MAK M20 - Maintenance

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Maintenance

en / 31.10.2001 AA000026 1/1

Maintenance

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Total Index2
Table of Contents2
Safety Instructions4
Working Pressures of Auxiliary Equipment7
Temperatures of Operating Media8
Viscosity/Temperature Dependence8
Table of Contents12
Introduction A3.0216
Safety Instructions A3.0317
Safety Measures for Local Control of the Engine18
Instructions for Heavy Fuel Operation A3.0419
Instructions for Heavy Fuel Operation Fuel System20
Instructions for Heavy Fuel Operation Care and Supervision / Engine Fuel21
Storage Tank22
Settling Tank HT5, HT622
Separator HSD1, HSD222
Self Cleaning Fuel Filter HF423
Day Tank HT 123
Fuel Pressure Pump HP1, HP223
Fuel Pressure-Regulating Valve HR123
Final Preheater HH124
Fine Filter HF124
Viscosity Measurement and Control Equipment HR224
Instructions for Heavy Fuel Operation Lubricating Oil System25
Oil Level Control26
Instructions for Heavy Fuel Operation Care and Supervision / Lubricating Oil26
Lubricating Oil Circulatory System Diagram27
Prelubrication LP2 (Standby or Prelubrication Pump)28
Check the Operation of the Engine-Driven Force Pump LP128
Lube Oil Automatic Filter LF2 (Flushing with Oil or Compressed Air)28
Lube Oil Automatic Filter LF2 (with Permanent Oil Flushing)29
Duplex Lube Oil Filter LF1 (with Indicator)29
Strainer Filter (for Pumps)29
Initial Operation Engine30
Additional Preparation Work for Heavy Fuel Operation31
Initial Operation Fuel System31
Lubricating Oil System Maintenance32
Plants with Lubricating Oil Separator32
Turbocharger with Independent Lubricating Oil Supply32
Initial Operation Lubricating Oil System32
Initial Operation Cooling Water System33
Initial Operation Starting Air System34
Initial Operation General Performance Testing35
Commissioning36
Putting into Operation/Starting36
Direct Start at the Main Engine36
Normal Start (Control Panel in Manometer Board)36
Emergency Start38
Direct Start at the Generator Engine39
Initial Operation Putting into Service/Starting39
Putting into Service/Loading40
Loading During the Warming up of a Main Engine40
Normal Loading40
Cold Starting, below the above Preheating Temperature40
Loading During the Warming up of a Generator Motor41
Normal Working Conditions41
Severe Working Conditions41
Increasing the Load of a Warmed-Up Engine (Generator Engine)42
Accelerated Load Increase43
Operational Supervision Engine44
Monitoring45
Operation in the Case of Low Intake Air Temperatures45
Intake Air Temperature A3.06.05.0045
Exhaust-Gas Temperature Monitoring46
Operational Supervision Exhaust System/Supercharging46
Assessment of the Engine Behaviour47
Turbocharger: Compressor/Turbine48
Charge Air Cooler48
Monitoring of Operation Exhaust System/Firing Pressure49
Exhaust Temperatures50
Operational Supervision Exhaust System/Supercharging50
Note for Exhaust Temperature Monitors51
Indication of the Firing Pressure52
Turbocharger: Compressor53
Air Charge Cooler53
Operational Supervison54
Exhaust Gas Temperatures54
Fuel System Supervision58
Alarm - Leakage Fuel Injection Pipe58
Changing the Type of Fuel59
Fuel Pressure System (Only Within Heavy Oil Circle)59
Lubricating Oil System Supervision60
Cooling Water System Supervision61
Partial Load Operation with Heavy Fuel62
Removal from Operation64
Placing out of Service/Stopping65
Operation Directly at the Generator Engine65
Engine Stop/Engine Emergency Stop65
Cooling65
If the Engine Is to be Started Again after a Short Interval66
Direct Operation at the Main Engine67
Engine Stop (Control Panel in Manometer Board)67
Decommissioning/Stopping68
Aftercooling69
Resumption of Engine Operation after Short Operating Stop69
Danger of Frost71
Danger of Frost72
Antifreeze Protection72
