief valve, fit the split pin

and check the valve plate for freedom.
en / 30.05.2000 IB021500 1/1

Explosion relief valve A5.05. 03.01.01.02
M20
1500
See also: 02.01.01.nn 03


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
freedom of movement of the explosion relief valve.
NOTE
Disassembly of the explosion relief valve is only required when the prescribed spring
tension can not be reached or abnormal fouling by oil or a leakage can be recognized.
1. Check the relief valve manually for freedom from inside of
the crankcase door (1). Thereto remove the crankcase door
or the explosion relief valve.
2. Disassembly
2.1 Remove hexagon screws (9) of the explosion relief valve and
the crankcase door (1).
2.2 Remove the explosion relief valve completely from

crankcase door (1).
2.3 Screw off the nuts (2) with the spring ring (3) from the
countersunk screws (4).
2.4 Lift off the deflection plate (5), the pressure spring (6) and the
valve plate (7).
2.5 Remove the two countersunk screws (4).
2.6 Remove the six spacer tubes (8) with retaining washers.
2.7 Take the rubber ring (10) out of the seat ring.
2.8 Clean all parts with gas oil.
2.9 Check all parts and renew if necessary.
en / 31.05.2010 IB025068 1/2

M20
1500
3. Reassembly 03
3.1 Reassembly is done in reverse order of disassembly.
3.2 Tighten connecting bolts (9) using a torque of
M = 24,5 Nm
3.3 Check the explosion relief valve for proper function by manual operation after assembly.
3.4 When mounting the explosion relief valve to the crankcase door be sure that the sealing between
seat ring and crankcase door is in proper condition.
en / 31.05.2010 IB025068 2/2

M20
1500
See also: 02.01.01.nn 03


--------------------------------------------------------------------------------------------------------------------------------
Check:
Ease of movement of the explosion relief valve every 1,500 h
Auxiliary materials:
Molykote Paste "G Rapid Plus“ *
Sealing compound "Dirko No. 610.020" *
* or equivalent product
NOTE
Removal of the explosion relief valve (5) is only required if the specified spring tension
is not provided any more, in the event of abnormal oil contamination or if any leaks
should be identified during operation.
Procedure:
1. Check the relief valve from the inside of the crankcase door (1) for ease of movement by actua-
ting the valve by hand. For this purpose dismantle the crankcase door (1) or the explosion relief
valve (5).
2. Disassembly
2.1 Unscrew and remove screws (8) from crankcase door (1).
2.2 Remove explosion relief valve (5) from the crankcase cover (1).
3. Assembly
3.1 Coat the threads of screws (8) slightly with Molykote Paste "G-Rapid Plus".
3.2 Clean the sealing face (10) on the crankcase door (1) and lubricate with sealing compound "Dirko
No. 610.020".
3.3 Put the explosion relief valve (5) in place on the crankcase door (1).
en / 30.09.2010 IB026533 1/2

M20
1500
3.4 Tighten screws (8) to a torque of 03

M = 15 Nm.
3.5 After assembly check the explosion relief valve for proper operation by actuating it by hand.
3.6 When mounting the explosion relief valve on the crankcase door care has to be taken to ensure
proper sealing between seat and crankcase door.
en / 30.09.2010 IB026533 2/2

Zylinderbuchse A5.05. 03.03.01.02
M20
30000, 15000
See also: 02.06.01.nn 03


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
- Of one cylinder liner after 15,000 h
- Of all cylinder liners every 30,000 h
- Of the cylinder liner after removing the piston. Before and

after fitting the cylinder liner.
Tools:
Gauge ruler for cylinder liners W1 2.9216-022
Precision inside micrometer W2 * 1.9425-300
* not illustrated , special tool
Sequence of operation:
1. Check the cylinder liner.
NOTE
wear can occur on the cylinder liners which has to be
evaluated and measured depending on the operating
time and operating conditions (fig. 3).
1.1 Dismantle the calibrating ring (02.05.50.nn) and extract the

piston (02.06.01.nn).
1.2 Clean the inside of the cylinder liner. The crankcase must be
properly covered when doing this.
1.3 Measure the cylinder liner at the measuring points specified

by the gauge ruler (fig. 1/W1) and the table (fig. 2)
longitudinally, transversally and 2 x diagonally to the engine
axis by means of the precision inside micrometer (W2).
1.4
Wear
Measuring Longitudinal Transverse

point direction direction Diagonal Diagonal
1
2
3 Reference
dimension
en / 31.05.2010 IB022447 1/2

Zylinderbuchse A5.05. 03.03.01.02
M20
30000, 15000
1.5 Enter the measured values in the table 03

(fig. 2) and then determine the wear (d1 -
reference dimension d3 etc.). Also refer to
the measuring sheet in the "forms for
maintenance reports" folder”.
1.6 When the wear limit, normally in the area

of the upper piston ring point of return (fig.
3/4; TDC, first ring) or other limit values
indicate in the table are reached, then the
cylinder liner must be replaced.
Reconditioning of the cylinder liners is only
possible by Caterpillar / MaK.
Cylinder liner wear chart
Evaluation criteria Wear limit Explanation

(mm)
Nominal Ø (new) * Radius r ≥ 3mm
200 +46 ** in circumferencial direction

*** 1: Gusset, 2: Pocket, 3: Scores
Wear 0,8 4: TDC 1st. ring, 5: Canyon
Max. out-or-round 0,25
Gusset Height 6,00 wedge-shaped indentation across the

Depth * 0,03 entire circumference, beginning from
the TDC of 1st. piston ring.
Canyon max. number 3 Individual deep blow-through ducts

Height 6,00 in the area of the first piston ring
total width 3,00 (TDC).
Scores Number 3 Vertical and linear scores.

Height 140,00
Depth 0,03
Pocket Number 3 Irregular indentations.

Height 45,00
Width ** 15,00
Depth * 0,02
en / 31.05.2010 IB022447 2/2

Cylinder Liner A5.05. 03.04.01.00
M20
30000
See also: 01.06.01.nn, 02.06.01.nn 03


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Removal of cylinder liners and changing O-rings after 30,000 h
Tools:
Device for mounting and extracting the W1 2.9216-A

cylinder liners
1. Put upper crosshead half (Fig. 1/W1) with
threaded rod and eye bolt on liner collar.
2. Mount lower crosshead half (1) and tighten

both crosshead halves firmly with each
other with nuts (2).
CAUTION
The cylinder liner holding
device must be removed. W1
3
3. Attach the extracting device to a crane and 4
lift the liner along its centre line out of the
cylinder and put it down.
4. Remove O-rings (Fig. 1/3 and 4) at the cy-

linder liner collar and in the cooling water
distributor housing. Thoroughly clean the
sealing surfaces and annular grooves for
the
O-rings.
5. Clean the seat of the liner collar and the fir

for the upper and bottom end of the liner in 1
the cylinder.
6. Clean the cooling water zone at the cylin- 2

der liner collar.
Fig. 1
en / 30.09.2010 IB021527 1/1

M20
See also: 03.04.01.nn 03


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Device for mounting and extracting the W1 2.9216-A

cylinder liners
Auxiliary material:
Vaseline *
NOTE
After fitting a new cylinder liner,
the engine must be driven in
according to the driving-in regu-
lation A3.10.01.nn!
W1
1. Clean cooling water distributor housing
before installation. 3
4 1
2. Insert new O-rings (Fig. 1/1 and 2) at the
cylinder liner collar and in the cooling 2
water distributor housing (3).
CAUTION 5
Fit the O-rings with vaseline or

green grease soap untwisted in
the grooves; do not pull the 5
rings over the liner collar.
3. Insert the cylinder liner with mounting de-

vice (W1) in the cylinder block and crank-
case (4) by means of an extracting device.
Fig. 1
en / 30.09.2010 IB001369 1/2

M20
03
4. The cylinder liner must slide into the fitting
of the cylinder block and crankcase (Fig. X
1/5) through its own weight.
NOTE
Insert the cylinder liner in such
a way, that the markings (11)
(Fig. 2/X, top view liner collar)
point in longitudinal direction to
the coupling side.
The cast nose (12) serves as
an aligning aid at the cooling
water distributor housing. Fig. 2
12
11
en / 30.09.2010 IB001369 2/2

Engine Bolting and Unions A5.05. 03.07.01.00
M20
150
See also: 02.02.01.nn 03


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of all bolts, unions and screwed connections for good fitting and leaks.
NOTE
This precautionary measure has to be taken once to detect any leaks and/or slack
screwed connections that might result from some parts or gaskets taking a set that
could cause damage.
When starting up a new plant (150 h) and/or after major repairs, the engine unions
and screwed connections have to be inspected for good fitting and leaks.
1. Check the flanged connections, filter thermostats and pipe clamps of the followinf systems for
good mounting and leaks:
• Cooling water
• Lubricating oil
• Fuel
• Exhaust gas
• Starting air
• Pneumatic control
2. Retighten the fixing bolts of the brackets for the injection pump control rod and check the locking
washers and pins of the linkage.
3. Check the monitoring and control equipment for good fitting. Cables and signal lines must not
scrape against any part.
4. Check the foundation bolts by knocking. Measure the crank web deflection after tightening slack
foundation bolts (02.02.01.nn).
Consult MaK aftersales service for tightening values.
5. Check the elastic bearing elements for damages.
en / 10.08.2010 IB001402 1/1

Camshaft Bearing A5.05. 04.01.01.00
M20
30000, 15000
See also: 02.01.01.nn, 04.01.02.nn 04


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
- Bearing clearance of one camshaft bearing after 15,000 h
- Bearing clearance of all camshaft bearings after 30,000 h
NOTE
Camshaft bearings are not subjected to load changes. The load on the bearing occurs
exceptionally in the lower contact area and is relatively heavy in this area. Smooth
overload along the edges is not unusual.
1. Check the camshaft bearing clearance.
1.1 Open corresponding inspection glass lid of the camshaft door on the control side.
1.2 Measure clearance camshaft bearing / bearing neck.
New clearance Clearance limit

mm mm
0,11 - 0,165 0,22
NOTE
With reaching the clearance limit the camshaft bearing is to be replaced (MaK
customer support) and the clearance of all camshaft bearings are to be checked.
Check running surface of the bearing necks of the corresponding camshaft bearings.
en / 30.09.2010 IB026569 1/1

Camshaft A5.05. 04.04.01.00
Repair / Disassembly and reassembly
M20
See also: 01.01.01.nn, 01.02.01.nn 04


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Camshaft - mounting device W1 2.9230-A

Locking screw W2
Torque wrench 40 - 180 Nm W3 1.9454-40
Hexagon socket wrench 10 mm W4 * 1.9039-10
Auxiliary material:
Sliding coating Metaflux **

Molykote paste ”G-Rapid Plus” **
1. Disassembly
1.1 Open the decompression valves.
1.2 Remove the camshaft cover at the W2

camshaft side and the cover on the
opposite side of the clutch.
1.3 Remove the valve rocker of this cylinder

and all cylinders to the right of it
(01.02.01.nn).
1
1.4 Lift the rockers of the corresponding inlet
and exhaust valve drives (Fig. 1/1) from
the cams and secure with locking screw
(W2).
Fig. 1
en / 31.05.2010 IB001455 1/3

Camshaft A5.05. 04.04.01.00
M20
1.5 Turn the camshaft to highest cam 04

elevation (TDC). Remove and fasten the
rocker (Fig. 2/1) of the corresponding
injection pump drives with locking screws
from injection cams (W2).
1.6 Assemble the camshaft - mounting device

(Fig. 3/W1) at the cylinder crankcase in
accordance with arrangement 1.7 and set
it with hexagon screws (21) to camshaft
flange height (X).
W2
1.7 Arrangement of the camshaft -
mounting device
Disassembly Camshaft -
camshaft mounting device
piece at cylinder unit 1
cylinder No.
1 3+6
2 4+6
3 5+6 Fig. 2
4 6
5 –
6 –
For removing the camshaft piece of

cylinder unit 6 or cylinder unit 5 lift the
21
camshaft piece of cylinder unit 6 out of the
engiene block through the mounting
W1
opening at face end..
1.8 Loosen the flange screws (22) of the

camshaft piece to be disassembled and
the camshaft piece right to it with hexagon
socket wrench (W4) and extension.
Release the inaccessible screws.
22
1.9 Shift the loosened camshaft with mounting
device carefully and without great force
to the right by one cylinder unit.
1.10 Remove the camshaft piece to the right

side from the loosened adjacent camshaft
covering.
X 21 W1
Fig. 3
en / 31.05.2010 IB001455 2/3

Camshaft A5.05. 04.04.01.00
M20
04
31
CAUTION
Do not cant camshaft piece in
the camshaft bearings during
removal.
Handle with utmost caution.
Danger of destruction of the
bearings.
2. Assembly
NOTE
The camshaft flange (Fig. 4/
31) of every piece is pinned
according to the cylinder and
position in accordance with the
firing order (32) and provided
with a flange index (33) (see
table).
32
Camshaft Flange
33
piece index Fig. 4
cylinder No.
1 4
2 2
3 3
4 4
5 5
6 6
2.1 Position the camshaft pieces in reverse disassembly order.
2.2 Grease the threads and contact surfaces of the flange screws with Molykote paste
”G-Rapid Plus” and bolt the loosened camshaft pieces.
2.3 Tighten the flange screws crosswise with a torque of
100 Nm = 50°° angle of rotation.
Remove the camshaft - mounting devices (W1).
2.4 Remove the locking screws (W2) of the raised valve and pump drive rocker.
2.5 Mount the valve rocker (01.02.01.nn) and check the valve clearance (01.01.01.nn).
2.6 Check the lubricating oil flow.
en / 31.05.2010 IB001455 3/3

Camshaft A5.05. 04.04.01.01
M20
See also: 01.01.01.nn, 01.02.01.nn 04


--------------------------------------------------------------------------------------------------------------------------------
Tools:

Locking screw W2
Auxiliary material:

1. Disassembly


(01.02.01.nn).
1
(W2).
Fig. 1
en / 30.09.2010 IB002113 1/3

Camshaft A5.05. 04.04.01.01
M20


flange height (X).
W2
mounting device
piece at cylinder unit
1
cylinder No.
1 3+7
2 4+8
3 5+8
4 6+9 Fig. 2
5 7+9
6 8
7 9
8 –
9 –
21
W1
opening at face end.

the camshaft piece right to it with hexagon 22


covering.
X 21 W1
Fig. 3
en / 30.09.2010 IB002113 2/3

Camshaft A5.05. 04.04.01.01
M20
04
31
CAUTION
removal.
bearings.
2. Assembly
NOTE
The camshaft flange (Fig. 4/31)
of every piece is pinned accor-
ding to the cylinder and positi-
on in accordance with the firing
order (32) and provided with a
flange index (33) (see table).
32
Camshaft Flange
piece index 33
Fig. 4
cylinder No.
1 1
2 1
3 2
4 3
5 4
6 4
7 3
8 2
9 1
2.5 Mount the valve rocker (01.02.01.nn)and check the valve clearance (01.01.01.nn).
en / 30.09.2010 IB002113 3/3

Camshaft A5.05. 04.04.01.02
M20
See also: 01.01.01.nn, 01.02.01.nn 04


--------------------------------------------------------------------------------------------------------------------------------
Tools:

Locking screw W2
Auxiliary material:

1. Disassembly


(01.02.01.nn).
1
(W2).
Fig. 1
en / 31.05.2010 IB002116 1/3

Camshaft A5.05. 04.04.01.02
M20


flange height (X).
W2
mounting device
piece at cylinder unit 1
cylinder No.
1 3+7
2 4+7
3 5+8 Fig. 2
4 6+8
5 7+8
6 8
7 –
8 –
21
W1
opening at face end.

the camshaft piece right to it with hexagon 22


covering.
X 21 W1
Fig. 3
en / 31.05.2010 IB002116 2/3

Camshaft A5.05. 04.04.01.02
M20
04
CAUTION 31
removal.
bearings.
2. Assembly
NOTE
The camshaft flange (Fig. 4/31)
of every piece is pinned accor-
ding to the cylinder and positi-
on in accordance with the firing
order (32) and provided with a
flange index (33) (see table).
Camshaft Flange
piece index
32
cylinder No.
33
Fig. 4
1 5
2 2
3 3
4 4
5 5
6 6
7 7
8 8
2.5 Mount the valve rocker (01.02.01.nn) and check the valve clearance (01.01.01.nn).
en / 31.05.2010 IB002116 3/3

Timing Gear Train A5.05. 04.08.01.00
M20
3750
See also: 04

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Working surfaces of the teeth 3,750 h
Sequence of operation:
1. Remove the covers at the gear housing on
1
the camshaft and exhaust side.
1.1 Check the tooth surfaces of the camshaft

gear (Fig. 1/1), intermediate wheel (2) and
crankshaft gear (3) (pitting, cross bearing,
disintegrations etc.) 4
1.2 Check the function of the oil nozzles (4, 5 2 6

and 6).
7
1.3 Fit the covers and check the gaskets.
5
2. Replace the O-rings on the intermediate
wheel axle (7).
2.1 Remove locking plate (Fig. 2/10).

3
2.2 Shift the intermediate wheel axle (7) from
Fig. 1
the gear housing in the direction of the
coupling side and renew the 10
O-ring (11).
CAUTION
The preset tooth meshing of the
intermediate wheel to the cams-
haft gear and crankshaft gear
must not be adjusted. Danger of
timing adjustment!
11 7
Fig. 2
en / 30.09.2010 IB022002 1/1

Governor Drive A5.05. 04.08.03.00
M20
15000
See also: 04

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Contact reflection at helical gear wheels every 15,000 h
Tools:
Auxiliary material:

Silicon sealing compound “Dirco Gray” **
1. Disassembly
1.1 Loosen the governor linkage from

the governor.
1.2 Unscrew the hexagon screws (Fig. 1/1) 2

and lift the governor (2) from the guide of
the governor housing (3). 1
1.3 Loosen the fillister head screws (4) and lift

the housing from the top edge of
the cylinder block and crankcase (3). The 4
housing is fixed with two dowel pins (5).
3
Fig. 1
en / 31.05.2010 IB022022 1/3

M20
15000
1.4 Loosen and remove the cover (Fig. 2/11) 04

at the gear housing, taking care of the do-
wel pin (12). Check the oil lubricating hole.
1.5 Loosen the hexagon screws at the helical

gear wheel (13) and remove the helical
gear wheel (13) from the camshaft gear
(14).
1.6 Release the castellated nut (15) and

unscrew it with the conical spring washer 20
(16) from the governor drive shaft (17).
21
1.7 Pull off the helical gear wheel (18) from the 22
governor drive shaft (17), taking care of
the parallel key (19).
14
17
1.8 Check the tooth surfaces of the helical
gear wheels (13 and 18) for wear (pitting,
cross bearing, disintegrations).
11
1.9 Lift the governor drive shaft (17) out of the
cylinder block and crankcase and check
for wear.
23
1.10 Remove the serration from the governor
drive shaft (17) and check the shaft (20) 12
for wear.
23
1.11 Check the washer (21) for wear and renew
it if necessary.
18
1.12 Check all oil lubricating holes for the lubri-
19
cation of the governor drive shaft (17) and
helical gear wheels (13 and 18) for flow
through. 16
15
NOTE
The governor drive shaft (17) is 13
installed in the top and lower
part of the cylinder frame. If
required, the bushes (22 and
23) are to be driven out with a
suitable mandrel from
the cylinder block and crank-
case and renewed.
Fig. 2
2. Reassembly
2.1 The reassembly is to be carried out in reverse order.
2.2 Grease the governor drive shaft (Fig. 2/17) and slide it into the cylinder block and crankcase with
washer (21) from above.
en / 31.05.2010 IB022022 2/3

M20
15000
2.3 Slide the helical gear wheel (18) with the conical spring washer (16) onto the governor drive shaft 04
(17) and tighten and secure it with a castellated nut (15).
2.4 Put the helical gear wheel (13) in the recess of the crankshaft gear (14). Grease the threads and
contact surfaces of the hexagon screws with Molykote paste “G-Rapid Plus” and tighten
crosswise with a torque of
M = 60 Nm.
2.5 Put the governor housing (Fig. 1/3) on the cylinder block and crankcase (taking care of the dowel
pins [5]) and tighten it with fillister head screws. (4).
2.6 Put the governor (2) on the governor housing (3) and tighten it with hexagon screws (1). The ser-
ration of the governor shaft (Fig. 2/20) must slide easily into the internal toothing of the governor
drive shaft (17).
2.7 Fit the cover (11) with silicon sealing compound at the cylinder block and crankcase. The position
is fixed with dowel pins (12).
2.8 Mount the governor linkage at the governor (Fig. 1/2) and, if necessary, readjust the governor (2)
(see also governor adjustment, Book C).
3. Carry out lube oil flow through inspection.
en / 31.05.2010 IB022022 3/3

Vibration damper on camshaft A5.05. 04.09.01.00
M20
15000
See also: 04

--------------------------------------------------------------------------------------------------------------------------------
Tools:
20 - 90 Nm 1/2" torque wrench W1 * 1.9454-020
12mm Allan key insert W2 * 1.9039-012
* not illustrated
Auxiliary tools:
"G-Rapid" Molykote paste **
** or product of equal quality
NOTE
The torsional vibration dampers must be replaced after 15,000 operating hours.
1
WARNING
Attention, there is a risk of injury!
Never open a vibration damper 5
1. Disassembly 6
1.1 Support the damper (1), loosen cheese

head screws (5). Lift off the damper with
cover disc (3) and sleeves (6). 3
2. Assembly
2.1 Clean the contact surface of the damper

(1) and the cover disc (3).
2.2 Apply "G-Rapid" Molycote paste to the

thread and contact surface of the cheese
head screws (5).
en / 31.05.2010 IB021594 1/2

M20
15000
2.3 Assemble the cover disc (3), the damper 04

(1), sleeves (6) and
cheese head screws (5) according to the
illustration.
2.4 Tighten the cheese head screws (5) with a

torque of
M = 60 Nm.
en / 31.05.2010 IB021594 2/2

M20
15000
See also: - 04

--------------------------------------------------------------------------------------------------------------------------------
Tools:
20 - 90 Nm 1/2" torque wrench W1 * 1.9454-020
12mm Allan key insert W2 * 1.9039-012
* not illustrated
Auxiliary tools:
"G-Rapid" Molykote paste **
** or product of equal quality
NOTE
The torsional vibration dampers must be replaced after 15,000 operating hours.
WARNING 1
Attention, there is a risk of

injury!
Never open a vibration damper
1. Disassembly
5
1.1 Loosen the cheese head screws (5),
lift off damper (1), disc (3) 6
with cover disc (2).
2. Assembly
2.1 Clean the contact surfaces of the dampers

(1), the disc (3)
and the cover disc (2).
2.2 Apply "G-Rapid" Molycote paste to the

thread and contact surface of the cheese
2 3
head screws (5).
en / 31.05.2010 IB021601 1/2

M20
15000
2.3 Assemble the cover disc, both dampers 04

(1) and disc (3), cheese head screws (5)
and sleeves (6) according to the
illustration.
2.4 Tighten the cheese head screws (5) with a

torque of
M = 60 Nm.
en / 31.05.2010 IB021601 2/2

Vibration Damper on Camshaft A5.05. 04.09.01.02
M20
15000
See also: - 04

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Hex cap screw drive A/F12 W2 * 1.9039-012
*no illustration
Auxiliary material:
Molykote paste „G-Rapid“ **
**or a product of equivalent standard
NOTE
After 15.000 operating hours, the vibration dampers have to be exchanged against
new ones.
7 5 8
WARNING
Attention, there is a risk of
injury!
Never open a vibration damper
4
1. Disassembly
6
1.1 Support dampers (1 and 2).
Loosen cylinder head screws (3).Lift off 9
damper with washers (4 and 5).
1.2 Support cover disk (6). Loosen hexagon

socket head cap screws (7). 3
Remove cover disk.
1 2 10
en / 30.09.2010 IB021607 1/2

Vibration Damper on Camshaft A5.05. 04.09.01.02
M20
15000
2. Reassembly 04
2.1 Clean contact faces of dampers (1and 2), washers (4 and 5) and cover disk (6).
2.2 Check bores (9) of cover disk (6) and bore (8) of washer (5) for free flow and clean, if necessary.
2.3 Lubricate thread and contact face of cylinder head screws (3 and 7) with Molykote paste „G-Ra-
pid“.
2.4 Mount cover disk (6).
2.5 Tighten cylinder head screws (7) with a torque of
M = 60 Nm
2.6 Slip-on damper (1) as shown in the illustration.
2.7 Place washer (5) and align it so that the bores (8 and 9) coincide.
CAUTION
The free flow of bores (8 and 9) is absolutely necessary to ensure a proper function.
2.8 Mount both dampers (2) with washer (4), cylinder head screws (3) and sleeves (10) in accordan-
ce with the illustration.
2.9 Tighten cylinder head screws (5) with a torque of
M = 60 Nm
en / 30.09.2010 IB021607 2/2

Control shaft bedding A5.05. 05.01.02.00
Maintenance / Checking
M20
1500
See also: - 05
Spare parts list: B1.05.04.2.4110, B1.05.05.2.4210, B1.05.05.2.4521, B1.05.05.2.4523

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Oil control shaft after 1.500 h
Auxiliary material:
Multi-purpose grease or lubricating oil according to A4.05.08.nn
1. Remove control shaft/injection pumps and control station covers.
2. Check control shaft and spindle to emergency-off lever and oil bearing areas slightly with lubrica-
ting oil.
CAUTION
After cleaning with fat dissolving agents, all bright-metallic components are to be oiled
slightly.
Care has to be taken that all cleaned bearings are thoroughly greased.
3. Oil all moving bearings of the following components slightly:
- swivel head of spring link between control shaft and regulator
- swivel arm between control shaft and injection pump
- dual pivoting bearing of clutch between control station and control shaft
4. Assemble covers.
en / 10.12.2010 IB026480 1/1

Fuel Limiter A5.05. 05.04.01.00
Inspection / Adjust
M20/M282/M332C/M452/M453C/M551/M552C
3750
See also: 05.04.02.nn 05


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of fuel limiter every 3,750 h
Note:
This unit limits the fuel injection depending on the carge air pressure so as to avoid a smoky ex-
haust. The exhaust can become black in the event of a rapid speeding up or a brisk load increa-
se. The fuel limiter is only installed on reversible engines and is operable from a
lubricating oil pressure of 0,8 bar. If the oil is contaminated, this may disturb operation.
A defective fuel limiter can be cut out, during engine operation, by turning the set screw in (item
11 on 05.04.02.nn).
Remove the lead seals only if a resetting is necessary.
1. Check all bolts and screwed connections Position while speeding up
for tightness.
Repair any leaks (05.04.02.nn).
2. Check adjusting screw (Fig. 1/1) whether

it admits starting fuel so that starting is po-
sitively possible.
3. Check the actuating speed when the

engine is warm.
3.1 Set the control handle rapidly on full load

at an engine speed of
0,3 to 0,5 max. speed.
en / 30.05.2000 IB021621 1/2

Fuel Limiter A5.05. 05.04.01.00
Inspection / Adjust
M20/M282/M332C/M452/M453C/M551/M552C
3750
05
3.2 Check whether the piston follows the charge air pressure change continuously and without hesi-
tation. Overhaul the fuel limiter if piston operation is not satisfactory.
Piston travel = 26 mm
3.3 If the exhaust gas becomes black turn adjusting screw (2) 1 to 1.5 turns clockwise to increase the
spring load.
3.4 Speed the engine up again and check the exhaust gas.
3.5 If the regulating speed is too slow turn the adjusting screw (2) counterclockwise until the regula-
ting speed is as desired without smoke in the exhaust.
4. Check the maximum fuel limiting screw (3) for correct position.
5. Lock the screws.
en / 30.05.2000 IB021621 2/2

Fuel Limiter A5.05. 05.04.01.01
Inspection / Adjust
M20
3750
See also: 05.04.02.nn 05


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of fuel limiter every 3,750 h
NOTE
This unit limits the fuel injection depending on the carge air pressure so as to avoid a
smoky exhaust. The exhaust can become black in the event of a rapid speeding up
or a brisk load increase.
1. Check all bolts and screwed connections
for tightness.
Repair any leaks (05.04.02.nn).
2. Check adjusting screw (Fig. 1/1) whether

it admits starting fuel so that starting is po-
sitively possible.
3. Check the actuating speed when the

engine is warm.
3.1 Set the control handle rapidly on full load

at an engine speed of
0,35 to 0,5 max. speed.
en / 31.05.2010 IB021625 1/2

Fuel Limiter A5.05. 05.04.01.01
Inspection / Adjust
M20
3750
3.2 Check whether the piston follows the charge air pressure change continuously and without hesi- 05
tation. Overhaul the fuel limiter if piston operation is not satisfactory.
Piston travel = 26 mm
3.3 If the exhaust gas becomes black turn adjusting screw (2) 1 to 1.5 turns clockwise to increase the
spring load.
3.4 Speed the engine up again and check the exhaust gas.
3.5 If the regulating speed is too slow turn the adjusting screw (2) counterclockwise until the regula-
ting speed is as desired without smoke in the exhaust.
4. Lock the screws.
en / 31.05.2010 IB021625 2/2

Servo-Actuator A5.05. 05.04.02.00
M20/M282/M332C/M452/M453C/M551/M552C
See also: 05.04.01.nn 05


--------------------------------------------------------------------------------------------------------------------------------
Auxiliary material:
Liquid seal “Loctite 221” *
Note:
The fuel limiter must not be removed when
there is pressure on the lubricating oil sy-
stem.
A defective fuel limiter can be cut out, du-

ring engine operation, by turning the set
screw in (11).

1. Disconnect the lubricating oil feed and out-
let and the charge air.
2. Remove the fuel limiter from the engine.
3. Disassemble the limiter completely and

clean the parts.
4. Inspect all parts.
5. Renew all gaskets and seals (1 to 10).
6. Coat the thread of the parts (12, 13, 14)

with liquid sealing compound (e.g. Loctite
221).
7. Assemble the limiter, fit it on the engine

and set it (05.04.01.nn).
en / 26.03.1999 IB000170 1/1

Servo-Actuator A5.05. 05.04.02.01
M20
See also: 05.04.01.nn 05


--------------------------------------------------------------------------------------------------------------------------------
Auxiliary material:
Liquid seal “Loctite 221” *
CAUTION
The fuel limiter must not be removed when there is pressure on the lubricating oil
system.
1. Disconnect the lubricating oil feed and out-
let and the charge air.
2. Remove the fuel limiter from the engine.
3. Disassemble the limiter completely and

clean the parts.
4. Inspect all parts.
5. Renew all gaskets and seals (1 to 10).
6. Coat the thread of the parts (12, 13, 14)

with liquid sealing compound (e.g. Loctite
221).
7. Assemble the limiter, fit it on the engine

and set it (05.04.01.nn).
en / 31.05.2010 IB020391 1/1

Starting Fuel Limiter A5.05. 05.05.01.00
M20-M601C
3750
See also: 05

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Torque wrench 20 - 90 Nm W1 * 1.9454-020
~ Safety note:
Vent the air system before doing any work.
Note:
All pneumatic elements are lubricated with a special grease (see operating media, section A4),
and it is not necessary to renew this for several years. Only this grease must be used for repairs.
Proper operation of all parts will no longer be ensured when other lubricants are used.
~ Safety note:
The piston is spring-loaded.
1. Functional check
1.1 Check the air connection for leaks.
1.2 Check whether the piston moves easily

under air pressure. If the movement is jer-
ky, vent the oil part (para 2).
1.3 Check the setting.
1.3.1 If maximum fuel limitation has been provi-

ded, check the setting (see the Accep-
tance Test Records).
1.3.2 Check whether 40 % fuel is admitted when

the piston is in the outer dead centre. Ad-
just by set screw (Fig. 1/11).
en / 30.05.2000 IB021410 1/3

M20-M601C
3750
05
1.4 Check whether full fuel is admitted within
15 seconds
after starting the engine. Adjust by throttle screw (Fig. 1/10).
2. Venting
2.1 Slip a transparent hose over vent screw (12) and put the other end into a an oil reservoir arranged
at a lower level. Turn the vent screw entirely in and then screw one turn back.
2.2 Remove plug (13), spring (14) and piston (15).
2.3 Fill oil in as far as 7 mm below the housing top edge (SAE 20).
2.4 Insert the piston. Drive the air out by screwing the plug in.
2.5 Proceed according to 2.3 and 2.4 until no air escapes any more. Unscrew the plug. Insert the
spring. Screw the plug in until it is flush with the housing top edge and secure it with locking
spring (16).
2.6 If the cylinder is of the older type, the air must be removed by the throttle screw.
3. Disassembly
3.1 Close the main air valve. Remove the air connection.
3.2 Remove the unit from the engine.
3.3 Measure and note down the position of throttle screw (10) and thrust screw (11).
3.4 Disassemble the unit entirely and clean it in spirit.
3.5 Inspect all parts.
en / 30.05.2000 IB021410 2/3

M20-M601C
3750
4. Reassembly 05
4.1 Renew all gaskets and seals
(Fig. 2/1 - 9).
4.2 Assemble the unit observing the following:
4.2.1 Tighten the socket head cap screws (17)

with a torque
M = 20 Nm.
4.2.2 Before fitting vent screw (12), plug (13),

spring (14), piston (15) and throttle screw
(10), apply a pressure of approximately
0,7 bar
to connection (A).
4.2.3 Fill oil (SAE 20) in as far as 7 mm below

the housing top edge at connection (B).
4.2.4 Tighten the throttle screw (10) and socket

head cap screw (18) with a torque
M = 20 Nm.
4.2.5 Vent the unit according para 2.
4.2.6 Adjust the unit and fit it on the engine.
4.2.7 Mount air connection.
4.2.8 Open main air shut-off valve
4.2.9 Check the operation according to para. 1.
Attention:
Do not shut off the air tank when the engine is in operation!
en / 30.05.2000 IB021410 3/3

Control Valves A5.05. 05.09.05.00
M20
30000
See also: 05

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
After four years carry out a random test of the low pressure valves.
In case of deficiencies recondition all control valves.
Special grease for all control units see MaK Lubricant Recommendations in A4.05.08.nn
The use of other lubricants may have a detrimental effect on the functioning of the fittings.
General maintenance instructions see “Description to Functional Diagram” in book C.
This will result in a certain cycle for control or inspection depending on the type and function of
the individual control units.
Regulating elements (pressure reducers) must be checked in their circuit after maintenance work
for their setting values and must be reset if required.
Ensure that no air is available at the components to be disassembled or that no air can be
admitted to these.
Prior to disassembly operations and where necessary, measure and mark the position of valves,
lever lengths and lever travels of e.g. actuators, limitations by set screws, and so on.
Do not disassemble control fittings at random since the built-in springs are somtimes prestressed.
Where a screw or nut is used for the adjustment of the prestressing, first loosen these completely.
Clean the individual components thoroughly and exchange worn down wear parts. During
assembly slightly grease rubber rings and their sliding surfaces with the prescribed grease.
en / 30.09.2010 IB022045 1/1

Compressed-Air Filter A5.05. 05.09.06.00
M20/M25/M32/M43/M453C/M552C/M601C
24, 150, 7500
See also: 05

--------------------------------------------------------------------------------------------------------------------------------
Maintenance/cleaning:
Drain compressed-air filter: every 24 h
Disassemble and clean compressed-air filter: initially 150 h
Disassemble and clean compressed-air filter: every 7,500 h
Auxiliary material:
Nitro-Solvents *
CAUTION
Close feed air lines and depressurize air system before every disassembly!
NOTE
It is to be checked to what extent following units/systems (emergency stop) in the
circuit are affected in their functioning by the execution of the disassembly and
cleaning measures!
en / 25.11.2010 IB021438 1/2

M20/M25/M32/M43/M453C/M552C/M601C
24, 150, 7500
1. Drain compressed-air filte

1
1.1 Loosen drain plug (7) and empty filter
completely.
1.2 Close drain plug.
2. Disassemble compressed-air filter and 2

clean
2.1 Loosen drain plug (7) and drain filter 3

completely.
4
2.2 Close compressed-air feed line and
secure. 5
2.3 Relieve compressed-air filter via drain

plug.
2.4 Loosen housing cap (5) and remove, 6

check O-ring (1) and replace if necessary.
8 7
2.5 Loosen Phillips screw (4), remove with
guide (3) and filter element (2).
2.6 Remove locking ring (8), unscrew drain

plug and check O-ring (6), replace if ne-
cessary.
2.7 Clean all disassembled parts and check for reuse.
2.8 Assemble compressed-air filter in reverse sequence. Open shut-off valve in the compressed-air
supply line.
2.9 Close drain plug after a short while.
en / 25.11.2010 IB021438 2/2

M20/M25/M32/M43
24, 7500
See also: C5.05.05.45.23.nn 05


--------------------------------------------------------------------------------------------------------------------------------
Maintenance/cleaning:
Drain compressed-air filter: every 24 h
Disassemble and clean compressed-air filter: initially 150 h
Disassemble and clean compressed-air filter: every 7,500 h
NOTE
Maintenance and trouble shooting see "engine documentation, chapter "Control/
Regulation" C5.05.05.45.23.nn
en / 25.11.2010 IB024847 1/1

Regleröl A5.05. 05.25.00.01
Inspection / Oil change
M20/M25/M32/M43
24
See also: C5.05.04.20.27.nn 05

Spare parts list:
Operating medium: Every fuel

--------------------------------------------------------------------------------------------------------------------------------
Check:
Visual check of the governor oil every 24 h
Attention:
A visual check of the governor oil must be carried out every 24 hours on the oil level sight
glass of the governor.
If the governor oil should show obvious contamination, it must be changed forthwith.
Note:
For further information and evaluation criteria please refer to the oil specification
in Book C (C5.05.04.20.27.nn).
en / 25.08.2006 IB025366 1/1

Exhaust Manifold A5.05. 06.01.01.00
M20
30000, 7500
See also: 06
Spare parts list: B1.05.06.2.72n0

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Exhaust manifolds must be examined for leakages after 7,500 h
Maintenance:
Remove and clean exhaust manifold after 30,000 h
Auxiliary material:
High temperature-thread paste “Dag S-5080” *
NOTE
Check also the exhaust piping after the turbocharger when doing the work on the ex-
haust manifold.
If excessive vibrations and noises occur in the exhaust-gas turbine, the flanged con-
nection on the exhaust pipe behind the turbine must be unscrewed and examined for
pipe tension.
To safeguard the expansion joints these must not be subjected to bending or radial
forces on removal and fitting. A small preload (expansion), however, is necessary in
axial direction when installing (about 3mm).
Fit all screws with high temperature-thread paste “Dag S-5080” to avoid sticking due
to heat.
1. Inspection
1.1 Remove the covering from the exhaust manifold.
1.2 Check all bolts for tightness.
1.3 Carry out a visual inspection at the flanged connections and expansion joints (inspection must be
carried out with the engine running).
en / 31.05.2010 IB022083 1/2

M20
30000, 7500
06
NOTE
Soot and soot deposits indicate a leak of the system. Renew the gaskets if no cracks
in the pipes or slack bolts are the cause of the leak. Replace expansion joints that
have cracks in the bellows. On assembly pay attention to the direction of flow
(arrow on the flange).
1.4 Fit the covering.
2. Maintenance
2.1 Remove covering and carry out inspections according to 1.3. Mark the mounting position of the
expansion joints and pipes.
2.2 Remove the exhaust manifold.
2.2.1 Loosen the flanged connections first at the expansion joint (Fig. 1/1), then at the cylinder head (2)
and remove the pipe.
2 1
Fig. 1
2.3 Clean the inside of the exhaust manifolds and check for cracks.
2.4 Check the expansion joints and replace them if necessary.
2.5 Fit the exhaust manifolds with new gaskets in reverse order and observe the markings.
2.6 Coat the thread and screw contact surface of the screws with “Dag S-5080”. Screw in the screws
with resilient sleeves and tighten on alternate sides in two stages with a
torque of 60 Nm and 110 Nm.
2.7 Fit the expansion joints after precise adjustment of the pipes (direction of flow marked with arrow).
2.8 Fit the covering.
en / 31.05.2010 IB022083 2/2

M20
7500
See also: 06
Spare parts list: B1.05.06.2.72n0

--------------------------------------------------------------------------------------------------------------------------------
Checks:
Check exhaust pipe for leaks after 7,500 hrs
Auxiliary material:
High temperature bolt lubricant "Rivolta G.W.F“ *
* or comparable product
NOTE
In order to prevent longitudinal strain of the expansion joints, they should not be sub-
jected to bending and/or radial forces during disassembly and assembly.
However, for the expansion joint ahead of the turbine, a slight preload in axial direc-
tion (strain) is required during installation.
Coat all bolts with high temperature bolt lubricant "Rivolta G.W.F." before installation
in order to protect them from seizure.
Procedure:
1. Remove exhaust pipe sheathing.
DANGER
Caution, hot engine components can cause burns!
Always check temperatures before beginning work on exhaust pipes! Let exhaust
piping cool sufficiently!
2. Check tightness of all bolt connections.
en / 30.09.2010 IB025358 1/3

M20
7500
3. Carry out visual inspections on flanges and expansion joints. 06
NOTE
Soot buildup and/or bubbles can be a sign of leaks.
Replace any expansion joints that show cracks in the bellows.
Observe indicated direction of flow when installing expansion joints before the
turbine.
4. Replace defective exhaust pipe.
4.1 Loosen the expansion joint clamps (1) and cautiously pull over the flange
4.2 Loosen bolts (2) at the cylinder head; remove exhaust pipe (3) and expansion joint (4).
4.3 Clean inside of exhaust pipe, check for cracks.
4.4 Check expansion joint for cracks and replace, if required.
NOTE
Prior to reassembly, thoroughly clean flange faces and mounting surfaces of clamps.
Coat mounting surfaces of clamps thoroughly with "Rivolta G.W.F".
Coat all bolts with high temperature bolt lubricant "Rivolta G.W.F." before installation,
in order to protect them from seizure.
en / 30.09.2010 IB025358 2/3