Preservation - Engine73
Light Preservation (Short Term Preservation)75
Heavy Preservation (Long Term Preservation)78
Starting System and Starting Air Distributor Storage79
Mechanic-Hydraulic Governor Storage79
Turbocharger Storage79
External Preservation80
Preservation Measures Fittings and Tools80
Depreservation81
Running-In83
Running-In84
Fault Tracing85
Fault Tracing86
Engine Starts Poorly or Does Not Start at All87
Engine Reaches Ignition Speed but Does Not Fire87
Filter Differential Pressure too High During Starting/Pre-Lubrication88
Engine Does Not Reach Full Speed And/Or Full Power88
Engine Speed Is Not Steady89
Opaque Exhaust Gas - Engine Is Emitting Soot89
Exhaust Gases Are Blue90
Exhaust Gases Are White90
Emergency Operation91
Defective Turbocharger92
Determination of the Maximum Permissible Fuel Rack Position92
Emergency Operation of the Generator Engine93
Monitoring the Engine While the Turbocharger Is Defective93
Charge Air Temperature While the Turbocharger Is Defective93
Finishing with Emergency Operation93
Emergency Operation of the Main Engine94
Fixed Propellers94
CP Propellers94
Multi-Engine Plants with One Propeller94
Operational Misﬁre - Protection of the Flexible Coupling98
Single-Engine Installations with Fixed or CP Propeller98
Twin Engine Installations99
Misﬁre100
Total Misﬁre101
Operating Media A4102
Introduction A4.02103
Safety Instructions A4.03105
Regulations and Care106
Regulations and Care108
Distillate Fuel108
Heavy Fuels111
ISO-Speciﬁcation111
CIMAC-Specifications112
BSI-Specification112
Notes to the Speciﬁcation of the Permissible Limits114
Fuel Additives115
CCAI-Limit Curves116
Admissible Limit Speciﬁcation for the Operation with Heavy Fuel117
Heavy Fuel Specification118
Viscosity Temperature Sheet119
Engine Lubricating Oil120
Base Oil120
Additives120
Care of Lubricating Oil121
Lubricating Oil Brand Recommendations121
Lubricating Oil Filtering (By-Pass)121
Lubricating Oil Filtering (Full Flow)121
List of Brands of Lubricating Oil for Operation with Distillate Fuel122
List of Brands of Lubricating Oil for Heavy Oil Operation123
Lubricating Oil Changing124
Limits125
Lubricating Oil Dilution by Fuel125
Alkalinity (TBN)125
Water Content/Contamination125
Lubricating Oil for Exhaust Turbocharger and Change-Over Controls126
Multi-Purpose Grease – Lithium Saponified – Consistency Number 2127
Recirculating Cooling Water128
Requirements for the Cooling Water128
Treatment of Cooling Water with Corrosion Inhibitors130
Anti-Corrosion Oil130
Chemical Corrosion Inhibitors131
Checking and Care of the Treated Water132
Changing the Cooling Water133
Anti-Corrosion Oil Emulsion133
Cleaning the Cooling Water Chambers before Changing the Emulsion133
Cooling Water with Anti-Freeze Agent134
Cleaning the Cooling Water Chambers134
Determining the Cooling Water Mixture for 10 Degrees Dgh135
Emulsion Freshening for Weak Concentration136
Maintenance A5137
Explanation of the Maintenance System142
Scheduled Maintenance142
Introduction A5.02142
Maintenance System143
Work Interval Schedule143
Job Cards144
Maintenance Schedule (Periodic Maintenance Work)146
General Safety Instructions147
Safety Instructions A5.03147
Working on Electrical Equipment149
Working with Hydraulic Devices149
Checking and Adjustment of Injection Valve149
Handling of Liquid Nitrogen or Carbon Dioxide Snow150
Cleansing Agents/Chemicals150
Periodical Schedule - Distillate Fuel151
Lubricating Oil System A5.05.08.02.01.00158
Lubricating Oil Duplex Filter A5.05.08.04.01.00158
Periodical Schedule - Heavy Fuel159
Prelubricating Pump/Prelubrication A5.05.08.10.00.00161
Pressure Switches A5.05.11.01.02.01162
Pressure Switches A5.05.11.01.03.00162
RPM Switch A5.05.11.05.01.01162
Lubricating Oil/Cooling Water Thermostat A5.05.11.06.01.00162