M20
7500
4.5 Install exhaust pipe (3) with expansion joint (4) and new seal (5). 06
4.6 Coat threads and washer face of bolts (2) with "Rivolta G.W.F". Insert bolts with extension slee-
ves in cylinder head and tighten alternately in 2 steps with a tightening torque of
M = 60 and 110 Nm
.
4.7 Coat mounting surfaces of clamps with "Rivolta G.W.F".
4.8 Cautiously pull clamps over the flanges
4.9 Tighten clamps with a tightening torque of
M = 25 Nm
.
4.10 When mounting the expansion joint (8) ahead of the turbine, fabricate a dummy.
Length of dummy x = 180 mm
4.11 Mount exhaust pipe with new seal and dummy.
4.12 Coat threads and washer face of bolts with "Rivolta G.W.F". Insert bolts with extension sleeves in
cylinder head and tighten alternately in 2 steps with a tightening torque of
M = 60 and 110 Nm
.
4.13 Remove dummy
4.14 Mount expansion tube; note the direction of flow as identified by the arrow on the flange.
CAUTION
The arrow on the expansion joint flange must point in the direction of flow
4.15 Coat threads and washer face of bolts (6) with "Rivolta G.W.F".
4.16 Fit bolts (6) from the expansion joint side.
4.17 Mount extension sleeves with hexagonal nuts (7) from the exhaust pipe side.
4.18 Tighten bolts with a tightening torque of

M = 90 Nm
4.19 Install exhaust pipe sheathing.
en / 30.09.2010 IB025358 3/3

Charge Air Cooler A5.05. 06.04.02.00
M20
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The charge air cooler is to be disassembled and cleaned at the air side if the differential pressure
before/after radiator reaches more than 1.5 times test bed value (see acceptance brake certificate
A1.10).
Tools:
Auxiliary material:
Cleansing agent according to recommendations of the manufacturer, e.g. of:

•
Vecom GmbH, Hamburg *
•
Drew Ameroid GmbH, Hamburg *
•
UNITOR chemicals *
1. Disassembly
1.1 Disconnect cooling water lines inlet and

outlet at the charge air cooler. 3
1.2 Loosen hexagon screws (Fig. 1/1 and 2).
1.3 Withdraw charge air cooler from housing 2

(3). Support with lifting gear and put it 1
down in a suitable container for the cle-
aning.
1.4 Clean charge air cooler according to ma- Fig. 1

nufacturer's regulation (refer to Book C).
en / 31.05.2010 IB001408 1/2

M20
06
WARNING
Observe regulations of the manufacturer for cleansing agent to be used, protect skin
against contact with cleansing agent, wear safety glasses. Ensure good ventilation.
2. Reassembly
2.1 Carry out reassembly in reverse order to disassembly.
NOTE
Ensure proper fit of the sealing plates in the housing.
2.2 Renew all seals.
2.3 Lubricate hexagon screws (Fig. 1/2) with Molykote paste “G-Rapid Plus” and tighten with a torque
of
M = 60 Nm.
en / 31.05.2010 IB001408 2/2

M20
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The charge air cooler is to be disassembled and cleaned at the air side if the differential pressure
before/after radiator reaches more than 1.5 times test bed value (see acceptance brake certificate
A1.10).
Tools:
Auxiliary material:
Cleansing agent according to recommendations of the manufacturer, e.g. of:

•
Vecom GmbH, Hamburg *
•
Drew Ameroid GmbH, Hamburg *
•
UNITOR chemicals *
1. Disassembly
1.1 Disconnect cooling water lines inlet and

outlet at the charge air cooler. 3
1.2 Loosen hexagon screws (Fig. 1/1 and 2).
1.3 Withdraw charge air cooler from housing 2

1
(3). Support with lifting gear and put it
down in a suitable container for the cle-
aning.
1.4 Clean charge air cooler according to ma- Fig. 1

nufacturer's regulation (refer to Book C).
en / 31.05.2010 IB002304 1/2

M20
06
WARNING
Observe regulations of the manufacturer for cleansing agent to be used, protect skin
against contact with cleansing agent, wear safety glasses. Ensure good ventilation.
2. Reassembly
2.1 Carry out reassembly in reverse order to disassembly.
NOTE
Ensure proper fit of the sealing plates in the housing.
2.2 Renew all seals.
2.3 Lubricate hexagon screws (Fig. 1/2) with Molykote paste “G-Rapid Plus” and tighten with a torque
of
M = 60 Nm.
en / 31.05.2010 IB002304 2/2

M20
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The charge air cooler is to be disassembled and cleaned on the air side, if the differential pressu-
re upstream/downstream cooler exceeds 1.5 times the test bed value (see acceptance test record
A1.10).
Tools:
* no illustration
Auxiliary material:
Cleaning agent acc. to recommendation of manufacturer, e.g.:

•
Fa. Vecom GmbH, Hamburg *
•
Fa. Drew Ameroid GmbH, Hamburg *
•
Fa. UNITOR chemicals *
Molykote-paste „G-Rapid Plus“ *
1. Disassembly
3
1.1 Disconnect cooling water supply and di-
scharge lines (5) on the charge air cooler
4
5
1.2 Loosen hexagon screws (1,2 and 3).
1.3 Pull charge air cooler forward out of the

casing (4), support it with hoist and place it 2
in adequate container for cleaning.
1
1.4 Clean charge air cooler acc. to the
manufacturer’s instructions (see book 10).
3
WARNING
Strictly observe the supplier’s handling instructions for the used cleaning agent!
Protect your skin against contact with the cleaning agent, wear rubber gloves, safety
glasses and evtl. respiratory mask! Ensure good ventilation!
en / 31.05.2010 IB004328 1/2

M20
2. Reassembly 06
2.1 Renew all gaskets
2.2 Grease hexagon screws (1,2 and 3) with Molykote paste „G-Rapid Plus“.
2.3 Secure charge air cooler on hoist and push cooler into casing
Strictly observe the tightening instructions for hexagon screws (1, 2 and 3).
2.4 Mount hexagon screws (1 and 3) and slightly tighten them crosswise to provide for uniform
contact of the charge air cooler on front and sides.
2.5 Tighten hexagon screws (1) crosswise in small steps up to a torque of
M = 60 Nm.
M = 60 Nm.
2.7 Mount hexagon screws (2) and tightem them crosswise in small steps up to a torque of
M = 60 Nm.
en / 31.05.2010 IB004328 2/2

M20
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The charge air cooler is to be disassembled and cleaned on the air side, if the differential pressu-
re upstream/downstream cooler exceeds 1.5 times the test bed value (see acceptance test record
A1.10).
Tools:
* no illustration
Auxiliary material:
Cleaning agent acc. to recommendation of manufacturer, e.g.:

•
Fa. Vecom GmbH, Hamburg *
•
Fa. Drew Ameroid GmbH, Hamburg *
•
Fa. UNITOR chemicals *
Molykote-paste „G-Rapid Plus“ *
1. Disassembly
3
1.1 Disconnect cooling water supply and di-
scharge lines (5) on the charge air cooler
5 4
1.2 Loosen hexagon screws (1,2 and 3).
1.3 Pull charge air cooler forward out of the

casing (4), support it with hoist and place it
in adequate container for cleaning. 2
1
1.4 Clean charge air cooler acc. to the
3
manufacturer’s instructions (see book 10).
WARNING
Strictly observe the supplier’s handling instructions for the used cleaning agent!
Protect your skin against contact with the cleaning agent, wear rubber gloves, safety
glasses and evtl. respiratory mask! Ensure good ventilation!
en / 31.05.2010 IB004322 1/2

M20
2. Reassembly 06
2.1 Renew all gaskets
2.2 Grease hexagon screws (1,2 and 3) with Molykote paste „G-Rapid Plus“.
2.3 Secure charge air cooler on hoist and push cooler into casing
Strictly observe the tightening instructions for hexagon screws (1, 2 and 3).
2.4 Mount hexagon screws (1 and 3) and slightly tighten them crosswise to provide for uniform
contact of the charge air cooler on front and sides.
M = 60 Nm.
M = 60 Nm.
2.7 Mount hexagon screws (2) and tightem them crosswise in small steps up to a torque of
M = 60 Nm.
en / 31.05.2010 IB004322 2/2

M20
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The charge air cooler must be removed and cleaned on the air side when the differential pressure
before/after the cooler exceeds 1.5 times the test bench value (see acceptance brake certificate
A1.10).
Auxiliary materials:
Cleaning agent as recommended by the manufacturer, such as:
• Vecom GmbH, Hamburg *

• Drew Ameroid GmbH, Hamburg *
• UNITOR chemicals *
Molykote Paste "G-Rapid Plus“ *
* or equivalent product
Procedure:
1. Disassembly
1.1 Loosen the bleeder bolts, or for engines

with continual bleeding, ensure that the
corresponding cock valves are open, re-
move the drain bolts (Fig. 1/5) and drain
water from charge air cooler.
1.2 Remove the coolant feed and return li-

nes(4) from the charge air cooler.
en / 30.09.2010 IB025507 1/3

M20
1.3 Remove hexagon screws (Fig. 2/28) with washers (37). 06
1.4 Pull the charge air cooler (9) out of the housing (3), suspend with hoist and lower into suitable
container for cleaning.
1.5 Clean the charge air cooler in accordance with the manufacturer's instructions (see Book C).
1.6 Inspect the housing, drain all condensation by opening the drain line.
WARNING
Follow the instructions contained in the handbook for the cleaning agent used, protect
skin from contact with cleaning agents, wear rubber gloves, safety goggles and respi-
ratory protection if necessary! Ensure adequate ventilation!
en / 30.09.2010 IB025507 2/3

M20
2. Assembly 06
2.1 Install charge air cooler in the reverse order as disassembly.
2.2 Insert new O-ring (8) into O-ring sheet (9).
2.3 Slide charge air cooler (2) into the housing (3) carefully.
NOTE
Apply a light coat of Molykote paste “G-Rapid Plus” to the contact surfaces and
threads of all bolts.
2.4 Insert hexagon screws (28) with washers (37).
2.5 Tighten hexagon screws (28) one after the other to a torque of
M = 52 Nm.
2.6 Attach coolant supply and return lines (4) to the charge air cooler.
2.7 Tighten drain bolts (5) and fill engine completely with coolant.
2.8 Tighten bleeder bolts or the corresponding cock valves tightly.
en / 30.09.2010 IB025507 3/3

Exhaust gas turbocharger A5.05. 06.05.00.01
M20
24, 300
See also: 06
Spare parts list: B1.05.06.25725n

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
a) Wash the compressor every 24 h

b) Wash the turbine every 300 h
Maintenance of the exhaust gas turbocharger should be carried out according to the
”Operating and Mounting Instructions” included in book C.
Refer to operating instructions A3.12.01.nn for information concerning the emergency operation
of an engine with a damaged turbocharger.
The following list indicates the maintenance work which has to be carried out after the specified
operating hours within the scope of the maintenance schedule according to the “Operating and
Mounting Instructions“ in book C.
Activity Operating hours (h)
Check for abnormal noises. every 24
Compressor washing during operation: every 24 - 50

Actuate compressor washing system or on demand
Turbine washing ( exhaust side ) during operation:

Actuate turbine washing system (for heavy fuel oil operation only). see 06.13.01.nn
Cleaning with water
approx. every 300-500
Clean air filter at silencer approx. every 250

or on demand
Check fastening bolts at feet, after first starting up than

tighten all housing bolts and piping joints every 1 000
Cleaning: Internal compressor parts, compressor every 10 000

impeller and diffuser.
Cleaning: Silencer and felt coat. every 10 000
Inspection: Disassemble, clean, replace bearing, check all parts. every 20 000
en / 31.05.2010 IB024928 1/1

M20
24
See also: A5.05.06.13.01.nn, A3.06.06.nn 06

Spare parts list: B1.05.06.nn7259 nn

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Compressor cleaning M 20 every 24 h
Prerequisites:
-The compressor stage must be cleaned with the engine at operating temperature and under full
load (> 85% load ), if possible; i.e., at high turbocharger rpm.
- Clean pipes from the charge air system and after each turbocharger.
NOTE
Deposits or dirt praticles inside the washing system can plug the nozzles and nega-
tively impact cleaning success.
Air side washing device operating instructions:
Basic position:
- Washing water container (3) : empty

- Cap (2) : closed
Washing procedure:
1. Remove thumb nut (1) with cap (2).
1.1 Fill washing water container (3) with clean water.
1.2 Install cap (2) with thumb nut (1).
CAUTION
A washing water container that has been locked insufficiently or not at all may
cause injury or death of the operator.
en / 30.09.2010 IB025455 1/3

M20
24
06
2. Open ballcock (4) for about 20 seconds until the entire water volume has been injected.
NOTE
After the air-side has been cleaned, the engine must be operated at least another 5
minutes under load.
When the compressor impeller was contaminated, the success of a cleaning can be
told by the charge air pressure after the turbocharger.
The cleaning parameters for turbocharger model KBB-HPR 5000 are as follows:
turbocharger rpm: full load – rpm ( >85% )

water excess pressure: none
water injection time: 20 seconds
water volume : 0.5 liter
en / 30.09.2010 IB025455 2/3

M20
24
06
CAUTION
Because of the increased risk of corrosion, only clear water (drinking water) -
never salt water - must be used for cleaning. This water should not contain any
coolant treatments or other chemicals that may form deposits in the air ducts.
CAUTION
The injection tube must never be connected directly to a water line, a different
or larger metering container or to a larger washing water containerother than the
one provided by Caterpillar Motoren.
CAUTION
Avoid getting uncontrolled amounts of water into the turbocharger or the engine. This
can cause personal injury and major damage.
Additional details on the exhaust turbocharger may be found in the maintenance instructions in book C or
in the operator’s manual of the turbocharger manufacturer.
en / 30.09.2010 IB025455 3/3

M20
24
See also: A5.05.06.13.01.nn, A3.06.06.nn 06


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Compressor cleaning M 20 every 24 h
Prerequisites:
-The compressor stage must be cleaned with the engine at operating temperature and under full
load (> 85% load ), if possible; i.e., at high turbocharger rpm.
- Clean pipes from the charge air system and after each turbocharger.
NOTE
Deposits or dirt praticles inside the washing system can plug the nozzles and nega-
tively impact cleaning success.
Air side washing device operating instructions:
Basic position:
- Washing water container (3) : empty

- Cap (2) : closed
Washing procedure:
1. Remove thumb nut (1) with cap (2).
1.1 Fill washing water container (3) with clean water.
1.2 Install cap (2) with thumb nut (1).
CAUTION
A washing water container that has been locked insufficiently or not at all may
cause injury or death of the operator.
en / 31.05.2010 IB025546 1/3

M20
24
06
2. Open ballcock (4) for about 20 seconds until the entire water volume has been injected.
NOTE
After the air-side has been cleaned, the engine must be operated at least another 5
minutes under load.
When the compressor impeller was contaminated, the success of a cleaning can be
told by the charge air pressure after the turbocharger.
The cleaning parameters for turbocharger model KBB-HPR 4000 are as follows:
turbocharger rpm: full load – rpm ( >85% )

water excess pressure: none
water injection time: 20 seconds
water volume : 0.5 liter
en / 31.05.2010 IB025546 2/3

M20
24
06
CAUTION
Because of the increased risk of corrosion, only clear water (drinking water) -
never salt water - must be used for cleaning. This water should not contain any
coolant treatments or other chemicals that may form deposits in the air ducts.
CAUTION
The injection tube must never be connected directly to a water line, a different
or larger metering container or to a larger washing water containerother than the
one provided by Caterpillar Motoren.
CAUTION
Additional details on the exhaust turbocharger may be found in the maintenance instructions in book C or
in the operator’s manual of the turbocharger manufacturer.
en / 31.05.2010 IB025546 3/3

M20
150
See also: A5.05.06.05.00.nn, A3.06.06.nn 06


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Turbine cleaning M 20 every 150 h
Prerequisite: - Wet cleaning
wet cleaning of turbine and nozzle ring require lower exhaust gas temperatures or lower engine
load*.
NOTE
The cleaning effect during turbine washing is caused by the mechanical impact of the
water droplets as well as by the water solubility of the deposits.
CAUTION
Please note that these cleaning instructions apply only to the engines listed on cover
A0 and thus, only the "low load washing" cleaning type:
"WASHING OF TURBINE AND NOZZLE RING AT LOW EXHAUST GAS TEMPERA-

TURE OR AT LOW ENGINE LOAD *"
may be used.
* Definition of low engine load:
Low engine load means that the engine either
- runs at zero pitch and rated rpm

- runs on the grid at rated rpm and max. 10 % load
- runs disengaged at rated rpm
- for fixed impellers at max. 15% load.
en / 10.08.2010 IB026792 1/4

M20
150
Quality requirements for water for washing turbine and nozzle ring: 06
NOTE
Water flow is controlled by a diaphragm located in the needle valve (Fig.2/1).
The cleaning parameters for the turbocharger models KBB - HPR 5000 are as follows:
exhaust gas temperature before

turbine intake: < 420 ° C
injection time: 3 -4 times for 30 sec.
water pressure before diaphragm: approx. 2 bar (on-board supply)
Quality requirements for water for washing turbine and nozzle ring:
Clear freshwater (drinking water) without cleaners or solvents must be used.
The wash water used should have minimal mineral and salt content.
Notes on the cleaning procedure:
The exhaust gas temperature after the turbocharger will decrease considerably during cleaning
(down to between 50° and 100°C).
en / 10.08.2010 IB026792 2/4

M20
150
Cleaning procedure: 06
For standard operation:
- Needle valve (Fig.2/1) is closed.

- Hose (3) has been disconnected and removed from the water supply.
For washing operation:

- Shut-off valve (4) is closed.
- Hose (3) has been installed and is connected to the water supply.
- Hose (3) is pressurized.
NOTE
After the engine has been started or the engine load has been reduced, the turbine
exhaust gas temperature must not exceed 400-420 °C.
Lower values will increase the success of washing.
Sequence:
1. Wait for 10 to 15 minutes until after the exhaust gas temperature has stabilized and is below 420
°C.
2. Shut-off valve (4) is closed.
3. Connecting hose (3) from the vessel’s internal water supply to the connecting branch (5) of the
turbocharger washing device.
Check whether the water supply is working.
en / 10.08.2010 IB026792 3/4

M20
150
4. Open drain valve (Fig.2/4); pressure 06

gauge (8) must indicate a pressure of:
p ~ 2 bar
(on-board supply) .
5. Close shut-off valve (4).
6. Open needle valve (1).

1
7. Open shut-off valve (4) for 30 secs.
8. Check if exhaust gas temperature after

turbocharger decreases.
9. The cleaning procedure is complete.
10. Repeat the cleaning procedure 3-4 times.
CAUTION
After washing, the water
supply must be disconnect-
ed completely; i.e., incl.
hose (3) from the connect-
ing branch (5) to the turbo-
charger washing device.
5
11. Disconnect the water supply completely,
incl. hose (3) from the connecting branch
of the (5) turbocharger washing device. 3
CAUTION
In order to prevent corrosion on the inside surfaces of the housing, the engine must
be run for 30 more minutes at the same load level.
Due to increased corrosion risk from wash water residue in the exhaust system, we
recommend not performing the washing procedure before longer engine standstill
periods.
For additional instructions, see User Manual A3.06.06.nn.
en / 10.08.2010 IB026792 4/4

M20
150
See also: A5.05.06.05.00.nn, A3.06.06.nn 06


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Turbine cleaning M 20 every 150 h
Prerequisite: - Wet cleaning
wet cleaning of turbine and nozzle ring require lower exhaust gas temperatures or lower engine
load*.
NOTE
The cleaning effect during turbine washing is caused by the mechanical impact of the
water droplets as well as by the water solubility of the deposits.
CAUTION
Please note that these cleaning instructions apply only to the engines listed on cover
A0 and thus, only the "low load washing" cleaning type:
"WASHING OF TURBINE AND NOZZLE RING AT LOW EXHAUST GAS TEMPERA-

TURE OR AT LOW ENGINE LOAD *"
may be used.
* Definition of low engine load:
Low engine load means that the engine either
- runs at zero pitch and rated rpm

- runs on the grid at rated rpm and max. 10 % load
- runs disengaged at rated rpm
- for fixed impellers at max. 15% load.
en / 10.08.2010 IB026801 1/4

M20
150
Quality requirements for water for washing turbine and nozzle ring: 06
NOTE
Water flow is controlled by a diaphragm located in the needle valve (Fig.2/1).
The cleaning parameters for the turbocharger models KBB - HPR 4000 are as follows:
exhaust gas temperature before

turbine intake: < 420 ° C
injection time: 3 -4 times for 30 sec.
water pressure before diaphragm: approx. 2 bar (on-board supply)
Quality requirements for water for washing turbine and nozzle ring:
Clear freshwater (drinking water) without cleaners or solvents must be used.
The wash water used should have minimal mineral and salt content.
Notes on the cleaning procedure:
The exhaust gas temperature after the turbocharger will decrease considerably during cleaning
(down to between 50° and 100°C).
en / 10.08.2010 IB026801 2/4

M20
150
Cleaning procedure: 06
For standard operation:

- Hose (3) has been disconnected and removed from the water supply.
For washing operation:

- Shut-off valve (4) is closed.
- Hose (3) has been installed and is connected to the water supply.
- Hose (3) is pressurized.
NOTE
After the engine has been started or the engine load has been reduced, the turbine
exhaust gas temperature must not exceed 400-420 °C.
Lower values will increase the success of washing.
Sequence:
1. Wait for 10 to 15 minutes until after the exhaust gas temperature has stabilized and is below 420
°C.
2. Shut-off valve (4) is closed.
3. Connecting hose (3) from the vessel’s internal water supply to the connecting branch (5) of the
turbocharger washing device.
Check whether the water supply is working.
en / 10.08.2010 IB026801 3/4

M20
150
06
4. Open drain valve (Fig.2/4); pressure
gauge (8) must indicate a pressure of:
p ~ 2 bar
(on-board supply) .
5. Close shut-off valve (4).
6. Open needle valve (1). 1

7. Open shut-off valve (4) for 30 secs.
8. Check if exhaust gas temperature after

turbocharger decreases.
9. The cleaning procedure is complete.
10. Repeat the cleaning procedure 3-4 times.
CAUTION
After washing, the water
supply must be disconnect-
ed completely; i.e., incl.
hose (3) from the connect-
ing branch (5) to the turbo-
charger washing device.
5
11. Disconnect the water supply completely,

incl. hose (3) from the connecting branch 3
of the (5) turbocharger washing device.
CAUTION
In order to prevent corrosion on the inside surfaces of the housing, the engine must
be run for 30 more minutes at the same load level.
Due to increased corrosion risk from wash water residue in the exhaust system, we
recommend not performing the washing procedure before longer engine standstill
periods.
For additional instructions, see User Manual A3.06.06.nn.
en / 10.08.2010 IB026801 4/4

Turbocharger A5.05. 06.13.01.00
M20
300
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Cleaning of the turbocharger every 300 h
NOTE
Particulary if the engine is running on the heavy fuel, deposits will form on the turbine
blades decreasing the charger efficiency and increasing the bearing loads by unba-
lance. These deposits must be removed by injecting freshwater (without addition of
detergents or solvents). The washing intervals depend on the fuel quality and the
operating conditions, and they can only be fixed by experience in operation.
It must always be prevented that water enters the exhaust manifold between the
washing operations. For this reason, the hose piece (Fig. 1/1) is to be removed after
washing.
1. Cleaning
1.1 Connect the cleaning pipe (2) with the

water supply (detachable hose clip (1) with
2 4
stop valve [3]).
1.2 Reduce the engine output to 20 % load

and exhaust gas temperature at the
cylinder outlets to 280 - 300 °C.
1
1.3 Open corner valves (4) and stop valve (3)
and adjust water pressure on pressure
gage (5) to
1.2 - 1.5 bar.
Washing duration: 5 minutes
1.4 3
Close stop valves and corner valves and remove hose clip (Fig. 1/1). 5
Fig. 1
1.5 Run the turbocharger dry with a written engine load approx. 30 min., then increase engine load
en / 31.05.2010 IB001462 1/2

M20
300
slowly. 06
NOTE
Repeat washing procedure if vibrations and sounds appear at the turbocharger which
were previously not present.
en / 31.05.2010 IB001462 2/2

M20
300
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
NOTE
washing operations. For this reason, the hose piece (1) is to be removed after
washing.
1. Cleaning

stop valve [3]).

1.3 Open corner valve (4) and stop valve (3)

gage (5) to
1.2 - 1.5 bar.
1.4 Close stop valves and corner valves and

remove hose clip (1).
1.5 Run the turbocharger dry with a written en-

gine load approx. 30 min., then increase
engine load slowly
en / 31.05.2010 IB002154 1/2

M20
300
. 06
NOTE
en / 31.05.2010 IB002154 2/2

M20
300
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
NOTE
washing operations. For this reason, the hose piece (1) is to be removed after
washing.
4
1. Cleaning

stop valve [3]).
1.2 Reduce the engine output to 20 % load 4


gage (5) to
1.2 - 1.5 bar.
Washing duration: 5 minutes 2
1
5
en / 31.05.2010 IB002574 1/2

M20
300
06
1.4 Close stop valves and corner valves and remove hose clip (1).
slowly.
NOTE
Repeat washing procedure if vibrations and sounds appear at the turbocharger
which were previously not present.
en / 31.05.2010 IB002574 2/2

M20
300
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
NOTE
It must always be prevented that water enters the exhaust manifold between the wa-
shing operations. For this reason, the hose piece (1) is to be removed after washing.
1. Cleaning
4
stop valve [3]).


gage (5) to
2
1.2 - 1.5 bar.
1.5 Run the turbocharger dry with a written engine load approx.
1 30 min., then increase engine load
5
3
en / 31.05.2010 IB003041 1/2

M20
300
slowly. 06
NOTE
en / 31.05.2010 IB003041 2/2

M20
300
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
NOTE
1. Cleaning 4

stop valve [3]).
4

gage (5) to
1.2 - 1.5 bar.

4
1.5 Run the turbocharger dry with a written engine load2 approx. 30 min., then increase engine load
slowly.
1
5
3
en / 31.05.2010 IB003046 1/2

M20
300
06
NOTE
en / 31.05.2010 IB003046 2/2

M20
300
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
NOTE
1. Cleaning
4
stop valve [3]).

and exhaust gas temperature at the 4

gage (5) to
4
1.2 - 1.5 bar.
slowly. 2
en / 31.05.2010 IB003054 1/2

M20
300
06
NOTE
en / 31.05.2010 IB003054 2/2

M20
300
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
NOTE
Particularly if the engine is running on heavy fuel, deposits will settle down on the tur-
bine blades decreasing the charger efficiency and increasing the bearing loads by
unbalance. These deposits must be removed by injecting fresh water (without additi-
on of detergents or solvents). The washing intervals depend on the fuel quality and
the operating conditions, and they can only be fixed by experience in operation.
It must be absolutely prevented that water enters the exhaust manifold between the
washing operations. For this reason, the hose piece (Fig.1/1) is to be removed after
washing.
1. Cleaning
4
stop valve [3]).
1.2 Open drain valve (Fig.2/1)öffnen. 4
DANGER
Attention, danger of burning!
The waste water runs off with a 4
temperature of > 70 °C.
1.3 Reduce engine output to 20 %,

exhaust gas temperature after cylinder
280 - 300 °C.
en / 31.05.2010 IB004495 1/2

M20
300
1.4 Open corner valves (Fig.1/4) and stop 06

valve (3) and set water pressure on
pressure gauge (5) to
1,2 - 1,5 bar
Duration of washing: 5 minutes
CAUTION
Check drain valve (Fig. 2/4)
and pipe (2) during the washing
process permanently for free
passage. Clogging by deposits
involves the risk that water runs
bakc into the engine through
the exhaust gas pipe. 1
In case of clogging pierce the
drain valve with a wire.
1.5 Close stop (Fig.1/3) and corner valves (4)

and remove hose clip (1).
1.6 If no further water runs out of the drain 2

pipe (Fig.2/2), close the drain valve (1).
1.7 Let the exhaust gas turbocharger dry for 2

about 30 minutes at the specified engine
load, then slowly increase the engine load.
NOTE
In case of previously non-
existent vibrations and noises at
the exhaust gas turbocharger,
repeat the washing process.
en / 31.05.2010 IB004495 2/2

Abgasturbolader A5.05. 06.13.01.07
M20
300
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
NOTE
washing.
1. Cleaning 4

stop valve [3]).
4
1.2 Open drain valve (Fig.2/1)öffnen.
DANGER
The waste water runs off with a
temperature of > 70 °C. 4

280 - 300 °C.
2
5
3
en / 31.05.2010 IB004503 1/2

Abgasturbolader A5.05. 06.13.01.07
M20
300
1.4 Open corner valves (Fig.1/4) and stop 06

1,2 - 1,5 bar
CAUTION
Check drain valve (Fig. 2/4)
and pipe (2) during the washing
the exhaust gas pipe. 1
drain valve with a wire.

1.6 If no further water runs out of the drain 2

1.7 Let the exhaust gas turbocharger dry for 2

load, then slowly increase the engine load.
NOTE
In case of previously non-existent vibrations and noises at the exhaust gas turboch-
arger, repeat the washing process.
en / 31.05.2010 IB004503 2/2

M20
300
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
NOTE
washing.
1. Cleaning
4
stop valve [3]).
1.2 Open drain valve (Fig.2/1)öffnen.
DANGER
The waste water runs off with a
temperature of > 70 °C. 2

280 - 300 °C.
en / 31.05.2010 IB004510 1/2

M20
300
1.4 Open corner valve (Fig.1/4) and stop 06

1,2 - 1,5 bar
CAUTION
Check drain valve (Fig. 2/4) and
pipe (2) during the washing
the exhaust gas pipe.
drain valve with a wire. 1

1.6 If no further water runs out of the drain

2
1.7 Let the exhaust gas turbocharger dry for
load, then slowly increase the engine load. 2
NOTE
In case of previously non-existent vibrations and noises at the exhaust gas turboch-
arger, repeat the washing process.
en / 31.05.2010 IB004510 2/2

Exhaust gas turbocharger - HPR 5000 - A5.05. 06.13.02.11
Repair / Replacement
M20
12000, 24000, 48000, 250, 1000
See also: A3.06.06.nn 06

Spare parts list: B1.05.06.nn725n nn

--------------------------------------------------------------------------------------------------------------------------------
NOTE
The exhaust gas turbocharger must generally be maintained according to the main-
tenance instructions in Book C or the Operating Instructions.
Below is a list of maintenance tasks that must be performed using the work interval
schedule according to the operating instructions in Book C after the number of oper-
ating hours listed.
The operating hours listed are guidelines that may need to be shortened or length-
ened depending on the operating conditions, as well as for adapting to engine main-
tenance intervals.
For "Washing the Turbocharger", the work processes are described in work cards
(A5.05.06.05.01.nn) & (A5.05.06.05.02.nn) .
Instructions for emergency engine operation with a defective turbocharger see User
Manual A3.12.01.nn.
en / 31.05.2010 IB025473 1/2

M20
12000, 24000, 48000, 250, 1000
06
Maintenance task Required Maintenance interval

Parts sets Operating hours (h)
Clean air filter on muffler approx. 250 h

or as needed
Check mounting bolts on the once after

turbocharger legs, all housing bolts and Start-up
tighten pipe connections. then every 1000 h
Inspection 1 ( 9910 ) 12 000 h

- Disassembly ( 9920 )
- Cleaning ( 9930 )
- Check rotor and its bearings
- Check housings
- Assembly
Note:
The service life of the turbine guide grid is approx. 12 000 h
; please note when scheduling maintenance.
Inspection 2 ( 4000 ) 24 000 h

- same as Inspection 1 ( 9910 )
- Replace bearings ( 9920 ) ( 9930 )
Inspection 3 ( 2000 ) 48 000 h

- Exchange rotor ( 9910 ) ( 9920 )
( 9930 )
Rotor --> ( 2000 ) Seal set --> ( 9910 )
Bearing set --> ( 4000 ) Fasteners 1 --> ( 9920 )
Fasteners 2 --> ( 9930 )
NOTE
When ordering parts, please provide the information from the turbocharger serial
plate.
--------------------------------------------------------------------------------------------------------------------------------
en / 31.05.2010 IB025473 2/2

M20
12000, 24000, 48000, 250, 1000
See also: A3.06.06.nn 06

Spare parts list: B1.05.06.nn725n nn

--------------------------------------------------------------------------------------------------------------------------------
NOTE
The exhaust gas turbocharger must generally be maintained according to the main-
tenance instructions in Book C or the Operating Instructions.
Below is a list of maintenance tasks that must be performed using the work interval
schedule according to the operating instructions in Book C after the number of oper-
ating hours listed.
The operating hours listed are guidelines that may need to be shortened or length-
ened depending on the operating conditions, as well as for adapting to engine main-
tenance intervals.
For "Washing the Turbocharger", the work processes are described in work cards
(A5.05.06.05.01.nn) & (A5.05.06.05.02.nn) .
Instructions for emergency engine operation with a defective turbocharger see User
Manual A3.12.01.nn.
en / 31.05.2010 IB025572 1/2

M20
12000, 24000, 48000, 250, 1000
06
Maintenance task Required Maintenance interval

Parts sets Operating hours (h)
Clean air filter on muffler approx. 250 h

or as needed
Check mounting bolts on the once after

turbocharger legs, all housing bolts and Start-up
tighten pipe connections. then every 1000 h
Inspection 1 ( 9910 ) 12 000 h

- Disassembly ( 9920 )
- Cleaning ( 9930 )
- Check rotor and its bearings
- Check housings
- Assembly
Note:
The service life of the turbine guide grid is approx. 12 000 h
; please note when scheduling maintenance.
Inspection 2 ( 4000 ) 24 000 h

- Replace bearings ( 9920 ) ( 9930 )
Inspection 3 ( 2000 ) 48 000 h

- Exchange rotor ( 9910 ) ( 9920 )
( 9930 )
Rotor --> ( 2000 ) Seal set --> ( 9910 )
Bearing set --> ( 4000 ) Fasteners 1 --> ( 9920 )
Fasteners 2 --> ( 9930 )
NOTE
When ordering parts, please provide the information from the turbocharger serial
plate.
en / 31.05.2010 IB025572 2/2

Injection Pump A5.05. 07.02.01.00
M20
See also: 07

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Tools:
Auxiliary material:
1. Disassembly
1.1 Empty fuel system (drain cock at counter-coupling side over fuel double filter).
1.2 Disassemble lube oil lines (Fig. 1/1) at the injection pump.
1
2
Fig. 1
en / 31.05.2010 IB001371 1/3

M20
1.3 Disconnect connection of the injection 07

pump control rack (Fig. 1/2) to the 11
regulating shaft and slide control rack
completely into the injection pump.
1.4 Disconnect holder for stop cylinder (3) at

the injection pump.
1.5 Loosen thrust screws (Fig. 2/11), lever off

transverse pressure piece of the injection
12
pressure line with cover (12) and pull to
the left out of the cylinder head and the
injection pump.
Slide sleeve (13) to the left into the 13
cylinder head.
1.6 Disconnect distributor housing of the fuel

collecting pipe at the injection pump.
1.7 Loosen nuts (14) of the fastening screws

at the injection pump uniformly and lift the
injection pump off cylinder crankcase.
CAUTION 14
Spacer plates (Fig. 3/23) belon- Fig. 2

ging to the cylinders must not
be removed.
WARNING
Caution! Spring tension of the
injection pump drive interacts
with the injection pump. 14
2. Reassembly 23
22
NOTE
To facilitate reassembly, turn
engine in such a way, that the
rocker lever (21) of the injection
pump drive is on the base circle
of the injection cam. 21
2.1 Clean supporting surface of the injection

pump.
Fig. 3
en / 31.05.2010 IB001371 2/3

M20
2.2 Renew O-ring (Fig. 3/22) at the injection pump and at the distributor housing of the fuel collecting 07
pipe and place the injection pump over the fastening screws.
2.3 Lubricate threads and contact surfaces of nuts (Fig. 2/14) with Molykote paste
“G-Rapid Plus” and pull the injection pump into place by tightening the nuts uniformly.
WARNING
Caution! Spring tension of the injection pump drive interacts with the injection pump.
2.4 Tighten nuts (14) with a torque of

X
M = 50 Nm.
2.5 Connect lube oil lines (Fig. 1/1) to the

injection pump and screw on holder for
stop cylinder (3).
2.6 Link regulating shaft with control rack (2)

of the injection pump. Observe clearance
“s” of 0.5 mm between articulated lever
and control rack
(Fig. 1/X) and ensure freedom of motion of
the accelerator control linkage.
2.7 Slide transverse pressure piece of the s

injection pressure line with cover (Fig. 4/
12) in reverse disassembly direction into
cylinder cover and injection pump. First
tighten the thrust screw (11a) and then 11b 13 11a
thrust screw (11b) with a torque of
M = 85 Nm.
Slide sleeve (13) to the right into injection

pump.
12
2.8 Vent fuel system with backing pump.
Fig. 4
en / 31.05.2010 IB001371 3/3

M20
See also: A5.05.07.15.01.nn 07


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Tools:
Auxiliary material:
soft green soap**

1. Disassembly
1.1 Empty fuel system (drain cock at counter-coupling side over fuel double filter).
X 3
1 2
1
en / 30.09.2010 IB003956 1/3

M20

pump control rack (Fig. 1/2) to the 11
regulating shaft and slide control rack 11
13
the injection pump. 12

injection pump.
Slide sleeve (13) to the left into the
cylinder head.
14
1.6 Loosen the fuel manifold and collector
(07.15.01.nn).

injection pump off cylinder crankcase. 2
CAUTION
Spacer plates (Fig. 3/23) be- 24
longing to the cylinders must
not be removed.
WARNING
Caution! Spring tension of the 14
with the injection pump.
23
2. Reassembly
22
NOTE
rocker lever (21) of the injec-
tion pump drive is on the base
circle of the injection cam.

pump. 21
en / 30.09.2010 IB003956 2/3

M20
2.2 Replace the O-rings on the lower spring plate (Fig. 3/22) and the connections for the fuel 07
manifold and collector (24).
2.3 Place the injection pump above the fastening screws.
WARNING

X
M = 50 Nm.

stop cylinder (3).

of the injection pump. Observe clearance
“s” of 0.5 mm between articulated lever
and control rack
(Fig. 1/X) and ensure freedom of motion of
the accelerator control linkage.
2.8 Slide transverse pressure piece of the

cylinder cover and injection pump. First s
tighten the thrust screw (11a) and then
11b 13 11a
M = 85 Nm.

pump.
2.9 Mount the fuel manifold and collector

(07.15.01.nn). 12
en / 30.09.2010 IB003956 3/3

M20
See also: A5.05.07.15.01.nn 07


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Tools:
Auxiliary material:
soft green soap**

1. Disassembly
1.1 Empty fuel system, drain cock (Fig. 5/30) .
25
en / 31.05.2010 IB026455 1/3

M20

pump control rack (Fig. 1/2) to the
regulating shaft and slide control rack

the injection pump.

injection pump.
Slide sleeve (13) to the left into the
cylinder head.
1.6 Loosen the fuel manifold and collector

(07.15.01.nn).

injection pump off cylinder crankcase.
CAUTION
Spacer plates (Fig. 3/23) belon-
ging to the cylinders must not
be removed.
WARNING
Caution! Spring tension of the
with the injection pump.
2. Reassembly
NOTE
rocker lever (21) of the injection
pump drive is on the base circle
of the injection cam.

pump.
en / 31.05.2010 IB026455 2/3

M20
2.2 Replace the O-rings on the lower spring plate (Fig. 3/22) and the connections for the fuel 07
manifold and collector (24).
2.3 Place the injection pump above the fastening screws.
WARNING

X
M = 50 Nm.

stop cylinder (3).

of the injection pump. Observe clearance “
of 0.5 mm between articulated lever(25)
and control rack (2) and ensure freedom of
motion of the accelerator control linkage.
2.8 Slide transverse pressure piece of the

cylinder cover and injection pump. First
tighten the thrust screw (11a) and then s
11b 13 11a
M = 85 Nm.

pump.
2.9 Mount the fuel manifold and collector

(07.15.01.nn). 12
en / 31.05.2010 IB026455 3/3

M20
15000, 7500
See also: 07

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Maintenance:
Disassemble injection pump if required, clean all parts and replace if necessary. Observe note!
Tools:
Torque wrench 20 - 90 Nm 1/2" W1* 1.9454-20
Auxiliary material:

Vaseline *
NOTE
All parts of the injection pump are manufactured with utmost precision in special
workshops. This is the only guarantee for proper function. When repairing a pump, it
is to be ensured that the various components of the pump, e.g. control sleeve, con-
trol rack, rack pointer etc. remain together with their respective housing.
Plunger and barrel must be renewed as a unit only. In order to keep repair costs low,
any parts to be reconditioned should be shipped only complete, and the possibility of
interchanging must be excluded. Lapped surfaces must be preserved and not touched
with fingers.