Vibration Damper A5.05.12.04.01.03163
Valve Clarance Inspection/Adjust167
Tools A6167
Valve Rocker Brackets Maintenance/Disassembly and Reassembly169
Valve Rotator Inspection/Evaluate174
Valve Guide / Oil Scraper Ring Inspection/Replace175
Media Line Maintenance/Disassembly and Assembly179
Cylinder Head Maintenance/Disassembly182
Nozzle Sleeve Maintenance/Disassembly and Reassembly186
Inlet and Exhaust Valves Inspection/Disassembly and Reassembly188
Valve Cones Repair/Checking192
Inlet Valve Cones Repair/Checking197
Refinishing of the Valve Cone Face199
Check of Contact Reflection/Grinding200
Exhaust Valve Cones Repair/Checking202
Valve Seat Ring Repair/Checking218
Cylinder Head Inspection/Checking227
Cylinder Head Maintenance/Cleaning228
Cylinder Head Repair/Reassembly230
Running Gear/Engine Timing Inspection/Checking235
Crank Web Deflection Inspection/Measuring236
Bearing Shells Inspection/Evaluate240
Bearing Shells Replacement241
Ai-Grooved Bearings Inspection/Evaluate244
Criteria for Replacement of the Grooved Bearings244
Wear and Levelling of the Ridges (Borderline Case)248
Overlay Fatigue Ruptures249
Overlay Fatique Ruptures and Empty Grooves250
Big-End Bearings Inspection/Disassembly251
Removing the Big-End Bearing Cap253
Removing the Bearing Shells253
Big-End Bearings Inspection/Reassembly260
Fitting the Bearing Shells260
Fitting the Bearing Cap261
Tightening the Big-End Bolts262
Main Bearings Inspection/Disassembly264
Main Bearings - Measure Clearance267
Main Bearings Maintenance/Reassembly274
Piston Maintenance/Disassembly278
Piston Rings and Grooves Inspection/Checking284
Piston Maintenance/Reassembly293
Crankcase Explosion Relief Valves Inspection/Checking296
Cylinder Liner Inspection/Measuring297
Cylinder Liner Maintenance/Disassembly299
Cylinder Liner Maintenance/Reassembly300
Engine Bolting and Unions Inspection/Checking302
Camshaft Repair/Disassembly and Reassembly303
Timing Gear Train Inspection/Checking312
Governor Drive Inspection/Disassembly and Reassembly313
Vibration Damper on Camshaft Repair/Disassembly and Reassembly316
Control Shaft Bedding Maintenance/Checking320
Fuel Limiter Inspection/Adjust321
Servo-Actuator Maintenance/Disassembly and Reassembly325
Starting Fuel Limiter Inspection/Disassembly and Reassembly327
Control Valves Inspection/Checking330
Compressed-Air Filter Maintenance/Cleaning331
Exhaust Manifold Maintenance/Disassembly and Reassembly333
Charge Air Cooler Maintenance/Disassembly and Reassembly335
Turbocharger Maintenance/Cleaning343
Turbocharger Sound Absorber345
Turbocharger Maintenance/Cleaning346
Injection Pump Repair/Disassembly and Reassembly364
Injection Pump Maintenance/Disassembly and Reassembly370
Fuel Injector Maintenance/Disassembly and Reassembly380
Fuel Injector Maintenance/Adjust383
Fuel Injector Repair/Disassembly and Reassembly385
Duplex Fuel Filter Maintenance/Cleaning389
Duplex Fuel Preliminary Filter Maintenance/Cleaning392
Fuel Feed Pump Maintenance/Disassembly and Reassembly396
Fuel Distributor Line/Manifold Line Repair/Disassembly and Reassembly399
Fuel/Fuel Collector Rail Repair/Disassembly and Reassembly401
Lubricating Oil System Maintenance/Oil Change403
Lube Oil Pump Inspection/Checking405
Lube Oil Pump Maintenance/Disassembly and Reassembly406
Lubricating Oil Duplex Filter Maintenance/Cleaning408
Prelubricating Pump/Prelubrication Maintenance/Checking412
Centrifugal Cooling Water Pump Maintenance/Disassembly/Reassembly413
Pressure Switches Inspection/Adjust420
RPM Switch Inspection/Adjust426
Lubricating Oil/Cooling Water Thermostat Maintenance/Checking428
Crankcase Monitoring Device Inspection/Checking432
Vibration Damper Maintenance/Disassembly and Reassembly433
Summary of Tools436

MAK M20 - Maintenance

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