1. Disassembly
1.1 Clean the outside of the injection pump.
1.2 Remove and check impact screws (Fig. 1/1 and 2).
1.3 Clamp injection pump upwards with injection pump bottom part (3).
en / 31.05.2010 IB001436 1/3

M20
15000, 7500
07
WARNING
Caution spring tension!
1.4 Loosen fillister head screws (Fig. 1/4) uni-

formly. 19
Remove injection pump bottom part (3)

with lower spring seat from injection pump
21
housing (5). Take care of fixing pin.
20
17
1.5 Remove the following single components 22
from injection pump housing (6):
24
Cam follower body (7), pressure plate (8), 23
distance plate (9), slot washer (10) (a
unit), pump spring (11), spring seat (12), 2 1
control sleeve (13), pump plunger (14).
1.6 Unscrew guide screw (15), pull control rod

18
(16) out of injection pump housing (6) and
14
check toothing.
6
1.7 Clamp injection pump housing (6) with val- 13 15
ve support pointing upwards (17). Uns-
12 16
crew locking screw (18).
11
1.8 Loosen fillister head screws (19) and
remove valve support (17). Take care of
stop (20) pressure valve spring (21), and
pressure valve (22).
10
1.9 Drive barrel (23) and constant pressure 9
release (24) with suitable piece of rounded
wood out of the injection pump housing 8
(6).
3 4
1.10 Clean all parts with gas oil and
a hard brush and blow through with
compressed air. Check lube oil bores 7
for free passage. 25
5
1.11 Renew all O-rings and sealing rings. Fig. 1
en / 31.05.2010 IB001436 2/3

M20
15000, 7500
07
NOTE
Insert O-rings with vaseline untwisted into slots, do not pull across sharp edges of
the components.
During visual inspection pay special attention to the following wear phenomena:
•plunger, scores marks on the running surface. Control helix worn by cavitation
or erosion
•barrel: score marks in the running surface
•piston with barrel, sliding fit of the piston in the barrel
•impact screws, cavitation,
•pressure valve: damaged contact faces, dented seat, worn pressure spring
•pressure plate/cam follower body, worn plunger contact face and needle guide
•fuel supply and discharge bores in the connecting flange, cavitation, erosion
2. Reassembly
2.1 The reassembly is carried out in reverse order to the disassembly procedure.
CAUTION
During reassembly see that the barrel is locked and that the marking of control rack -
control sleeve and control sleeve - plunger coincide.
2.2 Grease contact surfaces between valve support (17), constant pressure release (24) and barrel
(23) thinly with absolutely clean Molykote paste “G-Rapid Plus”.
2.3 Coat threads and contact surfaces of the following screws with Molykote paste
“G-Rapid Plus” and tighten crosswise with tightening torque:
Fillister head screw (Fig. 1/4)
M = 25 Nm
Fillister head screw (19)
M = 45 Nm
Imoact screws (1 and 2)
M = 50 Nm
During disassembly of the lower valve plate (5)
M = 40 Nm
2.4 Check freedom of motion of the control rack.
en / 31.05.2010 IB001436 3/3

M20
15000, 7500
See also: 07

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Tools:
Auxiliary material:

Vaseline *
NOTE
with fingers.

1. Disassembly
en / 31.05.2010 IB002110 1/3

M20
15000, 7500
07
WARNING
1.4 Loosen fillister head screws (Fig. 1/4) uni-

formly. 19

21
housing (5). Take care of fixing pin.
20
17
1.5 Remove the following single components 22
24
Cam follower body (7), pressure plate (8), 23
unit), pump spring (11), spring seat (12), 2 1

18
check toothing. 14
6
1.7 Clamp injection pump housing (6) with val- 13 15
crew locking screw (18). 12 16
11
10
1.9 Drive barrel (23) and constant pressure 9
wood out of the injection pump housing 8
(6).
3 4
compressed air. Check lube oil bores 7
for free passage. 25
5
1.11 Renew all O-rings and sealing rings. Fig. 1
en / 31.05.2010 IB002110 2/3

M20
15000, 7500
07
NOTE
Insert O-rings with vaseline untwisted into slots, do not pull across sharp edges of
the components.
During visual inspection pay special attention to the following wear phenomena:
•plunger, scores marks on the running surface. Control helix worn by
cavitation or erosion
•barrel: score marks in the running surface
•piston with barrel, sliding fit of the piston in the barrel
•pressure valve: damaged contact faces, dented seat, worn pressure spring
•pressure plate/cam follower body, worn plunger contact face and needle guide
•fuel supply and discharge bores in the connecting flange, cavitation, erosion
2. Reassembly
CAUTION
2.2 Grease contact surfaces between constant pressure release (24) and barrel (23) thinly with abso-
lutely clean Molykote paste “G-Rapid Plus”.
Fillister head screw (Fig. 1/4)
M = 25 Nm
M = 45 Nm
M = 50 Nm
M = 45 Nm
en / 31.05.2010 IB002110 3/3

M20
15000, 7500
See also: 07

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Tools:
Auxiliary material:

Vaseline *
NOTE
interchanging must be excluded. Lapped surfaces must be preserved and not tou-
ched with fingers.
1. Disassembly
en / 31.05.2010 IB003279 1/4

M20
15000, 7500
07
19
WARNING
21 17
20
1.4 Loosen fillister head screws (Fig. 2/32) 22 24

uniformly.
23
housing (Fig. 1/5). Take care of fixing pin. 2
1
1.5 Remove the following single components
18
Cam follower body (7), pressure plate (8),
distance plate (9), slot washer (10) (a 14
unit), pump spring (11), spring seat (12),
control sleeve (13), pump plunger (14). 6

(16) out of injection pump housing (6) and 15
13
check toothing.
16
1.7 Clamp injection pump housing (6) with val- 11
ve support pointing upwards (17). Uns- 12

remove valve support (17). Take care of 10
3
1.9 Drive barrel (23) and constant pressure
1 9
wood out of the injection pump housing
(6).
8
25 5 7
en / 31.05.2010 IB003279 2/4

M20
15000, 7500
1.10 Dismantle the fuel outlet throttle screw 07

(Fig.2/30) and the fuel inlet throttle screw
(31).

compressed air. Check lube oil bores
30
for free passage.
1.12 Renew all O-rings and sealing rings.
NOTE 31
Insert O-rings with vaseline unt-

wisted into slots, do not pull
across sharp edges of
the components.
During visual inspection pay

special attention to the following
wear phenomena:
•plunger, scores marks on the

running surface. Control helix
worn by cavitation or erosion
•barrel: score marks in the run- 33 32

ning surface
•piston with barrel, sliding fit of

the piston in the barrel
•impact screws, cavitation, 2
•pressure valve: damaged con-

tact faces, dented seat, worn
pressure spring
•pressure plate/cam follower

body, worn plunger contact face
and needle guide
•fuel supply and discharge bo-

res in the connecting flange, ca-
vitation, erosion
en / 31.05.2010 IB003279 3/4

M20
15000, 7500
2. Reassembly 07
CAUTION
2.2 Grease contact surfaces between constant pressure release (Fig. 1/24) and barrel (23) thinly with
absolutely clean Molykote paste “G-Rapid Plus”.
M = 25 Nm
M = 45 Nm
M = 50 Nm
M = 45 Nm
en / 31.05.2010 IB003279 4/4

M20
15000, 7500
See also: 07

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Maintenance:
Tools:
Auxiliary material:

Vaseline *
NOTE
with fingers.
1. Disassembly
en / 31.05.2010 IB024918 1/4

M20
15000, 7500
07
WARNING
1.4 Loosen fillister head screws (Fig. 2/32)

uniformly.

housing (Fig. 1/5). Take care of fixing pin
(34).
1.5 Remove the following single components

Cam follower body (7), pressure plate (8),

unit), pump spring (11), spring seat (12),

check toothing.
1.7 Clamp injection pump housing (6) with val-


1.9 Drive barrel (23) and constant pressure

wood out of the injection pump housing
(6).
en / 31.05.2010 IB024918 2/4

M20
15000, 7500
1.10 Dismantle the fuel outlet throttle screw 07

(Fig.2/30) and the fuel inlet throttle screw
(31).

compressed air. Check lube oil bores
for free passage.
1.12 Renew all O-rings and sealing rings.
CAUTION
If a possibly existing throttle (25)
is to be exchanged, it has to be
replaced, together with the
connector, by the throttle-
connector (26).
NOTE
Insert O-rings with vaseline unt-
wisted into slots, do not pull
across sharp edges of
the components.
During visual inspection pay

special attention to the following
wear phenomena:
•plunger, scores marks on the

running surface. Control helix
worn by cavitation or erosion
•barrel: score marks in the run-

ning surface
•piston with barrel, sliding fit of

the piston in the barrel

•pressure valve: damaged con-
tact faces, dented seat, worn
pressure spring
•pressure plate/cam follower

body, worn plunger contact face
and needle guide
•fuel supply and discharge

bores in the connecting flange,
cavitation, erosion
en / 31.05.2010 IB024918 3/4

M20
15000, 7500
2. Reassembly 07
CAUTION
2.2 Grease contact surfaces between constant pressure release (Fig. 1/24) and barrel (23) thinly with
absolutely clean Molykote paste “G-Rapid Plus”.
M = 25 Nm
M = 45 Nm
M = 50 Nm
M = 45 Nm
en / 31.05.2010 IB024918 4/4

Fuel Injector A5.05. 07.07.01.00
M20
See also: 07.08.01.nn 07


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Tools:
Removal tool for fuel injector W1 2.9122-A
Auxiliary material:

NOTE
Before working on the injection system, it is recommended to change to distillate fuel
in the case of heavy oil operation in order to rinse the fuel injector thoroughly.
1. Disassembly
1.1 Switch off the stand-by lubricating oil

pump of the main engine and/or the pre-
lubricating pump at generator operation.
1.2 Release and remove thrust bolts (Fig. 1/1

and 2) and lever off transverse thrust pie-
ce (3) with cover (4) and pull to the left out
of injection pump and cylinder head.
1.3 Pull the radial thrust piece (5) out by about

20 mm.
1.4 Release and remove nuts (Fig. 3/15) of

the studs (11). 5
1.5 Detach flange place (Fig. 3/12) and over

studs (11) turned by 180° (see Fig. 2).
4 1 3 2
Fig. 1
en / 31.05.2010 IB022247 1/3

M20
1.6 Screw extractor (Fig. 2/W1) onto adjusting 07

screw (13) of the nozzle holder (14). Turn
up nozzle holder from the seat against the
flange (12).
1.7 Pull fuel injector at eye bolt (W1) out of the

cylinder head.
1.8 Remove the soft iron sealing ring (17). W1

Clean bore and nozzle seat (16) in the
cylinder head.
1.9 Clean the outside of the fuel injector and 11

carry out function check of the injection
nozzle (07.08.01 nn).
13
1.10 Renew the soft iron sealing ring (17) and
all of the O-rings (18). 12
CAUTION 18
Only use original MaK spare
parts.
14
2. Reassembly
2.1 Apply a thin film of Molykote paste on 17

the threads of gudgeons (Fig. 2/11), O-
rings. 16
Fig. 2
Excessive paste has to be removed!
Through excessive paste there is the

risk of squeezing of the O-rings in the
locking groove in the cylinder head!
Grease the soft sealing ring (17) and

nozzle (16) with high temperature thread 15 11
paste to avoid sticking due to heat.
2.2 Insert injection carefully valve into cylinder

head. Attach flange (Fig. 2/12) and tighten
nuts (15) with torque
M = 55 Nm.
2.3 Slacken nuts (15) again by one turn.
2.4 Push in the radial thrust piece (Fig. 1/5).
2.5 Fit the transverse thrust piece (3).
17
16
Fig. 3
en / 31.05.2010 IB022247 2/3

M20
2.6 Tighteen the thrust bolts (1 and 2) manually in alternating order, becauce of tapered seat of the 07
transverse thrust piece (3) on the injection pump.
2.7 First tighten thrust bolt (2) and then thrust bolt (1) with a torque of
M = 85 Nm.
2.8 Tighten nuts ( Fig. 3/15) once again with a torque of
M = 30 Nm.
en / 31.05.2010 IB022247 3/3

M20
See also: 07.08.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Removal tool for fuel injector W1 2.9122-A
Auxiliary material:

NOTE
Before working on the injec-
tion system, it is recommen-
ded to change to distillate fuel
in the case of heavy oil opera-
tion in order to rinse the fuel
injector thoroughly.
1. Disassembly
1.1 Switch off the stand-by lubricating oil

pump of the main engine and/or the pre-
lubricating pump at generator operation.
1.2 Release and remove thrust bolts (Fig. 1/1

and 2) and lever off transverse thrust pie-
ce (3) with cover (4) and pull to the left out
of injection pump and cylinder head.
1.3 Pull the radial thrust piece (5) out by about

20 mm.
1.4 Release and remove nuts (Fig. 3/15) of

the studs (11).
1.5 Detach flange place (Fig. 3/12) and over

studs (11) turned by 180° (see Fig. 2).
en / 30.09.2010 IB026440 1/3

M20
1.6 Screw extractor (Fig. 2/W1) onto adjusting 07

screw (13) of the nozzle holder (14). Turn
up nozzle holder from the seat against the
flange (12).
1.7 Pull fuel injector at eye bolt (W1) out of the

cylinder head.
1.8 Remove the soft iron sealing ring (17).

Clean bore and nozzle seat (16) in the
cylinder head.
1.9 Clean the outside of the fuel injector and

carry out function check of the injection
nozzle (07.08.01 nn).
1.10 Renew the soft iron sealing ring (17) and

all of the O-rings (18).
CAUTION
Only use original MaK spare
parts.
2. Reassembly
2.1 Apply a thin film of Molykote paste on

the threads of gudgeons (Fig. 2/11), O-
rings.
Excessive paste has to be removed!
Through excessive paste there is the

risk of squeezing of the O-rings in the
locking groove in the cylinder head!
Grease the soft sealing ring (17) and

nozzle (16) with high temperature thread
paste to avoid sticking due to heat.
2.2 Insert injection carefully valve into cylinder

head. Attach flange (Fig. 2/12) and tighten
nuts (15) with torque
M = 55 Nm.
2.3 Slacken nuts (15) again by one turn.
2.4 Push in the radial thrust piece (Fig. 1/5).
2.5 Fit the transverse thrust piece (3).
en / 30.09.2010 IB026440 2/3

M20
2.6 Tighteen the thrust bolts (1 and 2) manually in alternating order, becauce of tapered seat of the 07
transverse thrust piece (3) on the injection pump.
2.7 First tighten thrust bolt (2) and then thrust bolt (1) with a torque of
M = 85 Nm.
2.8 Tighten nuts ( Fig. 3/15) once again with a torque of
M = 30 Nm.
en / 30.09.2010 IB026440 3/3

Maintenance / Adjust
M20
See also: 07.07.01.nn, 07.09.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Nozzle tester W1 1.9470 B

Adapter/Nozzle holder - nozzle tester W2 2.9208 A
Pressure pipe W3 1.9470-051
DANGER
When checking the opening pressure: Risk of accident! Keep your hands off the fuel
jet!
NOTE
Proper function of the injection nozzlescan only be assessed from the behaviour of
the exhaust gas temperatures or smoke emission behaviour.
The fuel injector should only be checked in case of a significant deviation of the
exhaust gas temperature from the respective cylinder value. For this purpose
the nozzle tester is provided, which can also be used for checking the nozzle
holes for unobstructed passage.
By means of the nozzle tester the behaviour of the nozzle in operation cannot be
reproduced, because the flow rates and the related pressure build-up are not compa-
rable with the real conditions on the engine, i.e. the spray pattern alone gives no indi-
cation of the function of the nozzle.
On the nozzle tester the specified opening pressure is to be adjusted after assembly
of the nozzle.
A drop in opening pressure after a short operating time (setting of nozzle spring and
needle) is normal.
en / 31.05.2010 IB026385 1/2

M20
1. Remove carbon deposits from the nozzle
with a hard brush (no wire brush).
2. Check the nozzle hole for sharp edges,

ovalization, corrosion and damage.
3. Place the injector with the adapter (W2) in

the tester (W1).
4. Connect the injector delivery pipe (W3).
5. Increase the pressure by means of the

pump until the nozzle opens.
Determine injector opening pressure
and free passage of the nozzle holes.
NOTE
If a high portion of fuel is lea-
king or if the nozzle holes are
clogged and the nozzle alrea-
dy opens below the minimum
nozzle opening pressure of
230 bar, repair or replace the
injector according to
(07.09.01.nn).
5.1 For adjusting the opening pressure

slacken the lock nut (1) and turn the
adjusting screw (2) until the correct
opening pressure is adjusted (see 5.2 and
5.3). Tighten the lock nut (1).
5.2 When using a new fuel injector or a new

nozzle element (8) and a new nozzle
spring (4) the nozzle opening pressure
is to be adjusted according to the
testbed record (A1.10.).
5.3 When continuing to use the old nozzle

element (8) and/or the old nozzle spring
(4) the opening pressure is to be adjusted
according to the testbed record value
(A1.10.) minus 10%.
Ptest = 350 bar - 10% = 315 bar
en / 31.05.2010 IB026385 2/2

M20
See also: 07.07.01.nn, 07.09.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Nozzle tester W1 1.9470 B

Adapter/Nozzle holder - nozzle tester W2 2.9208 A
Pressure pipe W3 1.9470-051
DANGER
When checking the opening pressure: Risk of accident! Keep your hands off the fuel
jet!
NOTE
Proper function of the injection nozzlescan only be assessed from the behaviour of
the exhaust gas temperatures or smoke emission behaviour.
The fuel injector should only be checked in case of a significant deviation of the
exhaust gas temperature from the respective cylinder value. For this purpose
the nozzle tester is provided, which can also be used for checking the nozzle
holes for unobstructed passage.
By means of the nozzle tester the behaviour of the nozzle in operation cannot be
reproduced, because the flow rates and the related pressure build-up are not compa-
rable with the real conditions on the engine, i.e. the spray pattern alone gives no indi-
cation of the function of the nozzle.
On the nozzle tester the specified opening pressure is to be adjusted after assembly
of the nozzle.
A drop in opening pressure after a short operating time (setting of nozzle spring and
needle) is normal.
en / 31.05.2010 IB026393 1/2

M20
1. Remove carbon deposits from the nozzle
with a hard brush (no wire brush).
2. Check the nozzle hole for sharp edges,

ovalization, corrosion and damage.
3. Place the injector with the adapter (W2) in

the tester (W1).
4. Connect the injector delivery pipe (W3).
5. Increase the pressure by means of the

pump until the nozzle opens.
Determine injector opening pressure
and free passage of the nozzle holes.
NOTE
If a high portion of fuel is lea-
king or if the nozzle holes are
clogged and the nozzle alrea-
dy opens below the minimum
nozzle opening pressure of
330 bar, repair or replace the
injector according to
(07.09.01.nn).
5.1 For adjusting the opening pressure

slacken the lock nut (1) and turn the
adjusting screw (2) until the correct
opening pressure is adjusted (see 5.2 and
5.3). Tighten the lock nut (1).
5.2 When using a new fuel injector or a new

nozzle element (8) and a new nozzle
spring (4) the nozzle opening pressure
is to be adjusted according to the
testbed record (A1.10.).
5.3 When continuing to use the old nozzle

element (8) and/or the old nozzle spring
(4) the opening pressure is to be adjusted
according to the testbed record value
(A1.10.) minus 10%.
Ptest = 500 bar - 10% = 450 bar
en / 31.05.2010 IB026393 2/2

M20
See also: 07.07.01.nn, 07.08.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Auxiliary material:
Molykote paste "G-Rapid" **
NOTE
The fuel injector valve should only be disassembled if the inspection (07.08.01.nn.)
yields deficiencies (e.g. leaking, too low opening pressure, poor atomization).
All parts of the injection system are produced with utmost precision in special work-
shops. This is the only guarantee for a proper function. For this reason, it is impossi-
ble for the operator to repair it and the necessary maintenance work should be
limited to
•cleaning
•inspection of opening pressure and tightness
•replacement of wearing parts making use of original parts and replacement ele-
ments.
In order to keep repair costs low, elements in need of repair should be got ready for
shipment as complete units and clearly marked to prevent them from being mixed up.
en / 31.05.2010 IB001412 1/2

M20
1. Disassembly
3
1.1 Loosen nut (Fig. 1/1) and relieve pressure spring (2) by
unscrewing setting spindle (3).
1.2 Loosen and screw off nozzle nut (4) by turning to the left.
1
1.3 Remove nozzle element (5) with needle, without damaging
the lapped surfaces or coming into contact with the fingers.
Take care of cylindrical pin (6).
1.4 Unscrew adjusting screw, check pressure spring and

compression bolt (7) visually. 8
1.6 Insert nozzle needle with gas oil into the nozzle element and
check whether the nozzle needle falls onto the seat through
its own weight. If the needle hangs or sticks, replace it
together with the element. 2
1.7 Subject all parts, especially seat and contact faces, to a

visual inspection. Replace defective parts.
7
2. Reassembly
2.1 Wipe all contact faces dry with clean paper.

6
2.2 Renew O-ring seal (8).
5
2.3 Coat thread of the fuel injector housing and the recess of the 4
nozzle element with Molykote paste “G-Rapid Plus”.
2.4 The reassembly of the fuel injector is carried out in reverse

order to the disassembly procedure.
2.5 Tighten nozzle nut (4) with a torque of

Fig. 1
M = 250 Nm.
2.6 Adjust fuel injector in accordance with 07.08.01.nn.
en / 31.05.2010 IB001412 2/2

M20
7500
See also: 07.07.01.nn, 07.08.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Auxiliary material:
Molykote paste "G-Rapid" **
NOTE
The fuel injector valve should only be disassembled if the inspection (07.08.01.nn.)
yields deficiencies (e.g. leaking, too low opening pressure, poor atomization).
All parts of the injection system are produced with utmost precision in special work-
shops. This is the only guarantee for a proper function. For this reason, it is impossi-
ble for the operator to repair it and the necessary maintenance work should be
limited to
•cleaning
•inspection of opening pressure and tightness
•replacement of wearing parts making use of original parts and replacement ele-
ments.
In order to keep repair costs low, elements in need of repair should be got ready for
shipment as complete units and clearly marked to prevent them from being mixed up.
en / 31.05.2010 IB026415 1/2

M20
7500
1. Disassembly
1.1 Loosen nut (Fig. 1/1) and relieve pressure spring (2) by 3
unscrewing setting spindle (3).
1.2 Loosen and screw off nozzle nut (4) by turning to the left.
1.3 Remove nozzle element (5) with needle, without damaging

the lapped surfaces or coming into contact with the fingers. 1
Take care of cylindrical pin (6).
1.4 Unscrew adjusting screw, check pressure spring and

compression bolt (7) visually.
1.6 Insert nozzle needle with gas oil into the nozzle element and 8
check whether the nozzle needle falls onto the seat through
its own weight. If the needle hangs or sticks, replace it
together with the element.
1.7 Subject all parts, especially seat and contact faces, to a

visual inspection. Replace defective parts.
2
2. Reassembly
2.1 Wipe all contact faces dry with clean paper.

7
2.2 Renew O-ring seal (8).
2.3 Coat thread of the fuel injector housing and the recess of the
nozzle element with Molykote paste “G-Rapid Plus”.
6
2.4 The reassembly of the fuel injector is carried out in reverse
order to the disassembly procedure. 5
2.5 Tighten nozzle nut (4) with a torque of 4
M = 250-20 Nm.
2.6 Adjust fuel injector in accordance with 07.08.01.nn.
en / 31.05.2010 IB026415 2/2

Duplex Fuel Filter A5.05. 07.12.01.00
M20
See also: 07

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Cleaning pistol W1 1.9100-110
Auxiliary material:
Cleaning fluid “Filterclean” from Vecom *
NOTE
Operation and maintenance of the filter have to be carried out with utmost care to
avoid troubles in the fuel injection system.
When using heavy fuel, never let the filter cool down in a filled state!
The cleaning intervals of the filter mostly depend on the engine operating conditions,
the fuel quality and the grade of the fuel purifying and thus differs from system to sy-
stem.
After commissioning of a new system or after working on the fuel piping, the filter is
be checked after 24 h and cleaned if necessary.
1. Change the filter over to the clean cham-
ber. Changeover procedure (see plate on
the filter cover).
2. Cleaning
1 4
2.1 During normal operation of the engine, cle- 2
an the filter when
X
50 % of the red mark
of the differential pressure gauge (Fig. 1/

1) becomes visible or if filter alarm is gi-
ven.
2.2 Remove the cover from the chamber that

has been cut out. 3
Fig. 1
en / 30.09.2010 IB001414 1/3

M20
07
WARNING
Depressurize chamber!
2.3 Open the sludge drain and let the fuel run
out.
2.4 Loosen self-locking nut (Fig. 1/2) on tie

rod (3) and lift out strainers (X) one by
one.
2.5 Place the individual strainers into

containers with cleansing agent and clean
them with a soft brush.
2.6 Blow air through cleaned strainers with

cleaning pistol (Fig. 2/W1) by moving up
and down from the inside (clean side). Air
pressure approx.
4 bar.
W1
2.7 In case of stubborn dirt (paint spots,
incrustation, fibers, chips), place the
strainers in a container with cleaning fluid
and allow them to soak for max. 4 h in
accordance with the regulation of the
cleansing agent manufacturer.
NOTE
The cleaning fluid may only to
reach up to the lower edge of
the top frame of the filter ele-
ment so that no contaminated
liquid can enter into the clean
space from the top.
2.8 Take the filter elements out of the cleaning

fluid and proceed with the cleaning in
2.5 and 2.6.
2.9 If necessary, repeat cleaning procedure in

the sequence of operations 2.7 and 2.8. Fig. 2
2.10 Rinse strainers in clean cleaning fluid and

blow through again with air.
en / 30.09.2010 IB001414 2/3

M20
2.11 Inspect the gauze of all strainers on the inside and outside for damage and replace if required 07
CAUTION
The individual strainers are connected in parallel, and damage on only one filter ele-
ment means malfunction of the entire element.
2.12 Put a strong light behind the gauze and check success of the cleaning operation.
Repeat if necessary.
2.13 Telescope the strainers again (Fig. 1/X), insert them into the chamber and tighten the nut (2)
slightly.
2.14 Replace the gasket (4) and fit the cover.
2.15 Fill the filter chamber and vent it (see the plate on the filter cover).
en / 30.09.2010 IB001414 3/3

Duplex Fuel Preliminary Filter A5.05. 07.12.02.02
M20/M32/M282/M332C/M452/M453C/M551/M552C/M601/M601C
750
See also: 07

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Cleaning of the filter every 750 h
Tools:
Auxiliary material:
Cleaner “Filterclean” of Vecom *
Note:
Operation and maintenance of the filter have to be carried out with utmost care to avoid troubles
in the fuel system.
The cleaning intervals of the filter mostly depend on the engine operation conditions and the fuel
quality and therefore are different from unit to unit.
When starting up a new plant or after doing some work on the fuel piping, check the filter after 24
hours and clean it if necessary.
1. Change the filter over to the clean chamber. See the proce-
dure from the plate on the filter cover.
2. Cleaning
2.1 Remove the cover from the chamber that has been cut out.
2.2 Open the sludge drain and let the fuel run out.
2.3 Withdraw the filter element (Fig. 1).
2.4 Rinse the chamber with gas oil.
en / 05.06.2000 IB022107 1/2

M20/M32/M282/M332C/M452/M453C/M551/M552C/M601/M601C
750
2.5 Put the filter element in a suitable cleansing liquid (e. g. “Filterclean” from Vecom). 07
The cleansing liquid must only reach up to the bottom edge of the top frame of the filter
element so that no contaminated liquid can enter into the clean space of the element.
Soaking time as required by the supplier of the cleanser, but maximum 8 hours.
2.6 Take the filter element out of the cleansing liquid. When withdrawing the internal and unprotected
straniners of an element, make sure that the gauze is not damaged.
Inspect all strainers on the inside and outside, because the individual strainers are con-
nected in parallel, and damage on only one strainer means malfunction ot the whole ele-
ment.
2.7 Blow compressed air through each strainer with the pistol (Fig. 2/W1) and clean the inside and
outside with a soft brush.
2.8 Flush the strainers with clean gas oil. Make sure that no contaminated gas oil can enter into
the clean space from the top.
2.9 Put a strong light behind the gauze and check the cleaning operation. Repeat it if necessary.
2.10 Telescope the strainers again and fit them in the filter chamber.
2.11 Fit the cover (check the gasket and renew it if necessary).
2.12 Fill the filter chamber and vent it (see the plate on the filter cover).
en / 05.06.2000 IB022107 2/2

M20-M601C
750
See also: 07

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Cleaning of the filter every 750 h
Auxiliary material:
Cleaner “Filterclean” of Vecom *
NOTE
Operation and maintenance of the filter have to be carried out with utmost care to
avoid troubles in the fuel system.
The cleaning intervals of the filter mostly depend on the engine operation conditions
and the fuel quality and therefore are different from unit to unit.
When starting up a new plant or after doing some work on the fuel piping, check the
filter after 24 hours and clean it if necessary
en / 16.12.2010 IB022114 1/2

M20-M601C
750
4
1. Cleaning
1.1 Change over to operable filter chamber.

3 5
1.2 Open the vent screw (1) of the filter cham- 6
ber which has been cut off in order to vent 8
the system.
1.3 Remove the drain plug (2) of the filter

chamber which has been cut off. 1
1.4 Dismantle the housing cap (3) of the filter

chamber which has been cut off.
1.5 Withdraw the screen basket (7) vertically

upwards.
7
1.6 Remove coarse dirt by shaking the screen
basket (7).
1.7 Put the screen basket (7) into a solvent. An

application time of 8 hours must not be ex-
ceeded.
2
1.8 After taking the screen basket (7) out of the
solvent carefully blow it out with compres-
sed air from outside to inside.
1.9 Remove tenacious dirt by means of a soft brush.
1.10 Insert the screen basket (7) into the filter chamber.
1.11 Check the O-ring (8) and replace it if necessary. Mount the housing cap (3).
1.12 Insert and tighten the drain plug (2).
1.13 To vent the filter chamber carefully set the operating lever (4) in such a way that the nose (5) of
the plug points towards the nearest screw of the plate (6).
1.14 When the fuel emerges without bubbles at the vent screw (1), close this screw.
1.15 Reset the operating lever (4).
en / 16.12.2010 IB022114 2/2

Fuel Feed Pump A5.05. 07.13.01.00
M20
15000
See also: 07

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The fuel feed pump is to be disassembled every 15,000 hours of operation and the drive checked
for wear.
Tools:
* not available as figure 3

W
Auxiliary material:
2
Molykote paste “G-Rapid Plus” * 1
Silicone sealing compound “Dirco Gray” *
NOTE
If the fuel feed pump cannot be
used due to natural wear and Z
tear, it should be replaced. The
installation of spare parts
cannot reproduce the original
performance according to the
Fig. 1
manufacturers.
1. Disassembly
1.1 Close stop valves.

5
1.2 Discharge fuel from lines.
1.3 Disconnect lines at the pump.

4
1.4 Loosen fastening screws and pull fuel feed
pump (Fig. 1/1) with coupling half out of
the drive housing (2).
1.5 Remove drive housing (2) from pump car- 3

rier plate and pull out of the cylinder block
and crankcase with toothed wheel (3). W
1.6 Loosen hexagon screw (4) and pull toothed wheel off (3) the drive shaft (5) with removal tool (W).
en / 31.05.2010 IB022122 1/3

Fuel Feed Pump A5.05. 07.13.01.00
M20
15000
1.7 Check tooth profiles for wear (pittings, 07

crooked running, breakage).
1.8 Remove circlip (Fig. 2/13) and pull drive 18 2 12

shaft (5) with deep groove ball bearings
13 x
(14 and 15) to the toothed wheel side out
of the drive housing (2).
1.9 Pull coupling half (11) off the drive shaft

(5). Take care of parallel key (12).
1.10 Check deep groove ball bearings (14 and

15) for wear and replace if required.
Remove circlips (16 and 17) in order to
pull off the deep groove ball bearings
2. Reassembly
2.1 Heat up coupling half (11) to 160 °C and

shrinkwrap on the shaft journal of the drive 14 16 5 15 17 11
shaft (5). Take care of parallel key (12).
Fig. 2
2.2 Slide drive shaft (5) with deep groove ball
bearings (14 and 15) and coupling half
(11) into the drive housing (2). Measure
dimension “x” from the drive housing y
flange face to the clutch.
NOTE
The axial layer of the shaft is fi-
xed by circlips (13 and 18) in
the drive housing (2).
2.3 Mount coupling half (21) on the fuel feed

pump shaft with dimension 21
“y” = x - 1.0 mm
(Fig. 1/Z). 22
Take care of parallel key (22). Z
2.4 Inspect contact reflection between toothed wheel cone and drive shaft cone by spot-grinding. A
uniformly distributed contact reflection must be offset to the thicker end.
en / 31.05.2010 IB022122 2/3

Fuel Feed Pump A5.05. 07.13.01.00
M20
15000
2.5 Heat up toothed wheel (Fig. 1/3) to approx. 150 °C and fit onto the corresponding drive shaft cone 07
up to stop (conical surfaces of the cones free from grease and dry) and immediately lubricate
thread and contact surface of the hexagon screw (4) and washer with Molykote paste “G-Rapid
Plus” and tighten with a torque of
M = 60 Nm.
Insert drive housing (2) into cylinder block and crankcase carefully with toothed wheel (3) (tooth
profiles of the drive toothed wheels must mesh with each other) and mount at the pump carrier
plate with sealing compound (backlash = 0.24 mm - 0.5 mm).
2.6 Mount fuel feed pump (1) and connect fuel lines.
2.7 Check lube oil supply of the toothed wheels.
2.8 Open stop valves and vent lines.
2.9 Check tightness.
en / 31.05.2010 IB022122 3/3

Fuel Distributor Line/Manifold Line A5.05. 07.15.01.00
M20
See also: 07

--------------------------------------------------------------------------------------------------------------------------------
Tools:

Auxiliary material:

1. Disassembly
1.1 Drain fuel distributor line and manifold line (drain spigot at anti-drive end above fuel double filter).
1.2 Disassemble covering.
1.3 Loosen screws (Fig. 1/1 and 2).
1.4 Remove distributor housing (3) with equalizer (4).
1.5 Pull equalizer (4) out of distributor housing (3).
2 4 2 1 3 2
2 2
Fig. 1
en / 21.07.93 IB002028 1/2

Fuel Distributor Line/Manifold Line A5.05. 07.15.01.00
M20
2. Reassembly 6 5 07
2.1 Clean faces at distributor housing (3).
2.2 Insert new O-rings (5).
2.3 Check bore (6) in equalizer for passage.

1
2.4 Insert and reassemble equalizer (4) in dis-
tributor housing (3).
2.5 Insert screws (1) with Molykote paste “G-

Rapid Plus” and tighten them with a 3
Torque = 50 Nm.
2.6 Insert screws (2) with Molykote paste “G-

Rapid Plus” and tighten them with a
Torque = 34 Nm.
2.7 Replace covering.
en / 21.07.93 IB002028 2/2

Fuel / Fuel collector rail A5.05. 07.15.01.01
M20
See also: A5.05.07.02.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Helpful resource:
Green soft soap**

** or a similar quality product
Sequence of work:
1. Disassembly
1.1 Empty fuel and fuel collector rail (2)

(Drainage tap on anti-drive end over fuel double filter).
1.2 Dismantle covering.
1.3 Only detach retaining ring (1) on one side.
1.4 Push fuel pipes (2) into the fuel pump (5) until they stop.
1.5 Fuel pump (3) detach (07.02.01.nn).
1.6 Pull fuel pipes (2) out of the pump (5).
3 2 5 1
en / 30.09.2010 IB003978 1/2

Fuel / Fuel collector rail A5.05. 07.15.01.01
M20
2. Assembly 07
2.1 Insert new O-rings (4) with green soft soap in both injection pumps.
2.2 Push fuel pipe ends into the fuel pump without retaining rings until they stop.
2.3 Assemble fuel pump (3).
2.4 Push fuel pipes (2) into fuel pump (3) until they stop.
2.5 Assemble retaining rings (1).
en / 30.09.2010 IB003978 2/2

Lubricating Oil System A5.05. 08.02.01.00
Maintenance / Oil change
M20
See also: A4.05.08.nn, A5.05.08.04.01.nn 08

Spare parts list: B1.05.08.2.64n0, B1.05.08.2.7810

--------------------------------------------------------------------------------------------------------------------------------
NOTE
The strainer on the suction side of the lubricating oil pumps must be checked and
cleaned, if necessary, 24 to 48 hours of operation after the start- up of a new installa-
tion or working on the suction side of the lubricating oil piping system.
The oil change interval depends on the following:
•Lubricating oil quality

•Engine operating conditions
•Lubricating oil consumption
•Lubricating oil filtering and centrifugal purifying
•Quantity of lubricating oil in the system
The oil change interval can be extended if allowed by the results of the oil analysis.
For permissible analysis values (see A4.05.08.nn, Regulations and Care, Engine
Lubricating Oil).
1. Drain the engine circulation system
and lubricating oil circulation tank.
2. Clean the tank and crankcase

if necessary.
3. If necessary, remove oil pressure control

valve (Fig. 1/1), check pressure spring
and valve seat.
Lift off pressure = 4.0 bar 1

4. Inspect strainer (2) at the suction side of
the lubricating oil pumps and clean
if necessary.
5. Clean lubricating oil duplex filter and lubri-

cating oil automatic filter.
6. Remove and clean lubricating oil cooler

(see manufacturer's documentation Book
C).
2
7. Refill new lubricating oil up to the respective mark on the sump tank (lubricating oil quality, see
Fig. 1
en / 31.05.2010 IB001483 1/2

Lubricating Oil System A5.05. 08.02.01.00
Maintenance / Oil change
M20
A4.05.08.nn). 08
8. Refill lubricating oil system and start the stand-by pump.
en / 31.05.2010 IB001483 2/2

Lube Oil Pump A5.05. 08.03.01.00
M20
15000
See also: 08.03.02.nn 08


--------------------------------------------------------------------------------------------------------------------------------
Control:
Check safety valve for function every 15,000 hours of operation.
1. Screw off valve cover (Fig. 1/1) and mark
set position of the valve spindle (2).
WARNING
Observe spring tension
2. Unscrew valve spindle (2) and take valve

cone (3) with valve spring (4) and spring
seat (5) out of the housing (6).
3
3. Check sealing faces of the valve cone and
if necessary grind them in. Clean sealing
faces carefully. 4
4. Fit the valve in reverse order and set to the

marked position.
5
5. Start up lubricating oil pump and 1
vent system. Check pump suction line,
the pump body and the shaft sealing 2
for tightness.
Fig. 1
en / 31.05.2010 IB022195 1/1

Lube Oil Pump A5.05. 08.03.02.00
M20
See also: 08.03.01.nn 08


--------------------------------------------------------------------------------------------------------------------------------
Auxiliary material:

Silicon sealing compound “Dirco Gray” *
NOTE
Remove the lube oil pump from the engine if required. Check the gear wheels, wheel
shafts and bearings for wear and renew them if necessary.
1. Disassembly
1
1.1 Empty the lube oil system.
1.2 Disconnect the suction pipe and delivery

pipe.
1.3 Loosen the pump flange from the pump

carrier plate and pull the lube oil pump
(Fig. 1/1) with gear wheel (2) from the cy-
linder block and crankcase.
3 4 2
1.4 Loosen the hexagon screw (3) free
and remove the gear wheel (2) from
Fig. 1
the driving wheel shaft (4) with an
extracting device.
12 11 13 14 15
1.5 Loosen the hexagon screws (Fig. 2/11)
and disassemble the end cover (12) with
the pressure control valve from 16
the housing (13).
NOTE
The end cover is fixed with two
taper pins.
4
1.6 Remove the driving wheel shaft (4) and
impeller axle (14) from the housing (13). Fig. 2
en / 31.05.2010 IB001444 1/2

Lube Oil Pump A5.05. 08.03.02.00
M20
1.7 Check the tooth surfaces for wear (pitting, 08

1.8 Check the bearing bushes (Fig. 2/15 and 16), driving wheel shaft ends and impeller axle ends for
wear and renew them if required with original MaK spare parts.
NOTE
Undercool new bushes before the installation.
2. Reassembly
2.1 Mount the lube oil pump in reverse order.
2.2 Check the contact reflection between gear wheel cone and drive shaft cone by spot-grinding. The
uniformly distributed contact reflection must be offset to the thicker end.
2.3 Heat up the gear wheel (Fig. 1/2) to approx. 150 °C in the oil bath and shrink it on the driving
wheel shaft (4) (The conical surfaces are free from grease and dry).
2.4 Grease the thread and contact surface of the hexagon screw (3) and the washer with
the Molykote paste “G-Rapid Plus” and tighten it with a torque of
M = 60 Nm.
2.5 Insert the lube oil pump (1) with gear wheel carefully in cylinder block and crankcase (2) (the tooth
surfaces of the driving gear wheels must mesh into each other) and mount it at the pump carrier
plate with sealing compound.
2.6 Connect the suction pipe and delivery pipe with new gaskets.
2.7 Check the lube oil supply of the gear wheels.
2.8 Start up the lube oil pump (1) and vent the system. Check for tightness.
en / 31.05.2010 IB001444 2/2

Lubricating Oil Duplex Filter A5.05. 08.04.01.00
M20
See also: 08

--------------------------------------------------------------------------------------------------------------------------------
Tools:

Cartridge drift W2 1.9100-120
Auxiliary material:
Cleansing liquid “Filterclean” from Vecom *
NOTE
Operation and servicing of the filter have to be carried out with utmost care.
The ingress of dirt from the tanks and piping could cause serious engine damage.
The cleaning interval of the filter depends on part load operation with heavy fuel,
poor combustion, poor centrifugal purifying or a defective automatic backflushing fil-
ter.
When starting up a new plant, after major repairs or work on the lubricating oil piping,
check the filter after 24 to 48 hours and clean it if necessary.
Disassemble the filter candles on every third cleaning (sequence of operations 2.3).
Ultrasonic cleaning of the filter candles is not permitted. An excessive cleaning peri-
od or improper suspension on cleaning might cause damage on the gauze that
cannot be detected with the naked eye.
1. Change the filter over (see the plate on the
filter cover).
2. Cleaning
2.1 Clean the filter when it is still warm from

operation and
50 % of the red mark
of the differential pressure gauge (Fig. 1/

1) becomes visible or if filter alarm is gi-
ven.
en / 31.05.2010 IB001418 1/4

M20
2.2 Filter cleaning with mounted filter 08

candles.
WARNING
Depressurize the filter
chamber!
2.2.1 Remove the cover from the filter chamber

that has been cut out. Open the sludge
drain and drain the contaminated liquid.
2.2.2 Remove the filter element.
2.2.3 Connect the cleaning pistol (Fig. 2/W1) to

the compressed air supply and impinge
the working pressure
(6 -max. 10 bar).
2.2.4 Shift the spouting guard (13) to the stop at

the pistol nozzle, put it into the cartridge
opening and hold it tight. Pull the trigger of
the cleaning pistol and introduce the
nozzle gradually down to the bottom of
each filter candles (14).
2.2.5 Fit the cover. Renew the gasket

if necessary.
2.2.6 Fill the filter chamber and vent it (see the

plate on the filter cover).
2.3 Filter cleaning with removed filter cand-

les (every third cleaning).
2.3.1 Empty the filter chamber by opening the

sludge drain.
2.3.2 Remove the filter element.
2.3.3 Flush the filter chamber with gas oil.
en / 31.05.2010 IB001418 2/4

M20
2.3.4 Put the filter element in a suitable cleansing liquid. The cleansing liquid must only reach up to 08
the bottom edge of the element plate (Fig. 3/2) so that no contaminated liquid can enter
into the filter candles (14) from the top. The top area of the gauze must be visible in the
filter candles. Soaking time as required by the suppliers of the cleanser, but maximum 4 hours.
2.3.5 Take the filter element out of cleansing liquid and blow through filter candles (14)
with compressed air (Fig. 2/W1) (sequence of operations 2.2.4).
Air pressure max. 10 bar.
2.3.6 Put the filter element again in clean cleansing liquid, allow to drip dry and blow through with com-
pressed air (W1). Turn filter element upside down, so that the cleansing liquid can drain off.
2.3.7 Check the filter candles occasionally for damage (sequence of operations 2.4).
2.3.8 Put the filter element in the chamber, fit the cover and renew the gasket if necessary.
2.3.9 Fill the filter chamber and vent it (see the plate on the filter cover).
2.4 Cleaning the filter candles in the case of heavy soiling.
NOTE
In the case of heavy soiling of the filter element (paint spots, incrustation, tar
deposits, fibers, chips), remove filter candles and clean them individually.
2.4.1 Soak the filter element in cleansing liquid (max. 4 hours).
2.4.2 Disconnect the base plate and carefully remove the protective shell from the filter element.
2.4.3 Remove the filter candles (14) with the drift (Fig. 3/W2) downwards and tilt them out. Remove
the O-ring (25) between the filter candles and the element plate (2), because O-rings must
not have contact with the cleansing liquid.
2.4.4 Inspect the filter candles and renew them in the case of damage and/or heavy folding of
the gauze.
CAUTION
The damage on only one filter candles means malfunction of the whole element.
Do not put the removed filter candles one upon another; this might damage the gauze.
2.4.5 Connect the cleaning pistol (Fig. 2/W1) to the compressed air supply.
Air pressure max. 10 bar.
en / 31.05.2010 IB001418 3/4

M20
08
2.4.6 Introduce the pistol into the cartridge, pull the trigger and move down to the bottom of each filter
candles.
2.4.7 Remove sticking dirt with a soft brush.
NOTE
If possible, clean the filter elements from the ouside with a high-pressure cleaner.
Working pressure of the high-pressure cleaner max. 60 bar. Cleansing agent: Warm
water or water with cleansing liquid.
CAUTION
When cleaning with the high-pressure cleaner, be careful not to hold the nozzle too
close to the gauze in order to avoid damage and/or displacement of the gauze wires.
2.4.8 Rinse the filter candles in clean cleansing liquid, blow through with air and allow them to dry with
the opening facing downwards.
2.4.9 Put a strong light behind the gauze and check the cleaning operation. Repeat it if necessary.
2.4.10 Fit the filter candles in reverse order as described under 2.4.3. The O-ring between element plate
and filter candles must be free from cracks and deformation.
3. Check the gasket between element plate and filter housing and renew it if necessary.
4. Fit the element in the filter chamber.
5. Fit the cover (renew the gasket).
6. Fill the filter chamber and vent it (see the plate on the filter cover).
en / 31.05.2010 IB001418 4/4

Oil pressure control valve A5.05. 08.05.01.00
M20
15000
See also: 08.03.02.nn 08


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Disassembly and adjustment of the
oil pressure control valve every 15,000 h
NOTE
Disassembly of the pressure control valve during the repair interval is only necessary
if the necessary lubricating oil pressure can no longer be set by adjusting the initial
tension of the spring. The lubricating oil pressure (see A1.05, engine data) is only
allowed to be adjusted at the nominal engine speed (A1.10) and at the specified lubri-
cating oil temperature (see A1.06).
1. Disassembly
WARNING
Pay attention to the tension of the pressure spring (Fig. 1/3) on the control valve (1)!
1.1 Loosen the cheese head screws (8) evenly to relieve the pressure spring (3).
1.2 Remove and dismantle the control valve (1).
WARNING
Pay attention to the tension of the pressure spring (13) on the screwed connection
(17)!
1.2.1 Remove protective cap (30).
1.2.2 Loosen the hexagon nut (18) and completely unscrew the spindle (19) by turning it counter-
clockwise and remove it together with the ball (16).
1.2.3 Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush (10).
1.2.4 Remove the locking ring (9) and take out the piston (11) with washer (15) and pressure spring
(13).
en / 31.05.2010 IB024704 1/3

M20
15000
1.2.5 Remove the screw plug (26) of the pilot control unit (A-A) with the sealing ring (25), 08
pressure spring (28) and ball (29).
1.3 Clean all parts with gas oil and check them.
1.4 Check the free passage of the control oil bore (12) in the pressure control valve and in the set
screw (5) and remove any deposits.
1.5 Check the valve seats, balls, piston seating as well as the slide faces and grind them if
necessary.
en / 31.05.2010 IB024704 2/3

M20
15000
2. Reassembly 08
2.1 Check the O-ring (7) and sealing ring (14) and replace them if necessary.
2.2 Assembly is effected in the reverse sequence of disassembly.

Pay attention to the free movement of the pistons (4 and 11)!
2.3 Check the lubricating oil pressure at the pressure gauge on the control panel and adjust it if ne-
cessary.
3. Adjustment
3.1 Pressure to be set (see engine data A1.05).
3.2 Loosen the hexagon nut (18).
3.3 Regulate the pressure by turning the spindle (19).
Counter-clockwise:Oil pressure drops

Clockwise:Oil pressure increases
3.4 Secure the setting with the hexagon nut (18).
en / 31.05.2010 IB024704 3/3

M20/M25/M32/M43
15000
See also: 08

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Disassembly and adjustment of the
oil pressure control valve every 15,000 h
NOTE
Disassembly of the pressure control valve during the repair interval is only necessary
if the necessary lubricating oil pressure can no longer be set by adjusting the initial
tension of the spring.
The lubricating oil pressure is only allowed to be adjusted at the nominal engine
speed and at the specified lubricating oil temperature, see engine documentation,
chapter "Technical Engine Data".
1. Disassembly
CAUTION
Pay attention to the tension of the pressure spring (Fig. 1/3) on the control valve (1)!
1.1 Loosen the cheese head screws (8) evenly to relieve the pressure spring (3).
1.2 Remove and dismantle the control valve (1).
CAUTION
Pay attention to the tension of the pressure spring (13) on the screwed connection
(17)!
1.2.1 Loosen the hexagon nut (18) and completely unscrew the spindle (19) by turning it counter-
clockwise and remove it together with the ball (16).
en / 26.11.2010 IB022593 1/3

M20/M25/M32/M43
15000
1.2.2 Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush (10). 08
1.2.3 Remove the locking ring (9) and take out the piston (11) with washer (15) and pressure spring
(13).
1.2.4 Remove the screw plug (26) of the pilot control unit (A-A) with the sealing ring (25),
washers (27), pressure spring (28) and ball (29).
en / 26.11.2010 IB022593 2/3

M20/M25/M32/M43
15000
1.3 Clean all parts with gas oil and check them. 08
1.4 Check the free passage of the control oil bore (12) in the pressure control valve and in the set
screw (5) and remove any deposits.
1.5 Check the valve seats, balls, piston seating as well as the slide faces and grind them if
necessary.
2. Reassembly
2.1 Check the O-rings (2 and 7) and sealing ring (14) and replace them if necessary.
2.2 Assembly is effected in the reverse sequence of disassembly.

Pay attention to the free movement of the pistons (4 and 11)!
2.3 Check the lubricating oil pressure at the pressure gauge on the control panel and adjust it if ne-
cessary.
3. Adjustment
3.1 Pressure to be set, see engine documentation, chapter "Technical Engine Data".
3.2 Loosen the hexagon nut (18).
Regulate the pressure by turning the spindle (19).
Counter-clockwise: Oil pressure drops

Clockwise: Oil pressure increases
3.3 Secure the setting with the hexagon nut (18).
en / 26.11.2010 IB022593 3/3

Prelubricating pump/Prelubrication A5.05. 08.10.00.00
M20/M25/M32/M43/M453C/M552C/M601C
150
See also: C5.05.08.10.00.nn 08

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Prelubrication and turning approximately every 150 h
NOTE
When multi-engine systems run on rigid bearings, the bearings might be damaged by
vibration when individual engines are shut down for more than 3 days.
Prelubrication alone is no guarantee that damage caused by vibration is prevented,

since the components which run on sliding bearings, are not able to float in the bea-
ring because of the prelubricating pressure. No or only a little quantity of oil is carried
to the endangered contact surfaces.
Damage caused by vibration during engine shut-down can only be avoided when the
engine is lubricated and turned simultaneously.
The following method is to be applied to avoid damage caused by engine shut-down,

without affecting the unattended operation of the system:
1. Carry out steps 1.1 and 1.2 simultaneously for approx. 5 min.
1.1 Start the stand-by pump
1.2 Turn the engine by means of the barring gear.
en / 26.11.2010 IB004168 1/1

Centrifugal Cooling Water Pump A5.05. 09.07.01.00
M20
15000
See also: 09

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The centrifugal cooling water pump is to be removed and checked for wear every 15,000 hours of
operation.
Auxiliary material:

Silicon sealing compound “Dirco-Gray” *
1. Disassembly
1.1 Empty the cooling water system in

the cooling water reservoir.
1.2 Remove pipes from the cooling water

pump.
1.3 Disconnect pump flange from the pump

carrier plate and remove the cooling water
pump (Fig. 1/1) with gear wheel (2) from
the cylinder block and crankcase.
1.4 Loosen the hexagon screw (3) with

the washer (4) and remove the gear wheel
(2) from the shaft (5) with an extracting
device (X).
1.5 Check the tooth surfaces for wear (pitting,

1.6 Loosen the hexagon nuts (Fig. 2/11)

and take the housing cover (12) with the
impeller (13) out of the spiral housing (14).
1.7 Loosen the impeller nuts (15). Remove the

impeller (13) with an extracting device
from the shaft (5). Observe the parallel key
(16).
1.8 Remove the mechanical seal (17).
en / 31.05.2010 IB022205 1/3

M20
15000
1.9 Loosen the hexagon screws (Fig. 2/18) and remove the housing cover (12) from the bearing car- 09
rier (19).
1.10 Loosen flat head screw (28).
1.11 Remove cover (26) with sealing ring (27).
1.12 Remove “Nilos“ lock ring (20).
1.13 Force shaft (5) and grooved ball bearing (22) out of bearing flange (19) with a suitable tool..
2. Inspection
2.1 Inspect the impeller (13) visually and renew it in the case of heavy cavitation.
2.2 Check the ball bearings for freedom of movement, wear, corrosion, ball disintegrations and renew
them if necessary.
2.3 Check the pressure compensating hole (24) and leaking liquid discharge (25) for free passage.
3. Reassembly
3.1 The reassembly is made in reverse order observing the following:
3.2 Renew all gaskets of the housings and mechanical seal (17).
3.3 Before mounting the impeller (13), check contact reflection between impeller cone and shaft cone
by spot-grinding. (Min. 60 % of profile bearing length distributed uniformly over the cone.)
11
18
24 19 28
17
16
15
5
27
22 26
13 22
20
25
12
14
Fig. 2
en / 31.05.2010 IB022205 2/3

M20
15000
3.4 Before mounting the gear wheel (2) (Fig. 1/X), check contact reflection between gear wheel cone 09
and shaft cone by spot-grinding. A uniformly distributed contact reflection must be offset to the
thicker end.
3.5 Heat up the gear wheel (2) to approx. 150 °C and push it up to the stop on the shaft cone.
3.6 Grease the thread and contact surface of the hexagon screw (3) and the washer (4) with Molyko-
te paste “G-Rapid Plus” and tighten it with a torque of
M = 60 Nm.
3.7 Insert the cooling water pump (1) with the gear wheel (2) carefully into the cylinder block and
crankcase (the tooth surfaces of the driving toothed wheels must mesh into each other) and
mount it at the pump carrier plate with sealing compound
(Backlash = 0.2 mm - 0.5 mm).
3.8 Mount the pipes and refill and vent the cooling water system.
3.9 Check the tightness.
en / 31.05.2010 IB022205 3/3

M20
15000
See also: - 09

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
operation.
Auxiliary material:

1. Disassembly


pump.


device (X).

1.6 Loosen the hexagon nuts (Fig. 2/11)

and take the housing cover (12) with the
impeller (13) out of the spiral housing (14).
1.7 Loosen the impeller nuts (15). Remove the

impeller (13) with an extracting device
from the shaft (5). Observe the parallel key
(16).
1.8 Remove the mechanical seal (17).
en / 31.05.2010 IB022224 1/3

M20
15000
1.9 Loosen the hexagon screws (Fig. 2/18) and remove the housing cover (12) from the bearing car- 09
rier (19).
1.10 Loosen flat head screw (28).
1.11 Remove cover (26) with sealing ring (27).
1.12 Remove circlip (21) and “Nilos“ lock ring (20).
1.13 Force the shaft (5) with grooved ball bearing (22 and 23) out in (X)-direction.
CAUTION
Force the shaft out in X-direction only so far that the grooved ball bearing can be
removed with a suitable tool, so that the bearing (22) is not demaged on the recess (Z)
1.14 Remove the grooved ball bearing (23)
1.15 Force the shaft with grooved ball bearing (22) out in (Y)-direction and take out of bearing support
(19).
1.16 Pull the grooved ball bearing (22) off the shaft.
2. Inspection
2.1 Inspect the impeller (13) visually and renew it in the case of heavy cavitation.
2.2 Check the ball bearings for freedom of movement, wear, corrosion, ball disintegrations and renew
them if necessary.
2.3 Check the pressure compensating hole (24) and leaking liquid discharge (25) for free passage.
3. Reassembly
3.1 The reassembly is made in reverse order observing the following:
3.2 Renew all gaskets of the housings and mechanical seal (17).
3.3 Before mounting the impeller (13), check contact reflection between impeller cone and shaft cone
by spot-grinding. (Min. 60 % of profile bearing length distributed uniformly over
the cone).
en / 31.05.2010 IB022224 2/3

M20
15000
. 09
11
18
24 19 28
17
16
15
Y X
Z
5
27
26
13 22
20 22
21
25
12
14
Fig. 2
3.4 Before mounting the gear wheel (2) (Fig. 1/X), check contact reflection between gear wheel cone
and shaft cone by spot-grinding. A uniformly distributed contact reflection must be offset to the
thicker end.
3.5 Heat up the gear wheel (2) to approx. 150 °C and push it up to the stop on the shaft cone.
3.6 Grease the thread and contact surface of the hexagon screw (3) and the washer (4) with Molyko-
te paste “G-Rapid Plus” and tighten it with a torque of
M = 60 Nm.
3.7 Insert the cooling water pump (1) with the gear wheel (2) carefully into the cylinder block and
crankcase (the tooth surfaces of the driving toothed wheels must mesh into each other) and
mount it at the pump carrier plate with sealing compound
(Backlash = 0.2 mm - 0.5 mm).
en / 31.05.2010 IB022224 3/3

M20
15000
See also: - 09

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
operation.
Auxiliary material:

1. Disassembly


pump.


device (X).

en / 30.09.2010 IB024271 1/5

M20
15000
1.6 Mark the position of the volute (Fig. 2/11) with respect to the housing cover (12) and 09
bearing carrier (13).
1.7 Loosen hexagon nut (14) and remove volute (11).
1.8 Loosen impeller nut (32) and impeller nut (15), remove shim (16).
1.9 Remove impeller (18) by means of an extractor.
1.10 Remove the mechanical seal (19) from the shaft (20).
1.11 Loosen hexagon screws (21) and remove the housing cover (12).
1.12 Press counter-ring (22) of the mechanical seal (18) out of the housing cover (12).
en / 30.09.2010 IB024271 2/5

M20
15000
1.13 Loosen screws (Fig. 2/23) and remove cover (24). 09

1.14 Remove slinger ring(25) from the shaft by means of an extractor.
CAUTION
Drive screw M12x45 into the shaft (20) and put the extractor on it.
1.15 Clamp bearing carrier (13) in a bench vice and heat inner ring of the ball bearing (26) up.
1.16 Drive shaft (20) out by means of a soft head hammer.
1.17 Remove ball bearing (26) from bearing carrier (13).
1.18 Heat slinger ring (27) and remove it.
1.19 Heat inner ring of the ball bearing (28) and remove the ball bearing.
2. Check
2.1 Check impeller (18) visually and exchange it in case of heavy cavitation.
2.2 Check leak liquid drains (29) for free passage.
3. Reassembly
3.1 Clean bearing seats on the shaft (20).
3.2 Heat new ball bearing (28) up to 80°C and mount it at the impeller end. The inner ring of the ball
bearing must fit closely to the shaft recess.
3.3 Feed shaft (20) with ball bearing (28) into the bearing carrier (13).
3.4 Clamp shaft (20) at the mechanical seal seat in the bench vice.
CAUTION
Use soft jaws in order not to endanger the shaft.
3.5 Heat new ball bearing (26) up to 80°C and mount it at the driving end. The inner ring of the ball
bearing must fit closely to the shaft recess.
3.6 Insert shaft (Fig. 2/20) in the bearing carrier (13).
3.7 Mount carrier cover (24) with screws (23), lock screws with Loctite.
3.8 Heat new slinger ring (25) up to 150°C and mount it on the shaft (20) at the driving end. The sling-
er ring must closely fit to the ball bearing.
en / 30.09.2010 IB024271 3/5

M20
15000
3.9 Heat new slinger ring (Fig. 2/27) up to 150°C and mount it on the shaft (20) at the impeller end. 09
The slinger ring must fit closely to the ball bearing.
3.10 Insert new split ring (30) in the housing cover (12).
3.11 Insert counter-ring (22) of the mechanical seal in the housing cover (12).
3.12 Mount housing cover (12) on the bearing carrier in the correct position.
3.13 Before mounting the impeller (18) check the bearing pattern between impeller cone and shaft
cone by spot-grinding. (Bearing portion of at least 60 % uniformly distributed on the cone).
3.14 Mount mechanical seal (19).
3.15 Hest impeller(18) up (max. 200 °C) and

slide it on the shaft.
3.16 Reference dimension (Z)
d = 1.8 ± 0,1 mm
3.17 Mount the shim (16) , recess shows into

the direction of the impeller.
3.18 Mount the nut (15) nd tighten it with
M = 90 Nm
3.19 Lock the nut (16) with the 2nd nut (32)
and secure the nuts with loctite.
CAUTION
Lock impeller nuts with Loctite
3.20 Insert new split ring (33) in the volute (11).
3.21 Put flat gasket (31) into the volute (11).
3.22 Mount volute (11) on the housing cover (12) in the correct position.
3.23 Before mounting the flywheel (2) (fig. 1/x) check bearing pattern between gear wheel cone and
shaft cone by spot-grinding. A uniformly distributed bearing pattern must be shifted to the thicker
end.
en / 30.09.2010 IB024271 4/5

M20
15000
3.24 Heat gear wheel (2) up to 150°C and place it on the shaft cone up to the limit stop. (Cone surface 09
grease-free and dry).
3.25 Coat thread and contact surface of the hexagon screw (3) and washer (4) with Molykote paste
"G-Rapid Plus" and tighten with a torque of
M = 60 Nm
3.26 Insert cooling water pump (Fig. 1/1) with gear wheel (2) carefully into the engine block (gear
flanks of the driving gear wheels must be meshing, backlash must be palpable) and mount it at
the pump carrier plate with sealing compound.
en / 30.09.2010 IB024271 5/5

Pressure Switches A5.05. 11.01.02.01
Inspection / Adjust
M20-M601C
3750
See also: 11
Spare parts list: B1.05.11.nn.4843

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Adjusting device, electro test instrument
Inspection:
Inspect the pressure switch for the set operating values every 3,750 working hours.
NOTE
The following test and adjustment instruction is valid for the following types:
• Pressure range 0.2 - 2.5 bar, mechanical switching differential: 0.15 bar
• Pressure range 0 - 6 bar, mechanical switching differential: 0.2 bar
• Pressure range 0.9 - 1.5 bar, mechanical switching differential: 0.08 bar
1. Connection of the adjusting device
1.1 Close the cock of the pressure piping (Fig. 1/1).
1.2 Loosen the union nut (2) and remove the dummy plug (pressure release of the piping, at liquid
medium collect the liquid with a rag).
en / 17.12.2010 IB021686 1/3

Inspection / Adjust
M20-M601C
3750
11
CAUTION
When loosen/thighten the union nut directly located at the pressure joint of the pres-
sure switch, it should be simultaneously counter acted at the key faces of the pressu-
re joint.
1.3 Connect the hose (with union

nut and cutting) with the adju-
sting device (Fig. 2).
2. Inspection of the set values
2.1 Ventilate the pressure switch

via the adjustment device.
CAUTION
For setting the differential pressure switch, the adjusting device must be equipped
with two text connections (+, –, pressure difference) refer to view “X”.
Pressure monitor Difference pressure monitor
2.2 Inspect the pressure control via the pressure gauge (of the device) and simultaneously the switch
point at the instrument or alarm unit for coincidence of the switch point with the set value.
2.3 At any deviation correct the adjustment due to item 3.
2.4 Deaerate the pressure switch slightly and simultaneously check the switch point via the test in-
strument. Inspect the displayed switch difference.
en / 17.12.2010 IB021686 2/3

Inspection / Adjust
M20-M601C
3750
3. Correction of the adjustment (Perfor- 11

mance with fixed switch difference)
(Fig. 3)
NOTE
The scale accuracy is ± 2 % of
the span. The instrument is in-
dividually calibrated (1 - 2 on)
so that no gauge inspection is
necessary.
3.1 Remove the case cover by loosening the

4 locking screws.
3.2 Connect terminal (1 + 4) via cable with the

adjusting device.
3.3 Loosen the stop screw (A).
3.4 Remove the cover aside by loosening the

locking screw (B).
3.5 Set the upper or lower switching point (dif-

ferential pressure switch) by means of the
range spindle (C).
The lower or upper switching point

(differential pressure switch) results in the
fixed switching difference.
3.6 Tighten stop screw (A).
4. Removal of the adjusting device
4.1 Loosen the cable connection

(terminal 1 + 4).
4.2 Loosen the connection hose of the adjusting device screw on the union nuts with plug (Fig. 1/2).
4.3 Fit the cover.
4.4 Tighten the cover of the range spindle.
4.5 Mark or lead the impected or corrected pressure switches.
en / 17.12.2010 IB021686 3/3

Inspection / Adjust
M20
3750
See also: 11

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Adjusting device, electric measuring instrument
Inspection:
Check the set operating values of the pressure switch every 3,750 operation hours.
NOTE
These testing and adjusting instructions apply to the following types:
Pressure range:0 -6 barSwitching difference:0.2 bar
Pressure range:0 -16 barSwitching difference: 0.8 bar
1. Connection of the adjusting device
1.1 Set cock of the pressure line (Fig. 1/1)

to test position.
1.2 Remove plug (2) (G1/8") (depressurizing

the line, catch liquid with a rag) and
connect adjusting device in accordance
with Fig. 2 and Fig. 3 to the test
connection.
en / 30.09.2010 IB021766 1/3

Inspection / Adjust
M20
3750
1.3 Pneumatic connection (Fig. 2) 11
10 Compressed air flange > 16 bar

11 Pressure reducer
12 Stop valve
13 One-way restrictor
14 Volume 1 l
15 Precision manometer
16 Pressure switch
1.4 Electric connection (Fig. 3)
Connect terminals 1, 2, 3 in the appliance plug.
2. Inspection
2.1 Vent pressure switch via adjusting device.
2.2 Check switching point via the precision manometer of the setting equipment and test lamps.
2.3 Gradually vent the pressure switch, thereby observe switching point on the precision manometer
the adjusting device and test lamp (Check the indicated switching differential in accordance with
measuring point list in Book C).
en / 30.09.2010 IB021766 2/3

Inspection / Adjust
M20
3750
3. Correction of setting 11
NOTE
In case of deviations from the set value (see measuring point list in Book C) correct
the setting in accordance with sequence of operations 3. Pressure switch is set in
the case of falling pressure.
3.1 Remove the lead seal
3.2 Disconnect housing cover (Fig. 4/20) of the pressure switch.
3.3 Set switching point with hexagon wrench (SW5) to

the required value according to measuring point list.
4. Removing the adjusting device
4.1 Undo cable connections and pneumatic connection of the

test device.
4.2 Seal test connection with plug and switch cock (Fig. 1/1) into
operating position.
4.3 Screw on housing cover and seal again with lead seal.
en / 30.09.2010 IB021766 3/3

RPM Switch A5.05. 11.05.01.02
Inspection / Adjust
M20/M25/M32/M43
7500
See also: C5.05.05.70.06.43 11

Spare parts list:
Personnel qualification: E-specialist

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Check the function of the rpm switches every 7,500 operating hours.
NOTE
The engine speed must be constant whilst testing.
1. Note the rpm switch point setting. Loosen
the pointer locking plate (2) and set the
pointer (1) at the highest engine speed.
The output relay on the plug-in card must

switch and the luminous diode (3) on the
dial will go out (Fig. 1).
2. Turn the pointer carefully to the left

towards 0 rpm. When reaching the engine
speed, the output relay will switch and the
diode on the dial must light up (switch
hysteresis ± 25 rpm).
3. Set the pointer again at the original rpm

switch point and lock it.
If the rpm switch does not work, proceed

as follows in order to locate the defect:
4. The automatic cut-out F 1.1 and F 2.1 on the plug-in card A1 in the rpm switch installation must
be switched on.
At constant speed and with the setting as under point 1, continue as follows:
5. Voltage check at the plug-in socket contacts of the plug-in frame.
en / 26.11.2010 IB021724 1/2

RPM Switch A5.05. 11.05.01.02
Inspection / Adjust
M20/M25/M32/M43
7500
5.1 Supply (24 V DC at contact z16 and z20, contact z20 positive). 11
5.2 PICK UP IMPULSE (dependent upon engine speed up to 1500 Hz at contact b14 and d14).
If nothing could be detected whilst checking points 4 - 6, renew the plug-in card.The engine speed must be
constant whilst testing.
NOTE
Carry out the rpm adjustment of the new plug-in card. For this see the "Engine Docu-
mentation, Chapter „Control / Regulation“, rpm switch".
en / 26.11.2010 IB021724 2/2

Lubricating Oil/Cooling Water Thermostat A5.05. 11.06.01.00
M20-M601C
7500
See also: 11

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Disassembly and functional check of the thermostatic
element of the lubricating oil/cooling water thermostat every 7,500 h
Note:
The thermostatic elements are adjusted by the manufacturer to the required temperature.
Modification of the adjustment or repair is impossible. Defective elements must be exchanged
completely.
Controlling the thermostatic elements in case of failure is enabled by a manual control facility.
Hereto slacken counter nut (1) and turn set nut (2) clockwisely in order to get a lower
temperature. After setting counter again.
The cooling line is fully opened and the bypass closed when the control pin (3) is in the upper
position.
This setting procedure may only be carried out if the thermostat fails.
With mounting a new thermostat, the control pin (3) must be set to its initial position by the nut (2).
1. Disassembly (Fig. 1)
1.1 Drain lubricating oil/cooling water lines.
1.2 Unscrew nuts (5) of housing lower part (6)

and remove housing cover.
1.3 Unscrew counter nut (1) from regulating

spindle.
1.4 Remove thermostatic element out of hou-

sing lower part.
1.5 Wash parts in gas oil and blow them clean.
en / 31.05.2000 IB021739 1/2

M20-M601C
7500
11
1.6 Check lower seat and sealing faces of thermostatic element for damage.
1.7 Wipe clean thermostat housing with a lint-free rag and check for corrosion and deposits. Check
upper plate for erosion.
2. Functional Check of the Thermostatic Element
2.1 Put thermostatic element (1) into a water bath of a termpature of approx. 10 K above the mean
temperature specified on the insert (XX) (specification in degree Fahrenheit).
2.2 The thermostatic element must open steadily.
3. Assembly
3.1 Slightly grease inner side of O-ring (4) and upper face of element and regulating spindle. By the
clearance of the O-ring, heat elongations are compensated.
3.2 Top up lubricating oil/cooling water system and check thermostat for leakage.
en / 31.05.2000 IB021739 2/2

M20-M601C
7500
See also: 11

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Disassembly of lubricating oil/cooling water thermostat,
making a funcional check of thermostatic element every 7,500 h
NOTE
The thermostatic elements (Fig. 1/5) are adjusted by the manufacturer to the requi-
red temperature. Modification of the adjustment or repair is impossible. Defective ele-
ments must be exchanged completely.
Controlling the thermostatic elements in case of failure is enabled by a manual con-

trol facility. Hereto slacken counter nut (3) and turn set screw (4) clockwisely in order
to get a lower temperature. After setting counter again.
The cooling line is fully opened and the bypass closed when the set screw (4) flushes
with the surface of the counternut (3).
This setting procedure may only be carried out if the thermostat fails.
With mounting a new thermostat, the set screw (4) must be set to its initial position by
the nut (3).
1. Disassembly
1.1 Drain lubricating oil/cooling water lines.
1.2 Unscrew hexagon nuts (2) of housing co-

ver (6).
1.3 Remove cover (6) with O-ring (1).
1.4 Turn out thermostatic element (5)

from valve housing (7).
en / 17.12.2010 IB021750 1/2

M20-M601C
7500
1.5 Wash parts in gas oil and blow them clean. 11

1.6 Wipe clean thermostat housing with lint-free cloth and check for corrosion and deposits.
2. Functional check of thermostatic element
2.1 Put thermostatic element (Fig. 1/5) into a water bath of temperature of approx. 15 K above the
temperature specified on the strap (XX) (specification in degree C).
2.2 The thermostatic element (5) must open steadiliy.
3. Assembly
3.1 Repalce O-rings (1 and 9) and gasket (8).
3.2 Assembly is done in reverse order of disassembly.
3.3 Top up lubricating oil/cooling water system and check thermostat for leakages.
en / 17.12.2010 IB021750 2/2

Pressure Switch A5.05. 11.06.05.02
M20/M25
22500
See also: 11.06.06.nn 11

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replacement of all pressure switches after 22,500 h
Tools:
Metric standard tools.
Set of replacement parts:

Pressure switch M2103 (emergency stop - cooling water pressure)
Pressure switch M1106 (emergency stop - lubricating oil pressure)
Depending on the equipment status all other pressure switches are to be replaced as well.
WARNING
- Ensure that the engine cannot be started!
- When exchanging the pressure pipe or draining off the cooling water it is
possible that "hot" cooling water leaks out.
- There is a danger of scalding.
- Avoid skin contact with cooling water emulsions, observe the safety data
sheets of the manufacturers.
en / 20.10.2010 IB026248 1/3

M20/M25
22500
Procedure: 11
1. Put the engine and the related safety systems out of operation.
- > Notify the engine to be ’’unserviceable’’ < -.
CAUTION
Prior to replacing the pressure switches the shut-off cocks of the media must
be closed.
Prior to installation the pressure switches are to be adjusted to the specified
pressure values.
2. Replacement of the pressure switches.
NOTE
The measuring point designations are always provided on the engine cable and the
engine.
2.1 Remove the old pressure switch.
2.2 Mount the new pressure switch. When

doing so, slightly grease the O-ring
(Fig. 1/1) at the foot of the new pressu-
re switch before inserting it.
2.3 Replacement of the plug.
3. Testing of the completed work:
3.1 Cooling water system

1
3.1.1 Start the engine and run up to nominal speed.
3.1.2 Simulate "Low cooling water pressure" by means of test valve (Fig. 2, 3, 4/2).
The engine has to stop automatically latest after 20 seconds.
3.1.3 Put test valve (2) into "Operation" position again.
3.1.4 Lubricating oil system
3.1.5 Start the engine and run up to nominal speed.
3.1.6 Simulate "Low lubricating oil pressure" by means of test valve (2).
The engine has to stop automatically without any delay.
3.1.7 Put test valve (2) into "Operation" position again.
3.1.8 The other pressure switches are to be tested according to the same procedure.
en / 20.10.2010 IB026248 2/3

M20/M25
22500
11
3.1.9 Put the engine and the safety system into normal operating condition again.
-> Notify the engine to be "ready for operation" <-.
en / 20.10.2010 IB026248 3/3

M20/M25/M32/M43
See also: 11.06.05.nn 11

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Pressure calibrating device W1*
Electric continuity tester (multimeter) W2*
* no picture
Procedure:
1. Mount new pressure switch, see A5.05.11.06.05.nn.
2. Close shut-off valve (Fig. 3/6) of the corresponding medium to the pressure pipe.
2.1 Remove the plug from the pressure switch and connect the pressure calibrating device (W1) to
the test connection. The adjustment value is to be inferred from the list of measuring points, see
"engine documentation, chapter "Control/Regulation".
2.2 In pressureless state the pressure switch contacts (Fig. 1)

1 + 2 are closed and contacts 1 + 3 are open (ohmic flow).
2.3 When the pressure drops, the pressure switch should switch at the measuring point value, in this
state contacts 1 + 2 are open and contacts 1 + 3 are closed.
2.4 If a pressure switch is replaced, the switching value is to be inferred from the list of measuring
points.
(The measuring point number is indicated on the cable or the related nameplate.)
NOTE
If the pressure switch responds before or after the read limit, the switching point has
to be readjusted, see item 3.
en / 26.11.2010 IB025583 1/2

M20/M25/M32/M43
3. Adjustment of switching point 11

3.1 Remove cover (Fig. 2/4).
3.2 By turning the hexagon socket screw

(5) the switching point can be adjusted
correspondingly.
4. Assembly:
4.1 Mount cover (4).
4.2 Remove pressure calibrating device (W1).
4.3 Clip on plug to the pressure switch.
4.4 Open shut-off valve (Fig. 3/6) of the

corresponding medium to the pressure pipe.
NOTE
Replacement of the complete
switch, see A5.05.11.06.05.nn.
en / 26.11.2010 IB025583 2/2

Crankcase Monitoring Device A5.05. 11.09.01.03
M20/M25/M32/M43/M453C/M552C/M601C
1500, 750, 7500
See also: 11
Spare parts list: B1.05.11.nn4810

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
a) Check the underpressure in the measuring chamber every 750 h
b) Clean the infrared filter and replace the sintered bronze filter
in the measuring attachment every 1.500 h
c) Replace the sintered bronze filter in the pressure control every 7.500 h
Tools:
Test equipment and spare parts.
Service box
NOTE
Maintenance and trouble shooting, refer, see "engine documentation, chapter "Ex-
ternal Documentation".
CAUTION
The engine is not monitored in the event of the device malfunctioning.
his can result in engine damage!
en / 01.04.2010 IB021758 1/1

Vibration Damper A5.05. 12.04.01.03
M20
30000
See also: 12

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
every 30,000 h
Auxiliary material:

Silicone sealing compound “Dirco-Grau” *
NOTE
When replacing (possible by way of exchange) and/or fitting dampers coat fastening
screws (Fig. 1/1), threads and screw head rests with Molykote paste “G-Rapid Plus”
and tighten with a pre-torque of
M = 100 Nm + 90°° angle of rotation.
The vibration damper is connected to the lube oil system of the engine.
Free passage of oil bores (2) must be ensured for the proper functioning of the dam-
per!
If running of the engine becomes unbalanced at certain speeds, the cause can be a
defective damper. In order to prevent further damage, avoid critical speed range and
determine defect as soon as possible by torsional vibration measurement.
1. Disassmbly
1.1 Remove pump carrier plate (3).
1.2 Mark two-piece stop disk (4), loosen screws (5), remove stop disk. If necessary, push off with
screw M12 in thread (6) (observe marking).
1.3 Mark position of flywheel rim (7) to carrier (8).
1.4 Pull out spring assemblies (9) with a wire hook.
1.4.1 Inspect stop surfaces of the spring assemblies for wear.

Smooth slight burr with soft emery paper. Replace spring assembly (9) in case of deeper grooves
since there is a danger of the spring leaf ends snap getting caught in the grooves and breaking
during further operation.
en / 30.09.2010 IB022217 1/2

Vibration Damper A5.05. 12.04.01.03
M20
30000
1.4.2 Telescope out spring assemblies (Fig. 1/9). 12

• Inspect springs for grooves and cracks.
• If individual springs show grooves or are broken, replace spring assembly (9) completely.
1.5 Clean the vibration damper thoroughly, check oil bores for free passage with wire.
1.6 Inspect the flywheel rim (7) on carrier (8) for easy turning.
1.7 Check the spring assemblies (9) for completeness.
1.8 Turn the flywheel rim (7) and the carrier (8) in the marked position, apply a thin film of Molykote
paste “G-Rapid Plus” to the springs and insert them into the damper. For this purpose, slightly
squeeze spring assemblies (9) together with a screw clamp.
2. Reassembly
2.1 The remaining assembly is carried out under observation of markings in reverse disassembly
order. Tightening torques of the screws:
M 12 = 60 Nm
M 8 = 25 Nm
2.2 Coat thread and screw head rest with Molykote paste “G-Rapid Plus”.
2.3 Secure all screws/nuts with wire/split pins or cup springs acc. to design.
2.4 Mount pump carrier plate (3) mit sealing compound on cylinder crankcase.
2.5 Check lube oil supply of the toothed wheels.
en / 30.09.2010 IB022217 2/2

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Maintenance A0

en / 26.01.2011 AA047781 1/1

en / 26.01.2011 AA047652 1/1

en / 26/1/11 AA047587 1/1

Note and observe the following points and actions.

Actions that must be performed after a safety/emergency stop* occurred:

- Work through list of corresponding sub-points.

- Contact your Caterpillar Service.

Type of emergency stop:

2. Lubrication oil (pressure and temperature)

3. Engine room monitoring

4. Cooling water - fresh water - HT (pressure and temperature)

7. Fault messages and measuring points

en / 15.12.2010 AA033984 1/5

Emergency stop due to excessive rpm.

1.2 Why did engine go into an overspeed condition?

• Check if emergency stop safety device is operational.

• Check free operation of adjustment shaft and joint

• Checking governor drive.

• Verification of possible out of calibration of actuator (if fitted).

1.3 Contact your Caterpillar Service.

2. Lube oil (lube oil pressure, lube oil temperature)

2.1 Emergency stop due to lack of lube oil

• Visual inspection of engine.

• Lube oil pump drive:

• Check lube oil pressure switch.

• Check lube oil filter for metal chips.

• Check oil sump and piping for leaks and cracks.

2.2 Contact the Caterpillar Service.

en / 15.12.2010 AA033984 2/5

2.3 Emergency stop due to high lube oil temperature

• Check temperature sensor.

• Check oil cooler.

• Check cooling water circuit.

2.4 Contact the Caterpillar/ MaK Service.

3. Engine room monitoring

• Check engine room monitoring device (operational test),

• Visual inspection of engine and gear train,

• of cam shaft trough,

3.1 Contact your Caterpillar Service.

4. Cooling water (fresh water - HT, pressure and temperature)

Emergency stop due to excessively high cooling water temperature

• Visual inspection of engine

• Check temperature sensors

• Check fresh water cooler

• Operational test of LT - Cooling water circuit with cooling water pump.

4.1 Contact your Caterpillar Service.

en / 15.12.2010 AA033984 3/5

Emergency stop due to excessively high exhaust temperature

• Check exhaust gas temperature sensors.

• Aftercooler (differential pressure) (refer to A5.05.06.04.02.nn).

• Fuel pumps and fill level scale on each fuel pump.

• Injection valves (refer to A5.05.07.08.01.nn).

5.1 Contact your Caterpillar Service.

6. Check pneumatic emergency stop system on engine after every emergency

• Check emergency stop pneumatic system on the engine for leaks.

en / 15.12.2010 AA033984 4/5

7. Fault messages and measuring points

7.1 General fault messages:

Fault message: Description:

6105 * Low shutdown air pressure

7.2 Plant-specific fault messages:

- Safety system failure